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OxyTrak™ 390 Panametrics Flue Gas Analyzer User`s Manual

1. lt TOH LU Local Controller Remote Controller OxyTrak 390 Panametrics Flue Gas Analyzer O HH a 2 J IRH s Junction Box Figure 1 Standard OxyTrak 390 Configurations 2 OxyTrak 390 Flow Gas Analyzer User s Manual Chapter 1 General Information 1 2 1 Sample System The convection loop analyzer package houses the sample system which consists of the components shown in Figure 2 on page 4 and Figure 3 on page 5 The functions of the sample system components are as follows e a manifold with removable thermocouple and cartridge heaters to prevent acid components of the flue gas from condensing in the sample system and causing corrosion e a zirconium oxide oxygen sensor an optional platinum catalyst combustibles sensor to monitor incomp
2. _ 9 11 231 _ 9 84 250 2 42 61 i l Ya H To 19 a Gi Wy LN N ze A ed Mm O 3 14 23 sS w Oe D OxyTrak 390 861 Panametrics Flue Gas Analyzer 3 35 85 a 1 2 NPT o G o O 22 86 581 3 lll G O CALIBRATION Ku E FLOWMETER S Ll Z s l L H E 0 300 CC MIN S ae F J o 7 m 3 9 7 45 A I 189 EXTERNAL GROUND 3 J L a HARDWARE ic 1 4 CALIBRATION PORT INLET MES f 1 4 6MM ADAPTER FITTING 27 159 x OPTIONAL 5 UU gt o e DIMENSIONS ARE IN INCHES MILLIMETERS 3x 1 2 NPT ADAPTERS OxyTrak 390 Flow Gas Analyzer User s Manual 29 1 OxyTrak 390 Panametrics Flue Gas Analyzer HE
3. rn TY D A o NU 2 M 7 b II o N il See U ASS J x 2 E m E Uu ro o cU o o o o Qa o a GA U lt gt QF AI Y T gt u A 3 o o E o Z AR S op me gn N H I o 03 I 2 2 IN Cc wo UY S Q gt LF G Ferm o 2 LY HL MP zuuwwuuounun nu mun 8 Y I 5 W IN gt G 3 o f o O al ae gt lt 9 r o 3 O m Z si N lt I u gt lt z lt S E O LLl u D mr O N yd A C VALVE _ BLOWBACK SOLENOID El By o bo mM N _ Pa T UT r 2 0
4. JUNCTION BOX N3d0 l cd L N3d0 el cq 1 N3dO ll cdL N3d0 0l cd L TAA 438 020 LOV NHO dad 119 LOV ZO cc 23 ac On ZO 438 NIYIN O L 13A NIVN 9 1 438 NYN4A O L TEMP CONTROL 13A NYN4A O L COMB SENSOR TEMP CONTROL LST t 3HIM PPT KPT str 134 434 OO LET qaq LOY OO NyO dad OO 119 LOY OO rer 1a KET NYS cer M18 LET qaq NIVIN O L ccf 419 LZ LHM NIYIN O L NHDA O L NHDA O L oro ONO SLI 119 GIF Ndg v r 119 e tp Ma crj 1a HELP THA L N TWISTED PAIRS 704 1104 XX SIGNAL CABLE ASSEMBLY 704 1102 XX A C CABLE ASSEMBLY 33 OxyTrak 390 Flow Gas Analyzer User s Manual OxyTrak 390 Flow Gas Analyzer User s Manual Chapter 2 Installation 34 Chapter 3 Operation Chapter 3 Operation 3 1 Introduction The OxyTrak 390 Flue Gas Analyzer is a monitoring device that is ve
5. o N LO JOVN4N43 230 240 VAC JOVN4NYW OH OH1 OHH NAdO HEATERS JOVN4N43 JOVN4NW HEATERS LK EE RH al F A O O I I cc a cc u o O O QO Ke F cc E Y W C LU Q lt o x O lt O m Ogu oc op J LU Lu op Zoro D LU LU lt W m Owe uj T ng T O oeo E LL T O L LC R En INSTALL JUMPER BETWEEN TB3 3 amp TB3 4 NONINOO S SYIM 4OVNHDd c Si SHIM T C FURNACE T C MANIFOLD FURNACE N ANALYZER MECHANICALS SHOWN FOR REFERENCE ONLY HEATERS Q 1O4INVN
6. 7 80 N 198 DIMENSIONS ARE IN INCHES MILLIMETERS Chapter 2 Installation Figure 15 Outline and Installation Drawing Remote Controller ref dwg 712 1256 sht 2 30 GASKET MOUNTING PLATE 2 SCH 80 MOUNTING PIPE SN Z P MOUNTING SURFACE 1 7 8 MIN 3 4 SLEEVE 14 PROBE SHROUD APPROX 12 O e M f Pr J le L u ge 4 i III E H To aly TL nr EN B OxyTrak 390 Flow Gas Analyzer User s Manual HARDWARE L MOUNTING FLANGES 4 50 MIN N ae A 7 K i i Z 1 3 OF STACK DIAMETER Z ZZ OR 1 2 FT WHICHEVER IS LESS Chapter 2 Installation Figure 16 Outline and Installation Drawing Mounting Details ref dwg 712
7. 19 84 504 I 4 22 107 5 00 127 RECOMMENDED CLEARANCE ee OxyTrak 390 Flow Gas Analyzer User s Manual 5X 1 2 NPT ADAPTERS Y Z E NE L ZZ AN W A IN SS U EN NI N S bc EN N N NN SN SN gt IN on NS gt gt NN N u N y r y J Z yd A REM OTE CABLES 10 25 50 100 Chet 4 49 114 4 00 102 2 86 73 8 80 224
8. 36 Combustibles Detector 1 10 Common Problems Avoiding 35 Communications PA EN 123 Eihemet POrt sz ue sob ass is 69 A as ae a Re 67 RS232 RSA8S Poll 2 444c aw dd dis 67 Contrast Adjusting 43 Convection Loop 8 Converting mV to ppm 94 OxyTrak 390 Flow Gas Analyzer User s Manual Index D Dat of Publications sida dida 1 Defaults AD AOR A GG am pis ek 127 Calibrate TTT 113 Communications 123 Disparo aa de 112 Sre a A O ui en 125 Non Aspirator 128 OUO ya E uma ES uu ya Lana a 114 RS aser od YN 117 A A saa usa Veeder usa 124 Detector Combustibles 1 10 Digital Display Components rs dolia aka 36 DIAS e is 36 Disconnect Devices 2 22 2252 Sein ln 18 Display Adjusting Contrast 43 PA A w E 112 AA E A asa 23 Selecting Measurement Mode Units 43 Selecting Number of Views 42 Document Number 2d Rd s Sa sansa 1 E EMC Compliance 19 Enelosures ci ti ahus ipana kisa Environmental Compliance Vill F Factory ol ili e ari TR huyu kusa 125 Men AA be ee ney Sas eee 84 GB ra e A ME RW TF aa 7 H Heater Block saw Sn ide eed hoe ee 8 Comtolsaia nitiadre daa miradas 11 Information Paragraphs V11 135
9. 49 AA a EEE de TTE EEE AIEE TEL A At eal RA ETE EEEE AT E EE one TEE mani 55 SN SA ee O 55 A E RWE ne ia dadas 56 SOS o A ee IN O O has Upa Lal ui of Ur E ies es ae aces oe re me erect Sie este ete aoe ee ears 58 EAS CU ecards Qan iu ae pie oh hacia gas aa waqa passat uwa Y qawa nents 60 CO Ss cdas ds Settee ae amam RH HNN k ya qaa ene 61 DE PR CNY SHAD za mapas A A A Nb Kama 61 G a L D 0 e 2 A uha una TERROR usun NR NA 66 Al A ua Ta m u aS 67 OR SR o A A use FC ee atau quan dee tee 67 AAA O CI YY ER EN CN Y A YY CN NR 69 Chapter 6 Advanced Programming 6 1 6 2 6 3 6 4 6 5 6 6 nos e A OS A Pk Tener ee 71 Display Relays and Communications MenuS 71 A AA A m uuu Su NET FARA Cee eer FE a ment eee RI Ne mae erence ae 72 GONG O ee Tuma Oa ee FF YN NE CR R Syiah 72 DOOF 13 BC glec o cle go a1 E arriendo id Y AD ae pas 73 SN II REN as A Eee EEE 74 OZ Sensor CIN mac Fatt cence in saco is ica 74 ca COLO y Cis er een AA yn 75 dol na nasa tose ip amas ee WT sue ua 76 65 A BIOW BOCK TT TH ee ee ee Bin esse one ehe ae 82 FOLIE MORU esse ee Bere een HO Y HI A SY Y A FN 84 OGIVO RT Y WN CA ia ea 84 0 0 Bea W uuu o RR HR DE FN EA RA 84 ASNO 08 Ana uc SE _ ee a ee ae et 85 AS A UD LG GU DD O CO 85 OxyTrak 390 Flow Gas Analyzer User s Manual Contents Chapter 7 Specifications A RER ICING AAA ee O Y NO 87 EA L 88
