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1. eorrourmn NI 949I edoing 00012 007164 OOETS OOG IG 00116 00016 00087 OOTLP 000 7 00997 00 lt 97 00797 0059 00697 00197 00097 Stand 15 04 08 Stand 15 04 08
2. User Manual nz Analyser Type ALSPEK H Equipment No Revision 1 2 Year of make 2006 FOSECO GmbH Gelsenkirchener Str 10 D 46322 Borken Telefon 02861 83 0 Telefax 02861 83 338 User Manual Alspek H TABLE OF CONTENTS 1 2 1 3 1 4 1 5 1 6 1 7 2 1 2 2 2 3 3 1 3 2 3 3 3 4 3 5 3 6 3 7 DECLARATION OF CONFORMITY WELCOME Introduction Post shipment checking procedure Information on copyright and other property rights Information for the user Training support Examples for topics in training lessons Attendance record SAFETY General Information on signs and symbols Safety instructions for operating personnel ANALYSER OPERATION Power requirements Starting the analyser Logging in Logging out Changing the password Setting Date and Time Setting alloy 2 12 2 12 2 13 3 15 3 15 3 16 3 18 3 19 3 23 3 23 User Manual Alspek H 3 8 3 9 3 10 4 1 4 2 4 3 4 4 5 1 5 2 5 3 5 4 6 1 3 7 1 Setting standard alloy 3 7 2 Setting custom alloy parameters Entering sensor calibration values On Board Diagnostics 3 9 1 Temperature error messages 3 9 2 Sensor indicator 3 9 3 Short circuit error 3 9 4 Diagnostics screen Data logging 3 10 1 Batch numbers 3 10 2Logger screen 3 10 3Making notes PROBE OPERATION Probe overview 4 1 1 Probe hot end 4 1 2 Sensors Fitting Sensors Fitting Adjusting probe clamp Probe maintenance 4 4 1 Hu
3. 3 and table 3 2 is the con nection between the sensor positive and negative terminals 2 and 4 shown in bold Therefore there is no need to re check all the other con nections with the short circuit cap the table is included in its entirety to avoid confusion Table 4 4 provides details of what action to take if the probe s electrical connections do not agree with tables 4 2 and 4 3 Stand 15 04 08 4 4 3 4 4 4 rN e FOSECO Connection Using cap Problem Solution See between section 2 und 4 Open circuit Not open circuit Replace ceramic insu 4 4 4 lators 2 und 4 Short circuit gt 200 Replace ceramic 4 4 5 sheath 1 und 3 Any gt 50 O Replace thermocouple 4 4 3 2 und 6 Any Not open circuit Replace ceramic 4 4 3 sheath 1 und 6 Any Not open circuit Replace thermocouple 4 4 5 Table 4 4 Correcting electrical connection problems at 25 C Replacing thermocouple e Open the hub and release the wires coming from the thermocouple by unscrewing the hub terminal connections 1 3 and 4 as labelled on figure 4 9 The thermocouple is mechanically attached to the hub by a bayonet fitting labelled 9 on fi gure 3 9 e Rotate the bayonet fitting anticlockwise and carefully pull the thermocouple all the way out of the probe e Perform this process in reverse to fit a new thermocouple Replacing the ceramic insulators The thermocouple which also acts as the sensor negative electr
4. Menu which appears press Operator Now press the button along the top of the screen labelled System then press Clock e Press the area to the right of the words Current Date or Current Time This will bring up the on screen keyboard similar to figure 3 4 e After changing the time or date press Ok then Apply A blue bar will appear in the top right hand corner of the screen to indicate that the analyser is busy Wait until this disappears this can take about 1 minute then return to the Home screen by pressing the Action button in the bottom right corner of the screen then Home from the operator menu Setting alloy In order to measure the dissolved hydrogen level the ALSPEK H analyser requires two al loy calibration values which depend on the chemistry of the melt Prior to measurement the appropriate calibration values must be set either by selecting from standard pre programmed alloys or by entering the alloy constants manually Whilst on the Home screen figure 3 1 press the Alloy button After a short wait the Select alloy screen will appear Stand 15 04 08 I IN 3 7 1 Setting standard alloy The analyser is pre programmed with the calibration values for the following common al loys LM2 LM5 LM6 LM13 LM16 LM20 and LM25 These are listed on the Standard Alloys section of the Select alloy screen figur
5. The purpose of the Master Archive folder is to maintain a copy on the PC of what is on the analyser Periodically e g every week the analyser and PC should be synchronised see later so that any new data recorded by the analyser can be transferred to the PC Bear in mind that the analyser s memory is limited to 400 hours 17 days of data Eventually this will run out and when this happens old data will be overwritten by new data On the other hand the PC has a huge storage capacity on its hard disc Nothing is deleted from the Master Archive folder and provided the analyser and PC are synchronised periodically this will contain all data measured during the lifetime of the analyser Stand 15 04 08 6 4 2 7 Database files In order to use the data it must be decoded After data is added to the Master Archive folder it gets decoded and stored in a Database file Whenever data is examined e g on a chart using Review this data has come from the Database file The software will automatically use the Default database This is stored in C Program files Recorders Review review erv Setting up for the first time e To start Review click Start Programs Recorders Review If this is the first time the program has been started you will be prompted to setup the Mas ter Archive folder Accept the default location of C Program Files R
6. connections section 4 4 2 then please arrange for the melt voltage to be checked by a qualified electrician The AC melt voltage should be lt 100 mV Anything more than this will cause unreliable hydrogen readings A high melt voltage may be caused by an electrical problem for exam ple a furnace element working loose and finding an electrical conduction path to the melt Stand 15 04 08 e g by touching the outside of an electrically conductive silicon carbide crucible A prob lem such as this should be repaired by a qualified electrician A high melt voltage may also be caused by electromagnetic induction e g induction heated furnace electromagnetic pump In this case the melt voltage can be reduced by earthing the melt Please contact FOSECO GmbH to arrange a melt earthing solution Earthing of furnace casing Bad earthing of the furnace casing can also be a source of electrical noise If noise problems persist then please contact a qualified electrician to check the earthing of the furnace casing and to resolve the problem if necessary 7 4 Technical assistance If you require technical assistance please contact you FOSECO GmbH representative Error message Cause Solution Probe not connected Probe not connected Connect probe cable to analyser Temperature too low Temperature is lt 650 C 1 Ensure melt temperature is gt 650 C 2 Wait for probe to heat up Temperature too high Probe temperature is gt
7. discrepancy the analyser must be shut down and the situation must be reported to the responsible staff First Aid equipment First Aid kit etc shall be provided in the immediate vicinity of the analyser Before starting any work at the analyser which affect the operation set up updating of the analyser or which may affect the safety devices the Start Stop switching processes must be realised strictly according to the information in the operating manual Closely observe the information for maintenance and repair work when performing any in Stand 15 04 08 7 spection service maintenance or repair at the analyser Any work at the analyser shall be performed by trained and authorised personnel only When selecting personnel for such tasks users shall observe the minimum legal age Only trained and authorised personnel shall be permitted to work at with the analyser Personnel under training or apprentices shall be permitted at or near the analyser only when supervised by an experienced person Stand 15 04 08 3 1 3 2 Analyser Operation Power requirements The ALSPEK H analyser is supplied with a power cable which mates with the standard IEC power socket on the front panel of the analyser The unit is suitable for use with all AC voltages between 85 and 265 V RMS 47 to 63 Hz and requires 60 VA max power Volt age selection is automatic Starting the analyser Plug the power cord
8. give the data a batch number As discussed in the preceding section the data logger is permanently recording all data which can make individual sets of readings difficult to identify The batch numbering system allows unique identification of measurement sets which can then be isolated and plotted transferred to a spreadsheet later on using the PC software Starting a batch Immediately prior to starting a set of measurements a new batch should be started e To enter the Batch screen press the area at the top of the screen as indicated on figure 3 11 The Batch screen will appear as shown in figure 3 12 Press to enter Batch screen LA Default etre Bratpwet Oper ator Wo Raich in ALSPEK H Hydrogen 0 29 ml 100g T 750 c Alloy LM25 Sensor Good OK Replace Figure 3 11 How to select Batch screen Stand 15 04 08 I IN e To start a new batch press New e To enter a batch number press the white area next to Melt code figure 3 13 The standard on screen keyboard will appear e Enter an appropriate melt code e g Furnace name alloy date then press e Finally press Start to begin the new batch The batch name and status will be shown in the area at the top of the screen highlighted on figure 3 11 Stopping a batch After completing a set of measurements it is important to remember to stop the batch e Press
9. in the previous section will appear in the left hand pane e In the Instrument user name box enter Engineering and next to Instrument password enter the Engineering password set to 100 by default Click inside the box labelled Backup enabled so that it is ticked The Destination for the backup files is filled in automatically and should correspond to the location of the Master Archive folder defined in section 6 4 2 followed by the in strument name defined earlier in the Add Instrument window e Click inside the box labelled Transfer enabled so that it is ticked To perform the data transfer click the Transfer now button Stand 15 04 08 rN e FOSECO A dialogue box will appear asking Are you sure click Yes If your computer is running Microsoft Windows XP a message may appear regarding the firewall settings e If this happens select Unblock This will open up the firewall ports necessary for the software to communicate with the analyser A Comms Log window will appear and data will be downloaded from the ana lyser and transferred into the database this may take several minutes e When the transfer has completed close the Comms Log window e Then click OK to close the Auto Backup Transfer screen After downloading the data from the analyser the PC automatically transfers data to the da tabase which may take some tim