10. Enter Value ENT Select Port Node ID Port Settings 7 Ethernet Settings K gt gt Figure B 1 Figure B 4 m Z mr ENT Enter Value ENT gt Enter Value Baud Rate Parity Stop Bits Data Bits Select Option Gateway Address Enter Value Appendix B Menu Maps Figure 23 Calibrate and Communications Menu Map 2719 passcode 99 Appendix B Menu Mops MAIN MENU DISPLAY CALIBRATE OUTPUT Z RELAYS COMMUNICATIONS SETUP gt FACTORY lt ENT ENT Figure B 1 Figure B 2 Figure B 3 Figures B 1 B 5 Interval d W a N NN M IN GE Energy Cal Comb Figure B 2 ENT Exit to run mode Reboot Furnace Temp Ws MAR Furnace Temp Upgrade Default Analyzer Gas Supply Time m z 3 Settling Time Figure B 2 Figure B 3 Air Offset m z 3 AN Failure Cal Setting 02 A V Tolerance Service Manual Furnace Temp Comb Cal Comb A V Tolerance Figure 24 Calibrate Output and Factory Menu Map 7378 passcode Development O2 Tolerance ENT Enter Value ENT QCal Com
11. rim Cal Setting _PUT Outeut G Measure Use the arrow keys to select the desired output variable and press ENTER Uc 4 Combustibles Fem Combustibles urnslce emr The current OxyTrak 390 analog output will now display the data for the variable chosen above When you have finished programming the Output menu press ESC until you return to normal run mode 6 4 Calibrate Menu In the Autocal option of the Calibrate menu the following two additional choices are available at this passcode level e O Tolerance e Comb Tolerance Note Ifnecessary see Chapter 5 General Programming for instructions on navigating to this menu At the Calibrate submenu of the Main Menu use the arrow keys to select the Autocal option and press ENTER 72 OxyTrak 390 Flow Gas Analyzer User s Manual Chapter 6 Advanced Programming 6 4 1 O Tolerance This option is used to define how close the actual oxygen reading must be to the calibration gas specification for a calibration to be considered complete Proceed as follows _AY CALIERATE Hutocal Use the arrow keys to select the 02 Tolerance option and press ENTER k Ue a HL Toler 18 Comb HU 24 BEEF Hex am D HEP m Auto Cal now Use the arrow keys as indicated to enter the desired tolerance value in 9005 When done press ENTER save changes ungdo chan e move Cursor change value When you have finished programming the
12. 4 COMMUNICATIONS sp Use the arrow keys to select the Node ID option and press ENTER select Port ie or ettin Ethernet Settings Use the arrow keys as indicated to specify the Node ID value for the port When done press ENTER save changes Undo chan ses move CURSO change Value 4 CCOMMUHICATIONS sp Use the arrow keys to select the Port Settings option and press ENTER or Select P ss Hode ID 16 erre E 1132 OxyTrak 390 Flow Gas Analyzer User s Manual 67 Chapter 5 General Programming 5 6 1 RS232 RS485 Port cont COMMU ICATIOANS Roco arity Stor Bits Data Bite lUNS Fscscrbaud Rate cda 260 S SEE COMMUN ICATIOHS FSe232 Baud Fate or Bits Data Bite COMMUNICATIONS RES Baud Rate Parity 68 Use the arrow keys to select the Baud Rate option and press ENTER Use the arrow keys to select the desired baud rate and press ENTER Use the arrow keys to select the Parity option and press ENTER Use the arrow keys to select the desired parity and press ENTER Use the arrow keys to select the Stop Bits option and press ENTER Use the arrow keys to select the desired number of stop bits and press ENTER OxyTrak 390 Flow Gas Analyzer User s Manual Chapter 5 General Programming 5 6 1 RS232 RS485 Port cont COMMUNICATIONS RS222 Use the arrow keys to select the Data Bits option and press ENTE
13. A ZN Combustibles Sensor Figure 8 Combustibles Sensor Elements The resulting temperature differential between the active and reference elements is proportional to the concentration of combustibles in the sample and a corresponding resistance change 19 then converted into a reading of parts per million by volume ppmy of combustibles 10 OxyTrak 390 Flow Gas Analyzer User s Manual Chapter 1 General Information Heater Control Circuit The oxygen sensor temperature in the OxyTrak 390 is maintained by a heater which is part of a complex temperature control loop This circuit constantly monitors the oxygen sensor temperature compares it to the set point temperature 700 C and turns the heater ON or OFF accordingly The specific type of control circuit used is called a Proportional Integral Derivative PID loop because of the three adjustable parameters involved Proportional Band Because the system cannot respond instantaneously to temperature changes the actual temperature of the oxygen sensor oscillates about the set point In general increasing the proportional band reduces the magnitude of these temperature oscillations e Integral Action A consequence of increasing the proportional band is the introduction of an offset between the set point and the control point The integral portion of the control loop acts to move the control point back toward the set point within a specified period of time Thus decreasin
14. Install a system to deliver the calibration gases to the OxyTrak 390 at the proper flow rate and pressure Program all user programmable calibration parameters Initiate either manually or automatically the calibration process Allow the calibration to continue until the new O and combustibles readings are within the programmed tolerances OxyTrak 390 Flow Gas Analyzer User s Manual 105 Appendix C Calibration Standard Convection C 6 Method 5 Calibration method 5 whether implemented in manual mode or using the autocal process includes the following steps 1 Obtain the four calibration gases Gas 1 A gas with known oxygen content to be used as the zero gas in a 2 gas oxygen calibration b Gas 2 A gas with known oxygen content to be used as the span gas in a 2 gas oxygen calibration c Gas 3 A gas with known combustibles content to be used as the zero gas in a 2 gas combustibles calibration d Gas 4 A gas with known combustibles content to be used as the span gas in a 2 gas combustibles calibration Install a system to deliver the calibration gases to the OxyTrak 390 at the proper flow rate and pressure Program all user programmable calibration parameters Initiate either manually or automatically the calibration process PM a oe NS Allow the calibration to continue until the new O and combustibles readings are within the programmed tolerances C 7 Method 6 Calibration method 6 whet