10. in your spreadsheet application in order to display the data properly e Figure 6 11 shows set of data exported to Microsoft ExcelTM Stand 15 04 08 Export Range C Current View Batch Find Batch Batch Name IV Show entire batch Hide data from other batches C Een Tenens ieee Duration H maama Days Hours Mins Secs Layout Copy To Clipboard Copy To File i Figure 6 10 Exporting data to a file or spreadsheet Excel A a Tims Messages 1806 2005 14 25 16 08 05 14 25 43 500 Batch start Engineenng Values IV Raw Data Sample Interval 20 Seconds Hyeregan ERES 18 08 2005 14 25 10 0805 14 25 43 500 Met Code sy sic shagal wide 3 1805 2005 14 25 Figure 6 11 Data exported to Microsoft 1 No dats date No data date No data No data No data No data 09 1 13 1 19 1 16 108 03 053 08 074 055 063 052 06 c Messages du HE dao co Hydrogen Ani Stand 15 04 08 7 1 7 2 Error messages and troubleshooting Summary of analyser error messages A comprehensive list of the different analyser error messages with causes and solutions it given on table 7 1 Startup error screen When the analyser starts up it checks its hardware to see if it is functioning properly If there is a problem then the Startup error screen will appear as shown on fig
11. pushed against spring loaded thermocouple Figure 4 5 Probe with sensor correctly fitted Stand 15 04 08 r IN 4 3 Fitting Adjusting probe clamp The removable probe clamp can be mounted at any position along the length of the probe handle shaft e After setting the clamp in the desired position secure by tightening the four retaining bolts shown on figure 4 6 1 Slide clamp to desired position 2 Secure by tightening 4 retaining bolts 7 Figure 4 6 Fitting clamp e To change the angle between the probe shaft and the clamp remove the four retaining bolts as shown on figure 4 7 Rotate the clamp clockwise or anticlockwise to the desired position then replace and tighten the four retaining bolts Stand 15 04 08 1 Secure using 4 retaining i bolts Figure 4 7 Adjusting clamp 4 4 Probe maintenance 4 4 1 Hub components e To gain access to the inside of the hub undo the retaining screws shown on figure 4 8 The hub components are labelled on figure 4 9 and their functions detailed on table 4 1 Stand 15 04 08 1 Hub lid retaining screws Figure 4 8 Hub lid in closed position secured by retaining screws 4 4 2 Checking electrical connections We recommend that the probe s electrical connections are checked regularly every week in order to ensure accurate measurements Inparticular dirt carbon and condensation of volatile alloying componen
12. sensor Sophisticated On Board Diagnostics OBD built into the ALSPEK H analyser are able to continuously monitor the sensor s hydrogen ion conductivity How ever because hydrogen ion conductivity is a non linear function of temperature the ana lyser must perform complex data analysis to evaluate the condition of the sensor This func tionality is provided by the Sensor Indicator feature visible on the analyser s Home screen Figure 3 9 shows a typical view of the main analyser Home screen when measur ing in molten aluminium Stand 15 04 08 3 9 3 EJ Default uhv e FOSECO hydrogen Analyzer Operator No Batch in Progress Hydrogen T Alloy ALSPEK 0 29 ml 100g 750 LM25 Sensor indicator Good U 5L EN Figure 3 9 Analyser Home screen under measurement conditions The analyser displays the hydrogen level melt temperature and alloy The Sensor Indica tor is visible as a coloured bar toward the bottom of the screen As the sensor begins to ex perience depletion the Sensor Indicator bar will increase in size and will change colour in the sequence blue green orange red When the sensor indicator has reached the end of the red region a change of sensor is required In this case the analyser will replace the hydrogen reading with NO DATA and the error message Replace Sensor Failing will appear Short circuit error If the a
13. sequence and allocation of personnel Aside from general compliance with the operating manual and applicable directives on ac cident prevention the user shall also ensure that generally approved and qualified technical rules for safe and proper working Without prior approval by FOSECO GmbH the user operator must not effect any changes alterations modifications or backfitting at the analyser which may in any way affect the sa fety of system This also applies to the fitting and set up of safety devices safety valves and Stand 15 04 08 7 to any welding work at load bearing structures Spare parts to be used for the analyser must comply with the technical specifications set forth by FOSECO GmbH This is always ensured when using original replacement parts Only trained and authorised personnel shall be allocated for the analyser Users shall desig nate responsibilities for operation set up service maintenance and repair 1 5 Training support As a company user you are responsible for informing and instructing your personnel on existing legal provision and directives on accident prevention as well as on safety devices and safety measures at and for the analyser Such training should consider the professional qualification of the respective employees The operating personnel must have understood the instructions and users supervisors shall ensure that the instructions are followed and applied Full compliance wit
14. socket on the front panel If you only wish to connect the analyser to a single PC this can be done relatively easily by following the instructions in section 6 2 1 To connect to an internal computer network Intranet the analyser requires the network set tings detailed in section 6 2 2 which should be available from your IT department Please contact a FOSECO representative to program the analyser with these settings Direct connection to PC To connect the analyser directly to a PC a cross over Ethernet cable is required supplied with ALSPEK analyser This type of cable has the send and receive wires crossed over inside the cable with the consequence that the send wire from the ALSPEK is con nected to the receive wire on the PC and vice versa allowing the two to communicate In order for the PC to communicate directly with the ALSPEK H the PC s IP address also needs to be on the same subnet as the analyser s IP address This means it s IP address must be the same as the ALSPEK s apart from the last number The factory setting for the ALSPEK H IP address is 192 168 3 100 Therefore setting the PC s IP address to for ex ample 192 168 3 101 will allow the two units to communicate directly e To change the IP address of a PC running Microsoft Windows XP click Start Control Panel Network and Internet Connections Network Connections If Network and Internet Connections is n
15. the Engineering level is accessible to the user the other access levels exist in order to allow FOSECO personnel to perform software upgrades To log in first lift the protective screen cover and press the Login button on the touch Stand 15 04 08 sensitive analyser screen as labelled on figure 3 1 The login screen will appear e Next press the area on the screen marked Logged out The three login levels will appear as shown on figure 3 2 e Press Engineering and then press in the white area marked Password An on screen keyboard will appear f Default uhv tapete Hydrogen Anatyser Operator Mo Progress ALSPEK Select the required access level and enter the password if required User ID Engineering Password Service Foseco Service Full Figure 3 2 ALSPEK H Login screen The default factory setting for the ALSPEK H Engineering password is 100 e To obtain an on screen numeric keypad press Numeric as labelled on figure 3 3 Stand 15 04 08 Defawtt utre eiea egen Analyser Operator Batch in Progress Figure 3 3 ALSPEK H Password screen e Enter the default Engineering password 100 then press If a mistake is made characters can be deleted using the BSpc Backspace key The analyser will return to the Home screen similar to figure 3 1 except the word Logge
16. the area at the top of the screen as indicated on figure 3 11 to enter the Batch screen and press Stop 1 Default shv agen Analyser Logger Mo Batch in Progress Nata I ArNNAF FOSECO Group Hydrogen Analyser 1 00 Status No Batch In Progress Figure 3 12 Analyser Batch screen Stand 15 04 08 I IN 3 10 2 Logger screen The ALSPEK H analyser has the capability to plot hydrogen level and temperature on a chart in real time This facility can be used to determine when the probe reading has stabi lised after immersion to monitor a degassing melt treatment or to monitor fluctuations in the hydrogen level as molten metal is added to a furnace etc To access the chart press the Logger button on the Home screen see figure 3 9 The logger will load and plot the most recently recorded data on the chart and will continue to plot new data The total time shown on the chart is 40 minutes and each grey vertical line is 6 minutes 40 seconds apart SE Note Please note that in the current version of the analyser firmware V108 pressing the button labelled High Speed on figure 2 14 has no effect of the chart speed It is intended that a future software release will allow switching between low and high speed chart recording modes Ed Default uty Hydrogen Analyser Logger No Raich in Progress Nata I annar Group Hydrogen Analyser Melt Code Figure 3 13 Analyser
17. 0 1100 1150 Figure 9 3 Hydrogen solubility as function of temperature for pure aluminium in equilibrium with 1 atm hy drogen gas Stand 15 04 08 A FOSECO 10 Alloy calibration constants 87971 69 1 87971 ST9 I 8 9 I 669 6 4 ri gt oF Fan lt gt 00 M c c M 0 c 2 19 LD m Ss 1 c 90971 90971 86971 06971 IA T 06 71 669c 24996 669c 6696 6696 6696 6696 6696 6595 669c 669c 6696 6696 6696 6696 6696 669c 4696 669c 6696 6696 669c 6696 VOV VOV SVEO VEDV AVVO sed INLSV VV ATL D 9 9541 NIG 06 15 806 USIT 096 646 196 095 196 6 96 9SEV GGG VGG YOG TOSI VSA NSS V Onrs V NSsS V GOSS V GIS V 15 DOILS V D6S V DJOLS V DG6S V 05 45 DLS V JOLO V LONS V GV Gcc 05 1ZSZ 1066 985 egz 166276 GEET E CYSTE GLET E 66 WI 9I NT IG 9 WI 6 0 INT ENONGISIV 00757 SININDGISIV 00887 UNENDGISIV 00597 SINENOGISIV OOIGT PUuO9ISIV 00057 GISIV O4 ZTISIV 00 X 00577 q cI SIV 0017 IHSIV 0007 93 9 NOTISIV SINGISIV 00587 NO DINOTISIV 00587 q SINOI SI
18. 10 8 4 1 Power 8 81 8 4 2 Ethernet 8 81 8 4 3 Analyser maintenance 8 82 APPENDIX HOW IT WORKS ALLOY CALIBRATION CONSTANTS Declaration of Conformity Make Type designation Company The following harmonised standards are applied Product design Analysing system ALSPEK H has been developed designed and manufactured in compliance with EU directives 2006 95 EG Low voltage 2004 108 EG Electromagnetic compatibility within the sole responsibility of FOSECO GmbH Gelsenkirchener Str 10 46325 Borken Germany DIN ISO 12100 Safety of machines plants and equipment DIN EN 60204 1 2006 Safety Electrical equipment DIN EN 61000 6 3 4 EMC Emission of interference DIN EN 61000 6 1 2 EMC Interference resistance Complete technical documentation is available The operating manual for the equipment is provided in the original language and in the user s language Place Date Signature Info on signing person 1 Welcome 1 1 Introduction ALSPEK hydrogen measurement system provides rapid accurate measurement of hydrogen dissolved in molten aluminium and its alloys The system can be used to 1 Perform spot measurements to check melt hydrogen levels prior 2 to casting continuously monitor dissolved hydrogen levels 3 Monitor a melt treatment in order to achieve a desired hydrogen level e g degassing The probe is of robust construction and has been designed in a m
19. 820 C 1 Remove probe from melt 2 Ensure melt temperature is lt 800 C 3 Re immerse probe Replace Sensor Failing Sensor needs replacing Replace sensor Probe electrical problem Check connections section 4 4 2 Replace Sensor Short Sensor aluminium ingress Replace sensor Circuit Probe electrical problem Check connections section 4 4 2 Thermocouple failure Thermocouple failure Replace thermocouple Probe cable not connected Connect probe cable Table 7 1 Summary of analyser error messages Stand 15 04 08 alloy calibration Problem Solution Section NO DATA displayed by Note error message displayed See table 7 1 for solution 7 1 analyser Hydrogen reading higher 1 Ensure alloy calibration constants are set correctly 3 7 lower than expected 2 Ensure analyser is programmed with the correct sensor calibration values 3 8 Unusually slow sensor re Clean end of sensor 5 4 sponse Erratic noisy readings 1 Check probe connections 4 4 2 2 Check degasser rotor position 5 2 3 Check melt voltage 7 3 Unable to enter sensor Log in as Engineering 3 3 calibration values Unable to change custom Log in as Engineering 3 3 Table 7 2 Troubleshooting problems and solutions Stand 15 04 08 8 1 8 2 9 2 1 8 2 2 8 3 8 3 1 System Specifications Description portable analyser for the direct and continuous
20. Batch screen Stand 15 04 08 7 History The entire contents of the analyser s memory can be accessed using the History function To enter History press and hold anywhere inside the data logger chart for a couple of seconds Unlike the chart on the Logger screen the History is displayed vertically e Pressing lightly on the black area inside the History screen will bring up a horizontal line The hydrogen level and time corresponding to the position of the line will be digitally dis played along the top on the History screen as shown on figure 3 15 e To change the digital display to temperature press the location shown on the top left of figure 3 15 e Press and hold the navigation bar shown on figure 3 15 to navigate through the data stored on the analyser The time and date will appear when the navigation button is pressed to allow easy browsing through the data 3 10 3 Making notes A note may be added to the data at any point This note will be permanently associated with the time at which it was entered and may be viewed at a later date either via the PC soft ware or on the History screen e To make a note press the button showing three horizontal lines circled in red on figure 3 10 e Then press Note and use the on screen keypad to enter a comment e Then press Ok Stand 15 04 08 Defau Luhy ogen Analyser Logger No Rai
21. ST NAME FIRST NAME SIGNATURE Stand 15 04 08 2 Safety 2 1 General The analyser has been designed and manufactured according to the latest state of the art and in compliance with approved rules for operational safety Nevertheless danger situations may develop for user operator or third persons or the ana lyser or other goods if the system is operated by untrained or non authorised personnel is not used as designed is improperly serviced or maintained 2 2 Information on signs and symbols The following signs and symbols are used in this operating manual to designate situations of important information CAUTION This sign warns of damage to the analyser or its equipment if the respec tive precautions are not observed All PRECAUTIONARY MEASURES must be complied with NOTE This sign advised of specific situations or conditions which shall be com plied with to ensure the proper safe and efficient use of the analyser All notes should be complied with to ensure the correct use of the analyser as designed The eye catching point designates work or control steps The listed steps must be followed in the sequence from top to bottom Stand 15 04 08 2 3 7 This dash designates itemised information Safety instructions for operating personnel The analyser may be used only when it is technically o k and when it is operated in full compliance with
22. V OOI amp F v S NOT ISIV 00067 9 OS NAISIV 00557 09NLISIV 00107 SINLISIV 00007 00017 SJNTISOTINDIV LLPhOIV 0011 LL9APNOIV 00017 66 IV eorroum 9491 NA NIG edoang Stand 15 04 08 p FOSECO 674 I 86 71 01 71 99 71 06971 60771 Oo 1 ON Ma M 10 DH C O c2 onIII BG 2 oO N gt 45 G Qo 515 ri m er 5 a T 6696 6696 669c 1696 6696 6696 6696 6696 6696 6696 996 9996 6696 6696 6696 G69G 6696 6696 6696 6696 669c 9 VLOV V80V SVEO HcOV saro GIDAV 01DAV 6 059 VIG G SIG G VIG 6 666 06 966 TETP GEE OSE V Tete 78 POSE OGZ V 99 99 V LE9 V DNO8IS V NAcIS V 1cIS V VAGIS V VDENLS V VA VEN6S V A amp N6S V VAENGS V 165 SIr INLSV VV ueder VSA G9c 095575 6c E Tec EGET E V9cc 955 9 9541 NIG 06 SY Auem WI OT WT WI 66 WI SC INT OG L WI WI OG WT 96 LG WT VG WI SINGUZIV OISINIV tS eS NIV GSINIV 69 NIV 9 eS NIV q eS NIV INSINUO CISIV INSINUOT6LISTV SINFUDLTISIV SJNINNOGTISIV 24 NOGTISIV ND ZTISTV SINENOGISTV CUOLISTY UZ 94 ENDGISTV SININOGISTV SINENOLISTV ENOSISTV OTIISIV 24 ENOGISIV
23. age from which the keyboard was called Cancel Causes a return to the page from which the keyboard was called without saving the new string Please Note The character on each display key is always a capital letter whether or not the actual character being entered is in capitals or lower case After entering the new password enter it a second time for confirmation in the area marked Retype Password Note There is also a section named Remote Password This password is re quired when connecting to the analyser using the PC software section 6 To avoid confusion it is recommended to set the remote password the same as the analyser password you have just entered e After keying in and then re typing the remote password press Apply A blue bar will appear in the top right hand corner of the screen to indicate that the analyser is busy e Wait until this disappears this can take about 1 minute then return to the Home screen by pressing the Action button in the bottom right corner of the screen then Home from the operator menu Stand 15 04 08 3 6 3 7 7 Setting Date and Time The time and date are displayed in the top right hand corner of the analyser screen e To adjust these first log in following the instructions in section 3 3 Next press the Action button in the bottom right hand corner of the screen labelled figure 3 1 e From the Root
24. alyser has built in high capacity data logger which records meas urement every 10 seconds The unit is capable of storing up to 17 days of data For security reasons it is not possible to stop the data logger it records all the time whenever the ana lyser is switched on even if the probe is not in molten aluminium After the 17 days of available memory is used up data older than 17 days is discarded and new data is added Therefore to avoid data loss the analyser should be synchronised with a PC computer and the new data downloaded at regular intervals e g every week Details of synchronising the analyser with a PC computer are provided in section 6 4 3 Meaning Raw sensor V Voltage output from sensor V Raw Temperature Temperature from thermocouple C Probe fitted Detects if probe is connected Probe impedance Probe impedance kQ A Sensor constant A B Sensor constant B C Alloy constant C D Alloy constant D R 700 Sensor constant R 750 Sensor constant R759 Hydrogen Hydrogen reading ml 100g Rc Internal calculation Sensor Indicator Numeric value of Sensor Indicator Temperature Temperature used in calculations C Table 3 2 Explanation of Diagnostics screen Stand 15 04 08 I IN 3 10 1 Batch numbers When making dissolved hydrogen measurements it is important to
25. and recording without the written permission of the copy right holder Applications should be addressed in the first instance to FOSECO GmbH Violation of this directive and or such rights are subject to legal proceedings and damage claims may be presented We FOSECO GmbH reserve the right to execute commercial protection rights All statements information and data contained herein are published as a guide and although believed to be accurate and reliable having regard to the manufac turer s practical experience neither the manufacturer licensor seller or publisher repre sents nor warrants expressly or impliedly 1 their accuracy reliability 2 that the use of the product s will not infringe third party rights 3 that no further safety measures are re quired to meet local legislation The seller is not authorised to make representations nor contract on behalf of the manufacturer licensor All sales by the seller are based on their conditions of sale available on request 1 4 Information for the user The operating manual is an essential elements of the ALSPEK H analyser The user shall ensure that all operating personnel will comply with these directives The user shall complement the operating manual with respect to existing national directives on accident prevention and environmental control including information regarding supervi sory activities by authorities and pertinent mandatory reports e g as to work organisation work