15. RELAYS RELAYS C B RELAYS RELAYS A NIYIN O L NIYIN O L Nana O L TEMP CONTROL NHNA O L NI JOVNgNA c EC SHIM Oro LE Lf LHM cr qaq NI v1P NYS HEATERS NOWNOD F Ef 3HIM A C IN ano LOAN Far AAI Z oro 13A 438 qaq LOV NyO 434 119 LOV i di Pa FIELD 4 20mA OUTPUT TWISTED PAIRS lt DISPLAY CONTROLLER
16. balance N2 Oxygen 5 0 02 Combustibles Zero Gas O ppm Combustibles CO H2 Cal Gas Cylinder Two 1000 ppm CO 500 ppm H2 1 O2 Combustibles Span Gas 1 500 ppm Combustibles CO H2 Oxygen Factory Calibration Data O2 Sensor Serial Number 2243 VI Furnace Temp 770 1 Air Offset 0 3214 mV Software Versions B BOOT 001 B P INST 002 E X AML 002 E Combustibles Factory Calibration Data Combustibles Sensor Serial Number 2363 E Aspirator Flow 4Lm 8 5 SCFH Zero Gas O ppm Span Gas 21 000 ppm Slope 0 7909 Intercept 178 8151 OxyTrak 390 Flow Gas Analyzer User s Manual 111 Appendix E Default Settings E 2 Display Defaults Note Default settings are in bold text DISPLAY of Views 1 View 2 Views 3 Views DISPLAY Normal Reverse Contrast 45 112 OxyTrak 390 Flow Gas Analyzer User s Manual Appendix E Default Settings E 3 Calibrate Defaults Note Default settings are in bold text CALIBRATE Manual Oxygen Combustibles Autocal Interval Hours 2 Hours 3 Hours 4 Hours 6 Hours 8 Hours 12 Hours Days Days 7 Days Start Time Hour 0 Hours Minute 0 Mins Gas Supply Time 2 Mins Settling Time 2 Mins A V Failure Alarm Alarm ReCal O2 A V Tolerance 0 10 Comb A V Tolerance 20 00 ppm O2 Tolerance 0 02 Comb Tolerance 20 00 ppm Auto Cal Now Yes No GE Energy Cal OxyTrak 390 Flow Gas Analyzer User
17. Comb Under Range Setpoint 0 00 ppm Comb Cal Error System Faults 118 Furnace Temp Over Range OxyTrak 390 Flow Gas Analyzer User s Manual Appendix E Default Settings Furnace Temp Under Range Furnace Low Temp Block Temp Over Range Block Temp Under Range Block Low Temp Active RTD Over Range Active RTD Under Range Ref RTD Over Range Ref RTD Under Range Normal Failsafe Normal Failsafe Relay C Type Measure Diag Errors System Faults Setting Measure O2 Combustibles ppm Combustibles Type High Setpoint 0 00 Deadband 0 00 Low Setpoint 0 00 Deadband 0 00 Diag Errors O2 Over Range Setpoint 100 00 O2 Under Range Setpoint 0 01 O2 Cal Error Comb Over Range Setpoint 30000 00 ppm Comb Under Range OxyTrak 390 Flow Gas Analyzer User s Manual 119 Appendix E Default Settings Setpoint 0 00 ppm Comb Cal Error System Faults Furnace Temp Over Range Furnace Temp Under Range Furnace Low Temp Block Temp Over Range Block Temp Under Range Block Low Temp Active RTD Over Range Active RTD Under Range Ref RTD Over Range Ref RTD Under Range Normal Failsafe Normal Failsafe Relay D Type Measure Diag Errors System Faults Setting Measure O2 Combustibles ppm Combustibles Type High Setpoint 0 00 Deadband 0 00 Low Setpoint 0 00
18. ENTER key oc eu ad Lock Menus The Lock Menus option will permit reentry to programming mode for programming the display only All other programming functions will be locked out The Lock Keypad option will completely lock out programming mode and restore the black closed padlock Note Ifthe unit is powered down Programming Mode will be locked when the unit is powered up again 38 OxyTrak 390 Flow Gas Analyzer User s Manual Chapter 3 Operation 3 7 Powering Down the System Powering down the OxyTrak 390 system is as simple as cutting the power to the system at the main disconnect device However be sure to heed the warning below WARNING Ifthe analyzer is left installed without power the unit s components become susceptible to acid condensation that will cause corrosion If the power must be removed for more than thirty minutes purge the analyzer through the calibration port with a continuous flow of instrument air at a minimum rate of 150 cc min 0 3 SCFH 3 8 Taking Measurements Allow the OxyTrak 390 to warm up sufficiently before taking any measurements Readings are output to the LCD Display in the format programmed into the system If the LCD Display is not included in the system you may use Equation 3 1 below to convert the OxyTrak 390 analog output reading into percent oxygen 20 9 V 48 273x 1 TR EEE yapasqan 700 mV i l 02 in Sample Gas Note See Appendix The Nernst Eq
19. H O L aged gt M SOLENOID VALVE ASPIRATOR Figure 27 Aspirator amp Blowback Panel Wiring Diagram ref dwg 702 681 OxyTrak 390 Flow Gas Analyzer User s Manual 133 no content intended for this poge 134 OxyTrak 390 Flow Gas Analyzer User s Manual A AC Cable Assembly 24 26 Accessing the User Program 37 Alarms Wiring 20 Ambient Temperature 13 Analog Outputs Wiring 20 Aspirated Flow Calibration Gas Flow Rate Test 109 AAA eit dee at ree ee ee 109 Response Test orce 2424 109 Aspirator Defaults 127 B Blow Back Installation ee ee 634 59 a 21 131 Prostammins YT dh Bek dod Be BAS Ale LS 82 Sample System 131 SEINES u pu dan ed UA 131 C Calibration Automatic One Gas Oxygen 49 SPAS RT ayka E iaa atas 113 sI laser EA 35 Gas Flow Rate Test isa riadas 109 Manual One Gas Oxygen 47 Manual Two Gas Combustibles 48 NI piru HN ee rer 47 72 METROS serrr A acne DA BY 103 PCC itu adhe adc ER EN 47 Sheet Example socias 111 CE Mark Compliance 18 Cleaning the OxyTrak
20. Proceed as follows AY FCALIBRATE Autarcal Use the arrow keys to select the Yes response of the Auto Cal Now option or see k Settlina TimeMins hu Failure the next step Then press ENTER 02 Al Toler 16 Comb Al 24 hhirrme Auto Cal now AY CALIERATE Autacal Use the arrow keys to select the No response of the Auto Cal Now option or see Settlina Timehins i hU Failure the previous step Then press ENTER oe A U Tolera 10 U 24 ARP me Auto Cal now Yez No matter which response you selected above you will be returned to the main Calibrate menu When you have finished programming the Calibrate menu press ESC until you return to normal run mode 54 OxyTrak 390 Flow Gas Analyzer User s Manual Chapter 5 General Programming 5 4 Output Menu The Output menu is used to configure the OxyTrak 390 analog outputs To configure your outputs proceed as follows 4 DUTPUT FELAYS cp At the Main Menu use the arrow keys to select the Output menu Then use the arrow keys to select the desired output to configure and press ENTER UTPLI Uutrut L Note The setup of Output A is shown here as an example The other outputs are programmed in a similar manner PLAY OUTPUT Outeut A The four programmable output parameters are now available Use the arrow keys to FE select the desired option and press ENTER kanse Trim Cal Setting Proceed to th