26. as follows e Login as Engineering To do this press in the top left of the screen where it says Logged out e Then press next to User ID and select Engineering e Then press on the blank space next to where it says Password e Then press Numeric towards to bottom of the window that appears e Then enter 100 using the on screen keypad Then press OK e Press the button in the bottom right hand corner of the screen then press Operator then Archive then Local e Puta memory stick into the left USB socket the one furthest from the Ethernet network socket Ensure the memory stick has at least 32MB of space on it Press where it says mediacard then select usb1 Press the Archive button The data will now be transferred to the memory stick The analyser will display a message when the data transfer is complete this may take a few minutes e When this message appears press e Then remove the memory stick from the analyser All the data will be in a folder called History in the memory stick To load the new data into the database of the Review PC software proceed as follows e Insert memory stick into a free USB slot on the PC e Start Review then go to File then Transfer then From removable Media e Select the drive corresponding to the USB memory stick and press The data from the memory stick will then be tran
27. b components 4 4 2 Checking electrical connections 4 4 3 Replacing thermocouple 4 4 4 Replacing the ceramic insulators 4 4 5 Replacing the ceramic sheath MEASUREMENT PROCEDURE Prior to measurement Procedure Sensor life Examples of response behaviour CONNECTION TO PC OR COMPUTER NETWORK PC software installation 3 24 3 25 3 25 3 27 3 28 3 29 3 30 3 31 3 32 3 33 3 35 3 36 4 39 4 39 4 40 4 41 4 42 4 43 4 43 4 44 4 49 4 49 4 50 5 51 5 51 5 51 5 53 5 54 6 59 6 59 User Manual Alspek H 6 2 6 3 6 4 7 1 7 2 7 3 7 4 8 1 8 2 8 3 8 4 Getting connected 6 2 1 Direct connection to PC 6 2 2 Connection to Ethernet network Remote Viewer Downloading processing data Review software 6 4 1 Understanding Review 6 4 2 Setting up for the first time 6 4 3 Downloading data 6 4 4 Plotting exporting data ERROR MESSAGES AND TROUBLESHOOTING Summary of analyser error messages Startup error screen Troubleshooting Technical assistance SYSTEM SPECIFICATIONS Description Technical Performance 8 2 1 Response time 8 2 2 Reproducibility Salient Features 8 3 1 The analyser unit 8 3 2 The measuring probe 8 3 3 The sensor Analyser connections maintenance 6 60 6 60 6 61 6 62 6 63 6 63 6 64 6 65 6 69 7 76 7 76 7 76 7 77 7 78 8 80 8 80 8 80 8 80 8 80 8 80 8 80 8 81 8 81 8 81 User Manual Alspek H 9
28. ch in Progress Hydrogen mi 100g 0 29 Temp Press to make a note Figure 3 14 Analyser Logger screen Stand 15 04 08 Navigation bar Press to switch between hydrogen and temperature Digital display E why regres ous ES Figure 3 15 Analyser History screen Stand 15 04 08 4 1 4 1 1 Probe Operation Probe overview Figure 4 1 shows a fully assembled ALSPEK H probe The metal handle includes a remov able clamp and a hub where all electrical connections are made The replaceable ceramic sheath is fitted to the handle by means of a collar and replaceable sensors are fitted to the end of the ceramic sheath 1 Sensor P 5 2 Ceramic sheath 3 Threaded collar _ _ 4 Adjustable clamp gt 5 Handle 6 Hub 7 Cable socket Figure 4 1 Fully assembled ALSPEK H probe Probe hot end Figure 3 2 shows the hot end end of the ALSPEK probe i e the end to be immersed in molten aluminium without a sensor fitted The thermocouple which also acts as the nega tive sensor electrode runs through the centre of the probe This component is spring loaded by means of a mechanism located in the probe hub ensuring that the end of the thermocou ple is in permanent contact with the negative sensor electrode when a sensor is fitted The threaded ceramic component is made from electrically c
29. ction 3 for full details of how to operate the analyser logging in etc Remote Viewer Configuration Host name 192 168 3 100 Username Engineering Car Alarm Password required Startas Lite Channel Alarm Sound START Police Siren lt Figure 6 2 Setup of Remote Viewer software Stand 15 04 08 rN e FOSECO 6 4 Downloading processing data Review software 6 4 1 Understanding Review The Review program allows the following 1 Downloading of data from the analyser 2 Generating charts of data These may be saved and printed 3 Exporting data to a spreadsheet e g Microsoft Excel Analyser data files The logged data inside the analyser s memory is stored in special files with the file exten sion uhh These are encoded for security reasons and can only be decoded using the view program The uhh files themselves can only be transferred to the PC via the Ethernet socket The data transfer process is performed using the Review program and once it has been set up data can be downloaded and plotted on a chart exported to a spreadsheet quickly and easily Review maintains a permanent record of all data which has ever been recorded by the analyser allowing complete data archiving in excess of the limitations of the analyser s memory The Master Archive folder All data downloaded from the analyser to the PC is stored in the Master Archive folder
30. d Out in the top left corner of the screen will be replaced with Engineering to in dicate that the user is logged in 3 4 Logging out e To log out press on the area labelled Engineering in the top left corner of the screen e Then press the Logout button Stand 15 04 08 3 5 Changing the password 13 Default uhy Hydrogen Analyser Operater No Batch in Progress sm Figure 3 4 ALSPEK H password entry The ALSPEK H analyser is shipped with the Engineering password set to 100 This pass word may be changed by the user for increased security To change the password first log in following the instructions in section 3 3 Next press the Action button in the bottom right hand corner of the screen labelled on figure 3 1 From the Root Menu which appears press Operator Now press the button along the top of the screen labelled Security then press Access The security access screen will appear as shown in figure 3 5 Press the area next to New Password An on screen keyboard will appear as shown in figure 3 3 Stand 15 04 08 Use the on screen keyboard to input the new password Stand 15 04 08 Any alphanumeric characters may be used and the passwords are case sensitive To access alphanumeric characters or numbers press the buttons along the bottom of the on screen k
31. e 3 6 e To select a standard alloy press the button corresponding to the desired alloy then press Exit The selected alloy will now appear on the Home screen M Default uhv Hyd ogen Analyser Alvy No Hatch in Progress Select Alloy Standard Figure 3 6 Alloy screen B Please Note It is necessary to be logged in to select an alloy from this list Stand 15 04 08 7 IN 3 7 2 Setting custom alloy parameters 3 8 If the desired alloy is not included on the list of standard alloys a Custom alloy may be specified by programming the analyser with two constants and D A list of and D values for a wide range of alloys is provided in Appendix B of this manual e To calibrate the analyser for a custom alloy first log in following the instruction in section 3 3 e Next press the Edit C button on the Select alloy screen A box called Custom Write C will appear e Press the area next to the word Constant currently contains a zero A numeric keypad will appear on the screen e Enter the appropriate value for constant C and press Ok Then press Write now e Repeat this procedure for the constant and then log out section 2 4 to prevent unauthorised users from changing the custom alloy calibration constants Note Note that it is necessary to be logged in to change the custom alloy calibra
32. e depending on the PC s hardware Please wait for this process to finish before proceeding This data download procedure only downloads new data which has been added to the ana lyser s memory since it was last connected Every time the analyser is connected to the PC and synchronised by pressing the transfer now button the Master Archive file gets updated with any new data which was recorded since last time the analyser and PC were synchronised Note It is recommended to perform this procedure at regular intervals e g every week to ensure that the PC maintains a complete copy of all data recorded by the analyser Stand 15 04 08 Auto Backup Transfer Run Auto Backup Transfer as a Service Instrument user name Engineering Instrument password I BACKUP Backup enabled Files to backup Archive Files Destination Program Files Eurotherm ReviewAlspek 10 Archiving On during backup Delete from instrument after backup TRANSFER Transfer enabled Files to also transfer to the database Instrument tag if not configured in instrument Alspek 10 AUTOMATE Nest run Day of month 5 o Min fo Repeat every fi Day Also run immediately new file detected Transfer now Figure 6 4 Synchronising analyser data with PC Stand 15 04 08 rN e FOSECO To transfer data from a Mk3 analyser to a USB memory stick proceed
33. e of response is shown on figure 5 1 This type of response is commonly seen when the probe has been used for the first time that day If the probe is exposed to air at room temperature for many hours e g overnight it takes on moisture from the atmosphere In the melt this moisture reacts with aluminium to form excess hydrogen causing an artificially high hydrogen reading After a time all the moisture will react and the true hydrogen level is measured It should be noted that the first measurement of the day will always take longer than usual to respond in a static melt This response is sometimes also observed if the end of the probe is completely sealed by frozen aluminium from the previous dip In this case hydrogen can come out of solution as the metal freezes causing an artificially high hydrogen level around the sensor at the start of the next dip Stand 15 04 08 7 Reading increases from a low value A low hydrogen level may appear immediately after immersion which will gradually in crease to the true hydrogen level An example of this type of response is shown on figure 5 2 This is common response behaviour which tends to occur if the probe was not sealed with frozen aluminium when removed from the melt after the previous dip Slow response curve After a number of repeated dips a slow response similar to that shown on figure 4 3 may be seen in a static melt This is likely to be caused by the build u
34. ecorders Review Next a dialogue box will appear asking Do you want to temporarily enable Review Full features e Click next to Don t ask me this again so that it is ticked then click No In order to retrieve data it is necessary to give the software details of the analyser This only needs to be done once in future when Review loads it will remember the settings needed to communicate with the analyser e Click Instrument then Setup then TCP IP The instrument list should be blank e Click Add Instrument in the bottom left corner e Type the analyser s IP address into the box labelled TCP IP address or host name this will be 192 168 3 100 unless modified by a FOSECO representative e In the Identifier box type in a name for the analyser e g ALSPEK then click Review has now been set up to work with the analyser the next time the software is star ted it will remember the above settings Stand 15 04 08 Instrument Setup TCP IP TCP IP Address Host Name Alspek 10 192 168 3 100 192 168 3 100 Identifier Alspek 10 Connect Timeout secs B Use proxy for FTP Use Passive FTP Add Instrument Remove Instrument Figure 6 3 Setup of Bridge software 6 4 3 Downloading data To download data from the analyser click Instrument then Auto Backup Transfer The instrument name ALSPEK H as defined
35. ed by every person who is engaged in work details at with the ana lyser as there are Operation including set up fault correction during normal operation removal of pro duction waste general care of the system disposal of operating and auxiliary media Service and maintenance general service inspection maintenance repair and or Transport of the analyser Post shipment checking procedure The components supplied with an analyser and a probe are listed on table 1 1 Please use this list to check the shipment has arrived intact The actual shipment may also include ad ditional components ordered as spares e g spare thermocouple ceramic sheath wa Sensor s depends on order Table 1 1 ALSPEK H shipment checklist Note The probe handle thermocouple and ceramic sheath are supplied pre assembled Stand 15 04 08 rN e FOSECO 1 3 Information on copyright and other property rights The operating manual shall be treated as a confidential document It shall be made available to authorised personnel only Access by third persons may be granted only after prior writ ten approval through FOSECO GmbH FOSECO the logo and ALSPEK are registered Trade Marks of the FOSECO Group of Companies used under licence All rights reserved No part of this publication may be re produced stored in a retrieval system of any nature or transmitted in any form or by any means including photocopying
36. ent Stand 15 04 08 A Figure 4 9 Hub components and electrical connections Stand 15 04 08 Number Identity 1 Negative thermocouple connection white 2 Positive sensor connection clear colour 3 Positive thermocouple connection green 4 Negative sensor connection black 5 Thermocouple 6 Hub casing 7 Graphite cap 8 Probe cable socket 9 Bayonet thermocouple fitting 10 Clamp for positive sensor wire Table 4 1 Identity of electrical connections gt CoO 1 I 2 3 4 lt 500 lt 10 OC Table 4 2 Checking probe electrical connections Open circuit cap OC Open Circuit OC lt 200 Stand 15 04 08 1 2 Q3 N e 1 I OC Cv gt 1 1 3 OC lt 500 OC 4 OC 5 OC lt 20 OC OC OC 10 6 OC OC OC OC OC Table 4 3 Checking probe electrical connections Short circuit cap Circuit OC lt 200 e After verifying the probe connections under open circuit conditions unscrew the open circuit cap and fit the short circuit cap e Verify that the resistance between points 2 and 4 the sensor positive and negative terminals is lt 20Q as shown in table 4 3 Note Note that the only difference between table 3
37. etup Before making a measurement e Ensure analyser is set to the correct alloy see section 3 7 e Ensure analyser is calibrated for the sensor currently in use see section 3 8 e Ensure melt is below 800 C or below 825 C if a high temperature sensor is being used Procedure Proceed as follows e Ensure that the protective screen cover is down so that the touch sensitive analyser Stand 15 04 08 7 screen is protected from aluminium splashes Clamp the probe firmly above the melt ensuring that the cable is clear of the molten metal Maximum cable temperature 250 C e Ensure that the probe hub does not exceed 250 C e Scrape the melt surface to remove dross Slowly lower the probe into the melt Ensure that the is between 15 30 cm beneath the melt surface If the cap is immersed less than the minimum depth lt 15 then erroneous hydrogen readings may occur Do not immerse deeper than 30 cm as this may cause the handle to overheat Wait for the dissolved hydrogen reading to stabilise This typically takes 1 5 minutes However the response time can vary for a number of reasons discussed in section 5 4 It is helpful to view the analyser logger screen to judge when the reading has stabilised see section 4 10 2 e After completing the measurements remove the probe from the melt clamp securely or place on a firm heat resistant surface away from the heat and allo
38. eyboard labelled Alphabet Alphabet 2 Numeric Symbols as required ET Default uhy Security Access New Password Retype Password 0 00 Connect from remote D lt Remote user name Engineering Remote password Retype remote password Login Disabled Edit Own Password gt lt Change Alarm Setpoints gt lt Acknowledge Alarms gt lt Edit Maths Constant ResetMaths Set Clock X Adjust Inputs Archiving Control DZ SaveRestore Paste Delete Files DZ Figure 3 5 ALSPEK H Menii Sicherheits Zugang Underneath the keyboard are six keys with the functions listed below When active the background colour changes to yellow for as long as the key is active Shift Pressing Shift causes the next entered letter to appear in capitals subsequent letters will be in lower case Caps When pressed all subsequent letters will appear in capital letters until the Caps key is operated again BSpc Press this key to delete a character if a mistake is made This key backspace deletes a character to the left of the cursor Ovr If selected the next entered character replaces overwrites the exist ing character to the right of the cursor position If Ovr is not se Stand 15 04 08 7 IN lected the next entered character is inserted into the existing text string at the cursor position OK Used to save the new text string and to return to the p
39. h the information provided during such training is prerequisite for correct and safety conscientious working of your personnel Therefore the company user shall keep a written record of training se minars which shall be countersigned by all participants The following pages show a range of topics for training lessons including a form sheet to be copied for the attendance record Stand 15 04 08 1 6 Examples for topics in training lessons SAFETY Directives on accident prevention General legal provisions General safety instructions Measures for emergency situations Personal protection equipment Safety instructions for using the ALSPEK H analyser Use of safety devices at the ALSPEK H analyser Safety devices in the vicinity of the ALSPEK H analyser Meaning of signs and symbols OPERATING THE ANALYSER Use of operating and control elements for the ALSPEK H analyser Training of operating personnel in the use of the operating manual Operating experience gained at the user s ALSPEK H analyser Use of operating media auxiliary media and accessories Special experience from the use of the ALSPEK H analyser Correcting of operational faults and discrepancies SERVICING AND MAINTENANCE Correct use of cleaning agents lubricants Special experience from service maintenance and general care of the ALSPEK analyser Stand 15 04 08 1 7 Attendance record ACKNOWLEDGEMENT OF TRAINING Training subject topic LA
40. ial which generates a known hydrogen concentration The electrode exposed to the solid state reference is the Reference Electrode and the electrode exposed to the measured gas is the Measuring Electrode Stand 15 04 08 Air Molten Aluminium Figure 9 2 Principle of probe operation Figure 2 2 shows a schematic arrangement of a probe to measure hydrogen concentration in molten aluminium At the end of the probe there is a porous diffusion barrier Hydrogen dissolved in the melt comes out of solution and the hydrogen gas enters a sealed cavity as shown The measuring electrode of a hydrogen concentration cell is exposed to the gas ity The voltage from the hydrogen concentration cell is measured and because the reference hydrogen concentration is known the concentration of hydrogen gas in the gas cavity can be calculated To work out the hydrogen concentration in the melt the solubility of hydro gen needs to be known Figure 9 3 shows the hydrogen solubility for pure aluminium and it can be seen that solubility depends strongly on temperature Therefore the melt temperature must also be measured in order to calculate the dissolved hydrogen level Hydrogen solubil ity also depends on the alloying components in the melt which is why the analyser needs to be set to measure the correct alloy Stand 15 04 08 Liquid aluminium Dissolved hydrogen ml 1009 Solid aluminium 750 800 850 900 950 1000 105
41. into the analyser and press the power switch It is not necessary for the probe cable to be plugged in to set up the analyser After approximately 5 minutes the analyser Home screen will appear as shown on figure 3 1 The Alpsek H analyser is operated using a touch sensitive colour screen Note Do not use solvents cleaning products on touch sensitive screen or pro tective screen cover Pressing a button on the screen will bring up a new screen or a menu from which various options may be selected Before measuring in molten aluminium the analyser needs to be set with the correct sensor and alloy calibration constants using the procedures detailed in the following sections Analyser firmware version is displayed in grey at the bottom right hand corner of the Home screen figure 3 1 If necessary the firmware may be upgraded by a FOSECO rep resentative to provide additional functionality e g alarm outputs Stand 15 04 08 3 3 Login button z Jefault utrv Hydrogen Analyser Operator Wo Hatch in Progress ALSPEK FOSECO mr a DATA ml 100g T NODATA C Alloy LM25 Replace Action button Figure 3 1 ALSPEK H Home screen with no sensor connected Logging in Unauthorised access to the analyser is prevented by means of a login system There are three logging in levels 1 Service FOSECO GmbH 2 Service Full 3 Engineering Only