21. calibration tolerance and a maximum allowable furnace temperature change of 20 C See Chapter 6 Advanced Programming for instructions on changing these values _LSPLAY DISPLAT Ai ews LEWS 3 U1 euz 4 CCALTERATE OUTPUT LIT 31 LAY LHL I ERHTE Tlanual ombustibles Fress ENTER At the Display submenu of the Main Menu press the gt key At the Calibrate submenu of the Main Menu use the arrow keys to select the Manual option and press ENTER Use the arrow keys to select the Oxygen option and press ENTER The current calibration data is displayed Start the calibration span gas flow When mV and have settled press ENTER OxyTrak 390 Flow Gas Analyzer User s Manual 47 Chapter 5 General Programming 5 3 1 Manual One Gas Oxygen Calibration cont 02 Calibration Turn off the calibration gas flow Allow the reading to return to process then press emits alg HAE Furnace 4 ah C ENTER Turn off 335 Press ENT after settled After the calibration is completed press ESC twice to return to normal run mode If O refer to Appendix G for thermal calibration 5 3 2 Manual Two Gas Combustibles Calibration To perform a manual combustibles calibration with two calibration gases 1 Enter the oxygen sensor s calibration menu from the main menu as in the previous section 2 Supply zero gas at the flow rate entered in the analyzer Note The flow ra
22. move CURSO change value a Use the arrow keys to select the Span O2 option Then press ENTER ce 93 a A Fan HA Dr Fm Use the arrow keys as Indicated to enter the span gas oxygen percentage combustibles must be 0 ppm When done press ENTER save changes ungo chan e move CURSO change Value Use the arrow keys to select the Span HC option Then press ENTER Use the arrow keys as indicated to enter the span gas combustibles ppm When done press ENTER save changes Unda changes Moe Cursor chanse Value When you have finished programming the Cal Method menu press ESC until you return to normal run mode 80 OxyTrak 390 Flow Gas Analyzer User s Manual Chapter 6 Advanced Programming 6 5 3f 4 Gas Oxygen and Combustibles This method uses four calibration gases 2 for oxygen and 2 for combustibles to perform the oxygen and combustibles calibrations als Use the arrow keys to select the Zero O2 option Then press ENTER Ka HE Ze ra HL A Beem Sram HC 1564 rem Use the arrow keys as indicated to enter the zero gas oxygen percentage When done press ENTER save changes Undo changes move Cursor change value Use the arrow keys to select the Span O2 option Then press ENTER Method l ero Oe cH 33 J HIE ero A EIFF m Sram HU 1564 rem Use the arrow keys as Indicated to enter the span gas oxygen percentage When done press ENTER
23. 390 Flow Gas Analyzer User s Manual 26 Chapter 2 Installation 2 5 8 Wiring The Line Power cont 1 Attach a cable or conduit with the three conductors to the right cable entry port on the display controller CAUTION Be sure that the input voltage is within the specified limits for your OxyTrak 390 2 Connect the line power leads as follows a Connect the line power lead to the LIVE pin J2 pin 2 on the power connector b Connect the neutral power lead to the NEUT pin J2 pin 1 on the terminal block c Connect the ground power lead to the earth ground connection in the enclosure IMPORTANT Do not alter any of the factory wired power connections in your OxyTrak 390 This completes the wiring of the OxyTrak 390 Proceed to Chapter 3 Operation for instructions on using the analyzer OxyTrak 390 Flow Gas Analyzer User s Manual 27 Chapter 2 Installation no content intended for this page 28 OxyTrak 390 Flow Gas Analyzer User s Manual Chapter 2 Installation
24. A Tel 800 833 9438 toll free 978 437 1000 E mail sensing ge com lreland Sensing House Shannon Free Zone East Shannon County Clare lreland Tel 353 0 61 470291 E mail gesensingsnnservices ge com An ISO 9001 2000 Certified Company www ge mcs com en about_us guality html www ge mcs com 2012 General Electric Company All rights reserved Technical content subject to change without notice 910 264 Rev C
25. Cal Method omb_rem Cl ame _PLAY SETUP Blow Back Use the arrow keys to select the Interval option and press ENTER ins uration S4Secs Settlina 6bS5ecs Blow back now Use the arrow keys as indicated to enter the time in minutes between blowbacks When done press ENTER ave changes ndo changes move Cursor change Value 82 OxyTrak 390 Flow Gas Analyzer User s Manual Chapter 6 Advanced Programming 6 5 4 Blow Back cont Use the arrow keys to select the Duration option and press ENTER 1113 Blow back now Use the arrow keys as indicated to enter the length of time in seconds that the blowback will last When done press ENTER save changes Undo changes move CURSO change value Fi Blow Bac Use the arrow keys to select the Settling option and press ENTER Interval ains Dorati or EEIZ eC Z Blow back mow Use the arrow keys as indicated to enter the length of time in seconds to allow after the blowback is complete When done press ENTER save changes ungdo chan e Moe Cursor change Value To force an immediate blowback complete the next step _PLAY SETUP Elcam Back Use the arrow keys to select the Yes response to the Blow Back Now option Then ia zo press ENTER to initiate the blowback Settlina 66S5ecs Blow back now ms NGO Note Ifyou select the No option at the above prompt the blowback will be aborted When you ha
26. For example at the standard operating sensor temperature of 700 C Equation A 3 below is used A 3 E mV 48 2736 log Do IMPORTANT For units that are operated at sensor temperatures of 770 C or 812 C replace 48 273 in Equation A 3 above with 51 745 or 53 829 respectively Do not use the graph or table on the following pages The voltage drop across the zirconium oxide sensor as calculated from the Equation A 3 above is then sent to the linearizer circuit This circuit produces a linear 4 20 mA output that is used to display the percentage of oxygen in the flue gas For convenience the standard Nernst equation for the OxyTrak 390 Equation A 3 above has been converted into a graphical format Use this graph see Figure 20 on page 93 to quickly correlate a raw sensor mV reading with the corresponding oxygen percentage at the operating temperature of the analyzer In addition similar data for some common oxygen percentages is presented in tabular form in Table A 1 on page A 4 92 OxyTrak 390 Flow Gas Analyzer User s Manual Appendix A The Nernst Equqtion 0 0001 0 001 0 01 0 1 Oxygen Concentrotion 1 10 100 O O LO 300 250 200 150 100 50 Sensor Ou
27. O A oo 35 Preventing Common Problems YO Y HN A ada 35 CI Grillo Me INC o t O u A A Wayaqa N 36 Powermod Up A Y A Qu FAN 36 SA INS DIEB a ONE VO WE YN TN YCC HR NY ee 36 Feria Programming MOS u usu unu ustiy uama ina ANA SS 37 rol golen Ja aae u y POE aaa ne Lae oad NN FN FR AU NR TS 38 5 ICH 6 816 Ce Valo D u sar kaysa HR HF HF NR NR RF A ne ee ee 38 3 6 2 Locking Programming MOOG costat NA GG O NAF DA 38 Powering Down the System 39 TOKIO ME AAA Caer aa ee ee ee sere 39 3 8 Chapter 4 Setting Up the Display 4 1 4 2 4 3 4 4 4 5 lO pil os 2 FN NG aus ee EN EC eee eer nS Se ee 41 Selecind Ine NUM Der Oh o ao SFE ___b RC NEA 42 AGIUSHMG MS Display CONMOST ss gcc trike th Retin ia ii 43 Selecting the Measurement Mode and Units 43 Measurement Units Description 44 OxyTrak 390 Flow Gas Analyzer User s Manual lli Contents Chapter 5 General Programming Dl O 5 3 5 4 39 5 6 do A E WYCH S E 45 duo o NA TTT 46 ES ee ea er tines 47 5 3 1 Man dl One Gas Oxygen Calibration irrita A sense 47 5 3 2 Manual Two Gas Combustibles Calibration 48 5 3 3 Automatic One Gas Oxygen Calibration
28. SS eT A muskuk GU DO pue wapu DD GU UCD 89 7 4 S cL 6 ee ee re A PO ee 89 ES OSA Mesure RP GRY Y NR EU A HY OERE 90 Appendix A The Nernst Eguation Aal NNN CHANG Ce TTT 91 A 2 Equilibrium ConditionS 91 AS TheOxyTrak t390 EHO au uuu l u re sto ata 92 Appendix B Menu Maps Appendix C Calibration Standard Convection CE a CREFFT CE en Er ee 103 GZ Meno laos o a aaa sates a ea ee aoe pee uuu DY a SR la as 2 wa m asua Sa 104 Cr o A II O RR ss 104 e MB TTT 105 Ca r ere AAA II E O te tn ON 105 O MENO e Stus o u a oa ee sa samusa e 106 ek o A 106 A A A IE 107 ES Calbraton GAS pia ta rin ainia iia 108 Appendix D Calibration Aspirated Flow PA A A I A CS NR 109 DA ao los as FIO se II en a SSS ae ss ei ena ae 109 D3 Oxygen Sensor Field C TITO uyo a a E arh ee ae se Saa NY 110 BEAM AA 6 uuu u u ee ee uama mua buy awa a eee RY N 110 OxyTrak 390 Flow Gas Analyzer User s Manual V Contents Appendix E Default Settings E 1 E 2 ES E 4 ES E 6 E E 8 F 1 F 2 COMI ROTOR Sheer Tae E R RHS NHW RR EE 111 DS A ee IN A O ee ar 112 COD o DIQUE RE _ I estad pues dy eae rasante 113 DEREAT _ I NR RY re I a A EEE A NWN FYNN 114 E IO D A E _ R TE Enns wear tne alnus ee 114 9 24 OU D ANAIS NY mus paui wayapa pa wa Waaa api ee wapu A RYN Y O NR 115 EI CUEU TTT 116 adei e i THE L DH II
29. Srecific Walue save changes Unda changes move CuUr or Chanae Value When you have finished programming the Outputs menu press ESC until you return to normal run mode 60 OxyTrak 390 Flow Gas Analyzer User s Manual Chapter 5 General Programming 5 5 Relays Menu The Relays menu is used to program the OxyTrak 390 alarm relays A D and to test the system control relays E H To program and or test your relays proceed to the appropriate section 5 5 1 Relays A D To program the alarm relays A D proceed as follows 4 PELRYS COMMUNICA At the Main Menu use the arrow keys to select the Relays menu Then use the arrow keys to select the desired alarm relay to configure and press ENTER el a Rela Relay Relay Relay T Relay Note The setup of alarm Relay A is shown here as an example Relays B C and D are programmed in a similar manner _SPLAY RELAYS Felau A The three programmable relay options are now available Use the arrow keys to c c select the desired option and press ENTER Hormal Failsafe Proceed to the appropriate section to program the option selected at the above screen 5 5 la Type The Type option 1Is used to specify the general category of parameters to which the alarm relay being programmed will respond _SPLAY FELEYS Felau A Use the arrow keys to select the Type option and press ENTER ettina Hormal Failsafe 9RELRYS Relau ArTupe Highlight
30. TB1 7 TB1 7 a COMB TEMP REMOTE RELAYS RELAYS a ER o 8 7316 FURNACE RHC CE E SENSOR CONTROL RS485 E G LT i T516 FURNACE RH Fl 3 ar u c Oo olo I li T 5 p LL 3 O LLI lt DC TIC MAIN T C MAIN J4 1 J4 4 J6 3 T C FURN J6 4 T C FURN J6 5 J6 6 r Hi aaa O O O oo cb D mnm 2 O 5 m 4 20mA OUTPUT RELAYS A B C A B RELAYS wae 5 LIVE 1 NEUT GND J5 4 OPEN J5 3 OPEN J5 2 OPEN J2 2 J2 OxyTrak 390 Flow Gas Analyzer User s Manual 32 Chapter 2 Installation 529 2044 BMP J 1 quiassy ajoway wRABDIg Burn asodind DA3U3H gT oJnDig FOR USE WITH 704 668 XX CABLE LNO GIOAINVW EF L SHIM D
31. The five clock parameters are now available for programming Use the arrow keys to CDG select the desired parameter and press ENTER Oreck d Dau cr 2 Hour Minute kl DISPLAY SETUP Clock Use the arrow keys as indicated to enter the desired value for the chosen parameter When done press ENTER sae changes undo chan es move CURSO chan se value The two screens above show the programming of the Year parameter to a value of 2005 repeat the same procedure to set the Month Day Hour and Minute parameters to the desired values When you have finished programming the Setup menu press ESC until you return to normal run mode 46 OxyTrak 390 Flow Gas Analyzer User s Manual Chapter 5 General Programming 5 3 Calibrate Menu A variety of calibration procedures may be used with the OxyTrak 390 see page 88 As all of the procedures are very similar only the manual and automatic procedures for performing a one gas oxygen calibration will be described In step by step detail The other procedures are presented in Appendix C Calibration Methods Refer to Figure 14 on page 29 for port locations 5 3 1 Manual One Gas Oxygen Calibration To perform a manual O calibration with one calibration gas access the user program as described on page 37 and proceed as follows IMPORTANT As an example these instructions assume the factory default settings of a 3 00 calibration gas a 0 02 O