42. ll settings If the analyser is situated behind a firewall the following ports will need to be opened by your system administrator if you wish to access the analyser from outside the firewall Program name Ports used Remote viewer 126 50010 Review 20 21 FTP access 20 21 Table 6 2 Firewall settings Stand 15 04 08 6 3 r IN Remote Viewer The Remote Viewer program allows remote operation of the analyser directly via the Ethernet cable or over a computer network To start Remote Viewer click Start All Programs Recorders Remote Viewer The setup screen will appear e In the Host name section type in the analyser s IP address If the analyser is connected directly to a PC this will be 192 168 3 100 e In the User name section type Engineering Tick the Password required box and leave the Start as lite box unticked e To connect to the analyser press Start e When prompted enter the Engineering password default is 100 If your computer is running Microsoft Windows XP a message may appear regarding the firewall settings e If this happens select Unblock This will open up the firewall ports necessary for the software to communicate with the analyser After a short wait the analyser Home screen will appear The analyser can now be controlled via the PC exactly as if the user is standing in front of the unit Please refer to se
43. lows easy navigation to the desired data There are three ways to navigate to the desired data 1 Relative date and time 2 Specific date and time 3 Batch Stand 15 04 08 Select Point Hydrogen Analyser Hydrogen Temperature Figure 6 6 Plotting exporting data Select Point DV13 DV46 Stand 15 04 08 amp Review Chart1 File Edit View Instrument Chart Security Options Window Help 1 Second vi Tempetature lt 2811 0 05 13 11 51 28 10 05 13 19 10 2871 0 05 13 20 46 E Figure 6 7 Default data chart If the data was not recorded as a batch see section 3 10 1 then it will be necessary to navi gate to the data using either of the first two options In this case the relative or specific time and date should be specified and also the duration of data to be displayed Ifthe desired data was recorded as a batch press the Find Batch button This will bring up the Batch Selector screen which is a list of all the data batches that have been recorded Select the desired batch the click Ensure that the Show entire batch option is ticked then click OK An example of a set of data is shown on figure 6 9 e The time scale can be adjusted by clicking the arrow circled in red on figure 6 9 The chart can be printed or saved by selecting Print or Save Chart from the File menu Stand 15 04 08 E
44. measurement of dissolved hydrogen in both foundry and wrought aluminium alloys Ein tragbares Analysegerat f r die direkte und dauernde Bestimmung des gel sten Was serstoffgehalts in Legierungen bei GieDereien und Schmieden Technical Performance Response time Time to indicate equilibrium hydrogen concentration in a static melt typically 5 minutes from point of immersion During continuous measurement of hydrogen thereafter response time to a change in hydrogen concentration is 5 seconds Reproducibility Reproducibility 0 01 ml 100g or 3 of hydrogen concentration Salient Features The analyser unit The analyser unit has the following features 1 The unit is of robust and portable construction being set in a briefcase style aluminium carrying case 2 The unit is provided with a touch screen which gives access to several display and di agnostics screen options 3 The main screen shows continuous hydrogen and temperature readings together with sensor condition indicator and sensor failure alarm 4 The second screen gives a real time and continuous graphic display plotting changes in both hydrogen level and temperature 5 data logger automatically records up to 17 days of measurements Data history can Stand 15 04 08 rN e FOSECO be accessed directly via the touch screen or downloaded to a PC computer for subse quent conversion into a graph A third screen gives full diagnostic information
45. nalyser detects a short circuit between the sensor electrodes the hydrogen reading will be replaced with NO DATA and the error message Replace Sensor Short Circuit will appear This may be caused by failure of the sensor due to aluminium ingress in which case a new sensor should be used Stand 15 04 08 I IN 3 9 4 Diagnostics screen To assist with troubleshooting a Diagnostics screen is available This collects all the data which is being used to calculate the hydrogen level and displays it on a single screen in or der to quickly and easily identify problems should they occur To access the Diagnostics screen press the Action button in the bottom right corner of the Home screen see figure 3 1 e Select Goto Group then select Diagnostics Figure 3 10 shows a typical view of the Diagnostics screen when measuring in molten aluminium The meaning of the items shown on the Diagnostics screen is detailed on ta ble 3 2 e To exit from the Diagnostics screen and return to the Home menu press the Action button in the bottom right corner of the screen see figure 3 1 then select Home kA Default utv Diagnostics 0 027 Fitted 2657 8 0 0 21 10 0288 teni 0 6194 749 SS ae Figure 3 10 Analyser Diagnostics screen under measurement conditions Stand 15 04 08 3 10 Data logging 7 The ALSPEK H an
46. ode is fitted with ceramic insulators shown in white on figure 4 2 to prevent an electrical short circuit To replace the insulators first remove the thermocouple following the procedure detailed in the above section e Pull firmly on the insulators to remove them from the thermocouple e To fit new insulators slide the first insulator over the thermocouple and push all the way to the end until the metal collar on the thermocouple is reached e Slide on the remaining insulators and re fit the thermocouple Stand 15 04 08 7 4 4 5 Replacing the ceramic sheath Removing the ceramic sheath Before replacing the ceramic sheath first remove the thermocouple as detailed in section 4 4 3 Release the positive sensor wire by unscrewing the terminal block connection labelled 2 on figure 4 9 and unscrewing the positive wire clamp labelled 10 on figure 4 9 Next undo the threaded collar shown on figure 3 1 by hand and carefully detach the ceramic sheath from the probe handle Fitting a new ceramic sheath A replacement ceramic sheath is supplied with an insulated wire protruding from one end This is the positive sensor wire First feed the wire carefully through the probe handle and into the hub Ensure that the wire passes through the positive wire clamp labelled 10 on figure 3 9 Next locate the metal collar of the ceramic sheath into the end of the probe handle Slide the threaded metal colla
47. odular fashion to allow easy replacement of any component Calibration is assured through individual calibration of each ALSPEK H sensor prior to shipment in a precisely controlled hydrogen atmosphere The ALSPEK H analyser employs state of the art hardware and has been built to withstand the demanding operating conditions of a foundry shop floor The analyser s numerous fea tures are accessed via a touch sensitive colour screen supplied with a replaceable protective cover The analyser offers secure and reliable data collection and storage and is managed by a login system to prevent unauthorised access Sophisticated On Board Diagnostics OBD continuously monitor the condition of the sensor and inform the operator in case of prob lems The unit may be controlled remotely by direct connection to a PC computer or from anywhere in the world by connection to an Ethernet computer network This operating manual is essential tool for the successful and safe use and operation of the ALSPEK hydrogen measuring system viz Analyser The operating manual holds important information the knowledge of which is prerequisite for the proper safe and efficient use of the analyser and to reduce repair cost and down times and to maintain and improve the reliability and service life of the analyser Stand 15 04 08 1 2 rN e FOSECO The operating manual must be readily available at the analyser and it shall be studied and the information be appli
48. on calibration constant settings and sensor outputs Maximum operating temperature 50 C 8 3 2 The measuring probe 8 3 3 8 4 8 4 1 8 4 2 The measuring probe has the following features l The probe is of metal and ceramic construction Connection to the analyser is by an armoured cable with quick fit connectors on both ends The probe is fitted with a thermocouple for continuous measurement of metal tempera ture The sensor The sensor has the following features The sensor is individually calibrated The sensor is a replaceable unit with a quick screw fit onto the end of the probe The sensor is a self contained unit requiring no outside gas source for reference or purging purposes The sensor is capable of measuring and recording changes of hydrogen concentration during a degassing treatment with an inert gas Analyser connections maintenance Power The unit is suitable for use with all AC voltages between 85 and 265 V RMS 47 to 63 Hz and requires 60 VA max power Voltage selection is automatic Ethernet Ethernet socket is a 10 BaseT connection Stand 15 04 08 7 IN 8 4 3 Analyser maintenance Cleaning Clean the analyser screen regularly using a soft cloth Ensure no dirt debris become at tached to the screen or between the screen and analyser enclosure NOTE Do not use solvents cleaning products on touch sensitive screen or pro tective screen cover Internal batte
49. onducting ceramic This allows sensors to be secured to the end of the probe and also acts as the positive sensor electrode A replaceable ceramic insulator is fitted to the thermocouple to prevent electrical contact between the positive and negative electrode wires Stand 15 04 08 a Figure 4 2 Hot end of ALSPEK H probe no sensor fitted 4 1 2 Sensors rN e FOSECO 1 Thermocouple tip elec trode 2 Ceramic Insulator 3 Threaded ceramic electrode 4 Ceramic sheath An ALSPEK H sensor is shown on figure 4 3 When in position the sensor negative elec trode shown makes contact with the thermocouple tip Each sensor is fitted with a threaded graphite cap which screws onto the threaded ceramic at the hot end of the probe When in molten aluminium the positive sensor electrode and graphite cap are in electrical contact as the molten metal is an electrical conductor Figure 4 3 An ALSPEK H sensor 1 Positive sensor electrode 2 Negative sensor electrode 3 Threaded graphite cap positive sensor electrode Stand 15 04 08 I IN 4 2 Fitting Sensors e Hold the sensor by the graphite cap and locate the thermocouple tip on the end of the sensor as shown in figure 4 4 e Rotate the graphite cap clockwise and screw the sensor onto the end of the probe Do not over tighten finger tight is sufficient A correctly fitted sensor is shown on figure 4 5 Figure 4 4 Sensor
50. or If the analyser de tects a problem with the sensor it will immediately display an appropriate error message in dicating the nature of the problem If a Replace Sensor error message appears the probe should be removed from the melt and the sensor changed The On Board Diagnostic fea tures of the ALSPEK H analyser are discussed in detail in section 3 9 The sensor life will depend on the type of measurements made e g continuous immersion batch testing and on the physical conditions alloy temperature degree of agitation in the melt Stand 15 04 08 5 4 7 Examples of response behaviour The response behaviour of the ALSPEK H can vary depending on operating conditions All of the following are known to influence response behaviour Agitation in the melt Alloy Temperature How long the probe has been out of the melt Whether or not the sensor is coated with frozen aluminium before immersion Number of dips Regardless of the transient behaviour immediately after immersion the true hydrogen level will always be measured after the reading has stabilised However it is useful to examine the transient behaviour to gain a better understanding of how the probe performs Reading decreases from a high value Sometimes a high hydrogen reading will appear immediately after immersion and the read ing will then decrease from this high value and stabilise at the true hydrogen level An ex ample of this typ
51. ot visible click Switch to Category View toward the top left of the window Then right click on the icon labelled Local Area Connection and select Properties Left click once on Internet Protocol TCP IP and click Properties Left click once on the button Use the Following IP Address and fill in the following IP Address 192 168 3 101 Subnet Mask 255 255 255 0 Leave the other fields blank Click OK then Close on the Local Area Connection Properties window and close any other windows e Finally connect the analyser to the PC using a crossover Ethernet cable Stand 15 04 08 6 2 2 7 The connection is now complete and the analyser can now be accessed via the PC using the procedures detailed in this section Note If the PC is being used on a computer network it may be inconvenient to keep changing the IP settings between the network and the analyser To avoid this we recommend installing a second Ethernet network card lt 50 Euros on the PC for dedicated use with the analyser Connection to Ethernet network The analyser can connect to the network automatically using an IP address from a BootP server or the network settings can be entered manually In the latter case the following are required 1 IP address 2 Subnet Mask 3 Default Gateway Please contact a FOSECO representative to set up the analyser on a Ethernet computer net work Firewa
52. p of a dross or oxide layer on the end of the probe This can be corrected by removing the probe from the melt and care fully wiping the molten aluminium from the end of the probe particularly the very bottom using graphite or alumina insulating blanket wool Stand 15 04 08 FOSECO e e 5 wo S 50 80 81 u 60 80 81 u 60 80 81 S N 5 gt 007 060 080 020 090 050 z 070 060 020 oro 000 ueBoJp H 0001 6 8 002 009 2 00 002 00 2 Figure 5 1 Probe response decreasing from high value Stand 15 04 08 Temperature C o 10 20 30 40 500 600 700 800 900 1000 Hydrogen ml 00 0 10 0 20 0 30 0 40 0 0 70 0 80 0 1 0 E a gt gt 18 08 05 RY L 18 08 05 HH T 18 08 05 18 08 05 St HH 18 08 05 16 54 00 Hydrogen E 18 08 05 16 56 00 e eo 8 3 1 a 18 08 05 Figure 5 2 Probe response increasing from a low value Stand 15 04 08 FOSECO xx e S Q og 60 80 81 8 2 e S 020 oro 00 000 006 008 Z c L eumesedue Figure 5 3 Probe response Slow response Stand 15 04 08 6 1 7 Connection to or computer network PC software installation The ALSPEK H analyser is s
53. pertinent safety rules and instructions Faults or discrepancies which in any respect may affect the operational safety must be correct with no delay Every person who is engaged with the mounting installation commissioning operation service or maintenance must have read and understood the contents of this operating man ual with particular emphasis on chapter 2 Safety In particular this applies to personnel who are not regularly active at the analyser This operating manual must be readily available in the immediate vicinity of the analyser Pertinent directives for accident prevention as well as other generally accepted rules and di rectives for health and work safety shall be complied with Responsibilities for the various activities and work details must be clearly defined and ad hered to This is the only way to preclude false handling and or control inputs particularly in danger situations The user operator shall enforce that operating personnel will wear personal protection equipment Where required or dictated by relevant directives personal equipment such as protective goggles leather or metal coated gloves and safety shoes must be worn Personnel shall not wear open long hair loose clothing or jewellery This is to preclude the possibility of injuries by getting caught or pulled into the machine by rotating parts If you should observe any safety relevant changes of the analyser s operating behaviour or any other
54. r constants B R700 and R750 e Then press Exit to return to the Home screen e Finally log out section 3 4 to prevent unauthorised users from changing the sensor calibration constants Stand 15 04 08 Default Hydrogen Analyser Sensor No Batch in Progress Sensor Calibration Calibration Constants 30 B 99 Edit A Edit B R 700 80 24750 50 Figure 3 7 ALSPEK H Sensor calibration screen 3 9 On Board Diagnostics The Alspek H analyser is equipped with sophisticated On Board Diagnostic OBD hard ware If the analyser detects a problem with the sensor the thermocouple the probe or the operating temperature it will display an appropriate error message and will immediately display NO DATA in place of the hydrogen reading to prevent erroneous readings from being taken The error messages will only appear on screens which involve data collection i e the Home and Data Logger screens Stand 15 04 08 ba Default uhy egen Analyser No Batch in Progress FOSECO Status OK Constant 0 Figure 3 8 Set constant A screen 3 9 1 Temperature error messages Thermocouple Failure The analyser continuously checks the thermocouple whilst measuring and will display a Thermocouple Failure error message if a problem is detected Temperature too low The minimum probe operating temperature is 650 C If the thermocouple
55. r over the ceramic sheath and screw this by hand into the probe handle Ensure that the ceramic sheath is securely fastened into the probe handle Secure the positive sensor wire using the clamp in the hub ensuring there is enough wire left to reach the positive sensor connection labelled 2 on figure 4 9 Finally locate the end of the positive sensor wire inside the positive sensor connection terminal labelled 2 on figure 4 9 and screw in tightly The thermocouple can now be fitted as detailed in section 4 4 3 After fitting a new ceramic sheath it is advisable to check the electrical connections as detailed in section 4 4 2 Stand 15 04 08 5 1 5 2 Measurement Procedure Prior to measurement Analyser position e Ensure that the protective screen cover is down so that the touch sensitive analyser screen is protected from aluminium splashes e Stand the analyser on a firm surface at least 1 metre away from the e Ensure that the analyser is not in the path of any access required by the operator e Protect the analyser from heat radiation by positioning it such that the screen is facing away from the melt The maximum operating temperature for the analyser is 50 C Ensure that the analyser does not exceed this temperature in service Reminder Do not clean the touch sensitive analyser screen or screen protector with solvents see section 8 4 3 for guidelines on cleaning the screen Checking analyser s
56. reading is below this level the analyser will display the message Temperature Too Low and will not dis play a hydrogen reading This message will appear on the screen immediately after the probe is plugged into the analyser assuming the probe is cold Stand 15 04 08 3 9 2 7 Temperature too high Standard sensors ALSPEK H sensors are rated at a maximum operating temperature of 800 C If the tem perature exceeds 820 C the analyser will display the error message Temperature Too High If this occurs the probe should be removed from the melt immediately High temperature sensors For customers wishing to measure at temperatures greater than 800 C high temperature sensors are available which can measure up to 825 C These sensors measure accurately in the temperature range 775 825 and are not suitable for use at lt 775 C For high tempera ture applications it is recommended that the analyser firmware is upgraded to version V109 or higher as this extends the analyser measurement range from 820 C to 830 C Sensor indicator An ALSPEK H sensor has a certain lifetime which will be determined by the way in which the sensor is used After prolonged exposure to the melt the sensor will eventually deterio rate due the extremely aggressive conditions which exist in molten aluminium Failure in this manner can be termed sensor depletion as it results from a loss of hydrogen ion con ductivity in the