32. e Method 1A manual O calibration using 1 calibration gas e Method 1B autocal O calibration using 1 calibration gas e Method 2A manual O calibration using 2 calibration gases e Method 2B autocal O calibration using 2 calibration gases e Method 3A manual O Combustibles calibration using 2 calibration gases e Method 3B autocal O Combustibles calibration using 2 calibration gases e Method 4A manual O amp Combustibles calibration using 3 calibration gases e Method 4B autocal O Combustibles calibration using 3 calibration gases e Method 5A manual O amp Combustibles calibration using 4 calibration gases e Method 5B autocal O amp Combustibles calibration using 4 calibration gases e Method 6A manual O Combustibles calibration using 1 calibration gas e Method 6B autocal O amp Combustibles calibration using 1 calibration gas e Method 7A manual O amp Combustibles calibration using 2 calibration gases e Method 7B autocal O Combustibles calibration using 2 calibration gases Step by step instructions are provided in Chapter 5 General Programming for calibration methods 1A and 1B As the other methods employ the same basic programming techniques such detailed instructions for these methods are not necessary Instead a basic outline for these procedures is presented in this appendix Also instructions for configuring the OxyTrak 390 for the intended calibration method are presented in Chap
33. ensure that no dilution will occur while performing a combustible sensor s field calibration OxyTrak 390 Flow Gas Analyzer User s Manual 109 Appendix D Calibration Aspirated Flow D 3 Oxygen Sensor Field Calibration An oxygen sensor field calibration may be performed upon initial installation but is not required It can also be performed as often as required thereafter An oxygen sensor field calibration can be programmed to occur automatically using the OxyTrak 390 s auto calibration capability Refer to Figure 14 on page 29 for port locations D 3 1 Manual Calibration Follow the steps on page 47 to perform a manual oxygen sensor field calibration 110 OxyTrak 390 Flow Gas Analyzer User s Manual Appendix E Default Settings Appendix E Default Settings E 1 Calibration Sheet Example The default settings are the settings when the unit is first powered up Later in the factory some of the default settings are changed for the specific calibration of a specific unit Here is a typical factory calibration data sheet OxyTrak 390 Calibration Sheet OxyTrak 390 S N R118 OxyTrak 390 Part Number OxyTrak390 3211 1100 Sales Order Number 508010000098 Calibration Date June 16 2006 Technician M Morales Output Type Range A 4 to 20 mA 0 10 O2 B 4 to 20 mA 0 2 000 ppm CO H2 4 to 20 mA 0 1096 O2 Field Calibration Calibration Method 2 Cylinders 1 O2 2 HC Comb Cal Gas Cylinder One 5 096 02
34. m NR RC RH EN I FN NN bz 117 Communications Der dulio ss LG ds Awd CND WG Ed GY di 123 SN DENUN RE HF Y RH HR EY I FI IO u HA Y RH 124 RLE A Eee oa tiene eau ae Gee E REN RR IA 125 A nn as os WA ee rer A NY O Y A RT 127 Fo Nea se I A RNA 128 Appendix F Blow Back Sample System breseg Sia EST O chek tect nates pea oan Dee ee ee See OY RR i 131 SCHEIN TTT 131 VI OxyTrak 390 Flow Gas Analyzer User s Manual Preface Information Paragraphs e Note paragraphs provide information that provides a deeper understanding of the situation but is not essential to the proper completion of the instructions e Important paragraphs provide information that emphasizes instructions that are essential to proper setup of the equipment Failure to follow these instructions carefully may cause unreliable performance Caution paragraphs provide information that alerts the operator to a hazardous situation that can cause damage to property or equipment Warning paragraphs provide information that alerts the operator to a hazardous situation that can cause injury to personnel Cautionary information is also included when applicable Safety Issues WARNING Itis the responsibility of the user to make sure all local county state and national codes regulations rules and laws related to safety and safe operating conditions are met for each installation Auxiliary Equipment Local Safety Standards The user must make sure that
35. of the mating flange 3 Weld the mating flange onto the end of the short pipe so that the raised face of the flange faces away from the mounting plate Be sure that the following requirements are met One end of the short pipe should be flush with the raised face of the flange The mating flange should be oriented so that its bolt holes straddle the vertical and horizontal center lines of the mounting plate Note The OxyTrak 390 can be supplied with an optional flange If a flange is desired it must be specified e g 3 150 flange at the time of purchase 4 Attach the mounting plate to the wall with the pipe extending into the drilled hole For probe lengths greater than 2 meters 6 feet a support sleeve is recommended 16 OxyTrak 390 Flow Gas Analyzer User s Manual Chapter 2 Installation 2 4 Mounting This section explains how to mount OxyTrak 390 analyzer at the site that was prepared in the previous section The OxyTrak 390 has integral male 1 1 2 NPT mounting threads This permits a flange to be threaded onto the analyzer and the resulting assembly is then bolted to the mating flange on the furnace boiler wall or flue duct CAUTION Flue gas condensate is extremely corrosive The OxyTrak 390 must be wired and powered up immediately after mounting to prevent damage to the unit If a blowback purge system is to be used install this system and turn it on right away also IMPORTANT Direct
36. programming options available at the 7378 passcode access level For the options available at the 2719 passcode level see Chapter 5 General Programming Note While in the User Program press ESC at any time to abort the current operation and return to the previous menu level Access the User Program as described on page 37 and refer to Figure 24 on page 100 and Figure 25 on page 101 while programming the OxyTrak 390 features discussed in this chapter DISPLAY CALIBRAT This 1s the initial programming screen 1 F Led From the Main Menu screen above proceed directly to the appropriate section to perform the desired programming task 6 2 Display Relays and Communications Menus There are no additional options that become available in these main menus at the 7378 passcode access level See Chapter 4 Setting Up the Display and Chapter 5 General Programming for a full description of how to program these menus at the 2719 passcode access level OxyTrak 390 Flow Gas Analyzer User s Manual 71 Chapter 6 Advanced Programming 6 3 Output Menu In the Measure option of the Output menu the following two additional choices are available at this passcode level e Furnace Temp C e Furnace Temp F Note Ifnecessary see Chapter 5 General Programming for instructions on navigating to this menu PLAY OUTPUT Outeut A Use the arrow keys to select the Measure option and press ENTER SFE Range
37. qaqivug 13ADVWP Y31NO dO 0 r dIHLS ONIA3378 MNIHHS 9 SHIM NIVHQ Zd31S g 1IVLIQ Q SAN H1O8 NO LL 8 01 E Sd31S LVdddt ZL Zv LO vZ86SdINV TOOL dWIHO ONISN AYIM NIVHO y WALI OL 2 WALI dNIHO LL 2H LO VZ86SdNIV TOOL dlNIHO ONISD 3HIM GNDOMHD HLEVA OL 6 WALI dWIHO OL SI4IM T IV NOHd SZ dld1S 6 SSUIM r JO 0 7 ONISOdXd MNIHHS LV3H 9 WALI HOV LLV G131HS GAGIVYE OL 29IM NIVHO Y WALI 9201029 SANI HlO8 AYIM NIVHG y WALI dO SZ dIHLS q13lHS d3GIVH8 SNISOdX3 LFIMOVF YALNO dO SZ dIHLS T H19N371 OL 418VO LNO S3HONI SNOISN3NIG SALON A n O OR ge d3dd 318VO9 L d31S Y TIN L90 NIO amp 140001 OLOS 14800 vO cOLL pOZ NIO 14667 OL Ge 14805 0 c0ll POZ NIO 14675 OL 0L l48Sc 20 2011 v02 NIOS amp 13466601 14 8 01 WOdcOll POZ S4ONVH1 TOL H19N31 HLONA1 UFaNNN 318VO ldVd T L a Z I xog NOILONAL OL GSYIM QNd SIHL J dT3IHS qaqivuq AV IdSIQ TIWLIDIO OL G3uYIM QNd SIHL SANS H109 ac XC 6 1 9 r C SHIM ANNOYD o N gt JHIM N 4HIM NIVY don N 7 I c JAIM 0 9 EN LIM TY HLSN31 Zi AC Cable Assembly ref dwg 704 1102 Figure 13 OxyTrak
38. s Manual 115 Appendix E Default Settings E 4 Output Defaults Note Default settings are in bold text E 4 1 Output A OUTPUT Output A Measure 02 Combustibles ppm Combustibles Furnace Temp DegC Furnace Temp DegF Type 4 20mA 0 20mA NAMUR special Zero 0 00 mA Span 0 00 mA Range Zero 0 00 Span 10 00 Trim Base Trim 0 00 mA Span Trim 0 00 mA 7o 0 Mode Test Normal Cal Setting Hold Last Value User Selectable Specific Value 1 0 mA Live Output 114 OxyTrak 390 Flow Gas Analyzer User s Manual Appendix E Default Settings E 4 2 Output B Output B Measure 02 Combustibles ppm Combustibles Furnace Temp DegC Furnace Temp DegF Type 4 20mA 0 20mA NAMUR special Zero 0 00 mA Span 0 00 mA Range Zero 0 00 ppm Span 2000 00 ppm Trim Base Trim 0 00 mA Span Trim 0 00 mA 90 0 Mode Test Normal Cal Setting Hold Last Value User Selectable Specific Value 1 0 mA Live Output OxyTrak 390 Flow Gas Analyzer User s Manual 115 Appendix E Default Settings E 4 3 Output C Output C Measure 02 Combustibles ppm Combustibles Furnace Temp DegC Furnace Temp DegF Type 4 20mA 0 20mA NAMUR special Zero 0 00 mA Span 0 00 mA Range Zero 0 00 Span 10 00 Trim Base Trim 0 00 mA Span Trim 0 00 mA 0 Mode T
39. shields to the nearest chassis ground terminal Wires enclosed in a properly grounded metal conduit do not require additional shielding 2 5 10 LVD Compliance For compliance with the European Union s Low Voltage Directive 2006 95 EC the analyzer requires an external power disconnect device such as a switch or circuit breaker The disconnect device must be marked as such clearly visible directly accessible and located within 1 8 m 6 ft of the unit Note Ifthe instructions in this section are followed the unit will comply with the Low Voltage Directive 2006 95 EC OxyTrak 390 Flow Gas Analyzer User s Manual 19 Chapter 2 Installation 2 5 2 Wiring the Analog Outputs A C To wire an analog output device to the OxyTrak 390 refer to Figure 12 on page 24 and Figure 17 on page 32 or Figure 18 on page 33 and make the following connections to terminal block J11 in the display controller 1 Connect the positive pin to the input of the analog output device a Output A J11 5 b Output B J11 3 c Output C J11 1 2 Connect the negative pin to the return of the analog output device Output A J11 6 b Output B J11 4 c Output C J11 2 2 5 3 Wiring the Alarm Relays A D To wire a warning device to any of the OxyTrak 390 alarm relays A D refer to Figure 12 on page 24 and Figure 17 on page 32 or Figure 18 on page 33 and make the following connections to terminal blocks J7 and
40. the probe s maximum operating temperature is not exceeded and that the probe is not situated in a non homogeneous flue gas mixture For boilers locate the analyzer downstream of the heat exchanger and just before the economizer air heater if one is installed The analyzer should not be placed downstream of any air heater because of possible air leaks that can cause inaccurate readings In general the sample point should be an area of high turbulence which will ensure a good homogeneous mixture of the flue gases Conditions to be avoided would include air leaks upstream of the sample point and dead spaces in the vicinity of the sample point Mounting Flange Shroud WA NENN i Si i SENSO NN EN EN 307 L gt Probe Probe Sleeve Figure 10 Permitted Flue Gas Flow Angles 14 OxyTrak 390 Flow Gas Analyzer User s Manual Chapter 2 Installation 2 3 1 Selecting the Site cont Finally the following installation requirements should be observed e Install the OxyTrak 390 in a location that provides ready access for programming testing and servicing the unit e Protect all cables from excessive physical strain bending pulling twisting etc Be sure that the input voltage at the planned installation site is within the limits specified for the OxyTrak 390 2 3 2 Preparing the Site Preparation of the installation site should include the following steps see Figure 16 on page 31 an
41. 04 OxyTrak 390 Flow Gas Analyzer User s Manual Appendix C Calibration Standard Convection C a Method 3 Calibration method 3 whether implemented in manual mode or using the autocal process includes the following Steps 1 a oe gt Obtain the two calibration gases a Gas 1 A gas with known oxygen content to be used as the span gas in a 1 gas oxygen calibration and as a zero gas in a 2 gas combustibles calibration b Gas 2 A gas with known combustibles content to be used as the span gas in a 2 gas combustibles calibration Install a system to deliver the calibration gases to the OxyTrak 390 at the proper flow rate and pressure Program all user programmable calibration parameters Initiate either manually or automatically the calibration process Allow the calibration to continue until the new O and combustibles readings are within the programmed tolerances C 5 Method 4 Calibration method 4 whether implemented in manual mode or using the autocal process includes the following Steps 1 GU gt ee Obtain the three calibration gases a Gas 1 A gas with known oxygen content to be used as the zero gas in a 2 gas oxygen calibration b Gas 2 A gas with known oxygen content to be used as the span gas in a 2 gas oxygen calibration and the zero gas combustibles calibration c Gas 3 A gas with known combustibles content to be used as the span gas in a 2 gas combustibles calibration