57. ry life The analyser has an internal battery with a lifetime of 2 years Please contact FOSECO GmbH to arrange a replacement battery after this time Stand 15 04 08 Lam APPENDIX Stand 15 04 08 9 How it works The probe is based on a ceramic material CaZrO3 In which can conduct hydrogen ions The principle of how this material can be used to measure hydrogen concentration is shown on figure 9 1 1 H gt H e H H e 2 1 hydrogen 10 hydrogen Hydrogen ion conducting ceramic Figure 9 1 Solid electrolyte hydrogen sensor A dense piece of hydrogen ion conducting ceramic is shown in green and this has been painted with metal electrodes on either side The concentration of electrons is higher on the right hand side than on the left because the hydrogen concentration is higher This results in the right hand side becoming negatively charged and the left positively charged Therefore if the voltage across the ceramic is known and the hydrogen concentration on one side is known the reference hydrogen concentration then the hydrogen concentration on the other side can be calculated This type of arrangement is called a hydrogen concentration cell To use a hydrogen concentration cell to measure hydrogen the reference hydrogen concen tration must be known at all times otherwise the measured voltage is meaningless All ALSPEK H sensors contain a Solid State Reference a solid mater
58. sferred to the Review database Stand 15 04 08 7 6 4 4 Plotting exporting data The procedure described in section 6 4 3 retrieves the data files from the analyser and stores them in the PC s database The data may now be retrieved from the database and plotted on a chart tabulated or exported to a spreadsheet Click File then New Chart The Chart Setup window will appear as shown on figure 6 5 Click the Add Point button Click next to Instrument and select the ALSPEK analyser from the drop down menu e and next to Log Group select Hydrogen Analyser e Then click Add Click OK on the Chart Setup menu figure 6 5 A chart will be displayed showing hydrogen in red and temperature in blue plotted a gainst time on the x axis Stand 15 04 08 Chart Setup Point ID Instrument Current Mode Chart Show Timezone on Chart Spreadsheet Chart Setup 4 r Spreadsheet Setup Show Messages IV Values Messages Keep traces clear of timestamps Raw Data Grid Major divisions 10 Grid Minor divisions total fi Add Point Edit Point Delete Point Auto Zone i Cancel Point Properties Figure 6 5 Plotting exporting data Chart Setup e To view the desired data press the Go To button circled in red on figure 6 7 The Go To menu will now be displayed which al
59. tion values e The operator may select the custom alloy from the Standard Alloys section of the Select alloy screen Entering sensor calibration values Each ALSPEK H sensor has been individually calibrated in a furnace containing a known hydrogen concentration The calibration procedure results in four calibration constants which can be found in the ALSPEK H sensor packaging These are detailed in table 3 1 Stand 15 04 08 Constant Purpose A Hydrogen measurement B Hydrogen measurement R700 R700 Sensor diagnosis R750 R750 Sensor diagnosis Table 3 1 ALSPEK H sensor calibration constants Whenever a new sensor 15 fitted to the ALSPEK H probe the analyser needs to be grammed with the new calibration constants for that sensor e To do this first log in as Engineering as detailed in section 3 3 On the Home screen press the Sensor button After a short wait the Sensor calibration screen will appear on which the current calibra tion settings are shown see figure 3 7 e To enter a new calibration value for the constant press Edit A box called Custom Write A will appear e Press the area next to the word Constant currently contains a zero A numeric keypad will appear on the screen e Enter the correct value for constant A and press e Then press Write now e Repeat this procedure for the othe
60. ts can create a partially conducting layer at the hot end of the probe This can be corrected quickly and easily by replacing the ceramic insulators as de tailed later in section 4 4 4 The probe should be checked at 25 C under open circuit and short circuit conditions Each ALSPEK H probe is provided with an open circuit cap and a short circuit to facili tate this To perform electrical testing the following will be required 1 A digital multimeter We recommend a high quality unit e g Fluke 87 2 Open circuit test cap provided with the ALSPEK H probe 3 Short circuit test cap provided with the ALSPEK H probe Screw the open circuit cap onto the end of the probe and set the multimeter to measure resistance Stand 15 04 08 rN e FOSECO e Setthe multimeter to measure resistance and verify that the probe s electrical connections agree with table 4 2 For example table 4 2 states that an open circuit should exist between point 1 negative thermocouple connection see table 3 1 and point 2 Positive sensor connection see table 4 1 e To check this push one of the multimeter terminals onto the brass terminal block 1 and push the second multimeter terminal onto the brass terminal block 2 The multimeter should indicate an open circuit e Take care not to touch the metallic part of the multimeter terminals with fingers as this will introduce noise and prevent a correct measurem
61. upplied with a comprehensive suite of computer software to allow downloading and archiving of logged data and to allow remote operation control of the analyser Before installation of the software please ensure that your PC meets the minimum requirements listed below PC must be running Windows XP or Vista For all operating systems Internet Explorer 4 01 or greater must be installed At least 32MB of RAM is required 64MB preferred At least 100 MB hard disc space free PC must be set to at least 65536 colours Please follow these instructions carefully to ensure a correct installation e Insert the PC software CD into the PC s CD rom drive and double click on Setup exe e Follow the on screen instructions and accept the license agreement to install the software After installation the following programs may be found by clicking Start Pro grams then Recorders summarised on table 6 1 Program Name Purpose Remote Viewer Remote viewing and control of analyser Review Downloading archiving data Quick Chart Not utilised at present4 It is intended that future ALSPEK H analysers will include a re movable memory card for use with the Quick Chart software Table 6 1 PC software suite Stand 15 04 08 6 2 6 2 1 7 Getting connected The connection between the ALSPEK H analyser and a PC computer or computer network is made via the RJ 45 Ethernet
62. ure 7 1 The most likely cause for the Startup error screen being displayed is damage to the touch sen sitive screen Alternatively if pressure is being applied to the screen while the analyser is starting up then the Startup error screen will also appear If this screen is displayed then perform the following checks 1 Inspect the screen for signs of damage 2 damage is apparent carefully clean the screen using a soft cloth 3 Check for grit or debris along the edges of the screen which may be applying pressure Note Note that if no action is taken the Startup error screen will proceed to the touch screen calibration screen To see if the problem has cleared switch the analyser off then on again If the problem is not resolved then please contact FOSECO GmbH to arrange for repair Stand 15 04 08 MEDIA Detail Figure 7 1 The Startup error screen 7 3 Troubleshooting A list of possible problems with solutions is given on table 7 2 Melt voltage Due to the design of the probe the sensor positive electrode is electrically common with the melt Under normal circumstances this will not cause any problems and no special electrical connections to the melt are required However if noise erratic readings are permanently displayed by the analyser despite replacing the sensor section 4 2 and checking the probe s electrical
63. w to cool Stand 15 04 08 7 Note The probe may be immersed into the melt at an angle provided that the minimum immersion depth is achieved and the immersion angle does not result in the hub or probe cable being heating above their maximum rated temperature Precautions Ensure that the temperature of the analyser does not exceed 50 C in service Take care not to drip molten aluminium onto the probe cable Do not expose the probe to temperatures above 830 C Never hang the probe from the cable Do not immerse the probe deeper than 30 cm Use with degasser When using the probe with a degassing unit position the probe as far away as possible from the rotor ideally 75 cm 1 m Mounting too close to the rotor may result in Damage to the probe due to collision with the rotor Erratic readings caused by bubbles of purging gas passing beneath the sensor 5 3 Sensor life An ALSPEK H sensor has a certain lifetime which will be determined by the way in which the sensor is used After prolonged exposure to the melt the sensor will eventually deterio rate due the extremely aggressive conditions which exist in molten aluminium Failure in this manner can be termed sensor depletion as it results from a loss of hydrogen ion con ductivity in the sensor Sophisticated On Board Diagnostics OBD built into the ALSPEK H analyser are able to continuously monitor the condition of the sens
64. xporting data to a file or spreadsheet To export data click File then Export GoTo C Relative date and time ard Days Hours Mins Move Specific date and time Batch Find Batch Batch name Mk Show entire batch Hide data from other batches Save Batch Name with Chart Duration re Days Hours Mins Secs i Cancel Figure 6 8 To menu There are three ways of selecting which data to export 1 Current view 2 Batch 3 Specific point in time duration Stand 15 04 08 amp Review Chart1 File Edit View Instrument Chart Security Options Window Help mil Se olal zx 20 Seconds 58 vi gt 8 08 05 14 25 40 1 8 08 05 14 36 00 1 8 08 05 17 24 00 Figure 6 9 Example of a set of data Select the data to be exported using one of the above options A quick way to transfer the data to a spreadsheet is to press the Copy to Clipboard button e Then create a new blank spreadsheet in your spreadsheet application and select Paste from the Edit menu of the spreadsheet Alternatively data may be saved to a file by pressing the Copy to File button The file may then be imported to the spreadsheet The file will contain the data in the format Time Messages Hydrogen Temperature sepa rated by Tabs e It may be necessary to re size the columns

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