42. 115 120 or 230 240 VAC 50 60 Hz Power Consumption 350 W Ambient Temperature Range Analyzer 30 to 70 C 22 to 158 F Controller 30 to 60 C 22 to 140 F Flue Gas Temperature Range sample probe available in materials for temperatures up to 1200 F 650 C 1200 to 1750 F 650 to 950 C 1750 to 2900 F 950 to 1600 C 2900 to 3450 F 1600 to 1900 C Warm Up Time 1 hr Calibration Verification Modes Manual AutoCal and AutoVerify Calibration gas flow rate 250 10 cc min 88 OxyTrak 390 Flow Gas Analyzer User s Manual Chapter 7 Specifications 7 3 Physical Sensor Type Oxygen stabilized zirconium oxide Combustibles Optional catalytic combustion platinum resistance thermometer Wetted Materials 316 stainless steel various sample probe materials Probe Lengths Standard Convection Loop 24 0 6 m 39 1 0 m 55 1 4 m Dimensions overall h x w x d 22 x 17 x 12 not including mounting flange probe and probe sleeve Total Weight 19 in probe 25 Ib 11 4 kg Mounting Standard 1 1 2 MNPT Optional DN80 PN16 3 and 4 CS flanges Housing Analyzer NEMA 2 IP52 Controller Weatherproof NEMA 4X IP66 European Compliance complies with EMC Directive 2004 108 EC 2006 95 EC LVD installation category II pollution degree 2 and PED 97 23 EC for DN lt 25 7 4 Calibration Calibration Options 1 1 gas bottle O only auto amp
43. 1256 sht 3 31 Chapter 2 Installation T C FURNACE T C MANIFOLD ON s FURNACE ll Y ANALYZER MECHANICALS SHOWN AS REFERENCE ONLY E COMBUSTIBLE SENSOR la _ 02 SENSOR mu ger INNER LEAD in rh a OUTER LEAD LEFT HEATER CARTRIDGE LHC FOR USE WITH CD 704 668 XX CABLE _ RIGHT HEATER CARTRIDGE RHC EN OUT GRN J14 3 RED J14 2 IN WHT J14 1 230 240 VAC 115 120 VAC Wiring Diagram Horizontal Local Electronics ref dwg 702 623 Zn ole 5
44. 3 Figure B 1 Figure B 4 Relay A Relay B Measure Relay C System Faults amp EN Relay E CTRL see text for details Applies to output setting during calibration and blowback purge aa 2 a 2 oa lt a lt he Le red Relay F CTRL Relay G CTRL Figure 22 Outputs and Relays Menu Map 2719 passcode Normal Failsafe ENT Enter Value K K tts Relay H CTRL Normal OxyTrak 390 Flow Gas Analyzer User s Manual 98 MAIN MENU DISPLAY AN OUTPUT E lt RELAYS A Y COMMUNICATIONS S SETUP FACTORY r Figure B 1 Figure B 2 Figure B 2 m lt VA VA VA AY A V Failure O2 A V Tolerance d lt gt gt Comb AN Tolerance Auto Cal Now OxyTrak 390 Flow Gas Analyzer User s Manual m m m z mar m z mar ne Start Time
45. 37 PassWord See ansehe 37 W Warm Up PTE A d R E en 35 30 a n ee een 139 WEER Directive va sa ae vili W L D a T 18 AC Cable Assembly 24 26 7a 22 EEEE ocd E E ATE 20 Analog Outputs 20 Blow Back Sample System 21 CE Mark Complian e l saus dR R asa 18 EMC Compliance ura ys ass 19 IE POWE sun A 25 LVD Complianc 18 19 I ara Y am aha dl MD en Dd 21 RS gt 57 Output 694 64545 224 4304 ae 22 RS485 OUPUE a 22 Signal Cable Assembly 23 OxyTrak 390 Flow Gas Analyzer User s Manual Index 137 Index no content intended for this poge 138 OxyTrak 390 Flow Gas Analyzer User s Manual Warranty Warranty Each instrument manufactured by GE Sensing is warranted to be free from defects in material and workmanship Liability under this warranty is limited to restoring the instrument to normal operation or replacing the instrument at the sole discretion of GE Sensing Fuses and batteries are specifically excluded from any liability This warranty 19 effective from the date of delivery to the original purchaser If GE Sensing determines that the equipment was defective the warranty period 19 e one year from delivery for electronic or mechanical failures e one year from delivery for sensor shelf life If GE Sensing determines that the equipment was damaged by misuse imprope
46. 90 for the type of calibration method you wish to use see Appendix C Calibration Methods for details on the various choices At the Setup submenu of the Main Menu use the arrow keys to select the E de Sensor Teme Cal Method option and press ENTER Clack ou Back Comb_rrm Llamr ETUP Buto Cal Method Use the arrow keys to select the desired calibration method from the list E Then press ENTER Proceed to the appropriate subsection to complete the programming of your chosen Cal method 6 5 5a 1 Gas Oxygen This method is used to perform an oxygen calibration with one calibration gas Lal MethodeicyL 1082 To program the O span gas press ENTER of HHZ Fran Ug Use the arrow keys as indicated to enter the span gas oxygen percentage When done press ENTER save changes Unda changes move Cursor change Value When you have finished programming the Cal Method menu press ESC until you return to normal run mode 76 OxyTrak 390 Flow Gas Analyzer User s Manual Chapter 6 Advanced Programming 6 5 30 2 Gas Oxygen This method is used to perform an oxygen calibration with two calibration gases Cal Methad zchL_202 cH 332 Far a E1 changes Undo chanses move Cursor change Value Cal Method 2CcYL 202 ero Oe cH 33 ran Ue HE save changes Undo changes move Cursor change value Use the arrow keys to select the Zero O2 opti
47. Adyanced a A amas ua 71 Blow Back nui ci a Se 82 GS Sea E E ee te aca 45 Proportional Band Value 11 R Relays Delauls a GYR dd dl 117 DI A een ea Be ea nee tod ee 55 61 NV Ill l suu ua uye unu sua a a ua el eae 21 Remote Display o oo uu 23 Response ost ua ya ein 109 Return Poley a y zaza ya uqaqa 2242 yu yasa 139 RS232 Output Wiring 22 RS485 Output Wiring 22 S Safety Auxiliary Equipment vii General Issuesau su ara a vu Personal Equipment vu Sample System us 4 cae Eee ee 3 Blow Back orar near 131 Sensor o A EN 8 OSM cris rd da 1 9 Setup Blow Back Sample System 131 Detalla as aqa puk ku 124 MEU ataca kuupa er id eta ze 46 74 Real Time Clock 46 Signal Cable Assembly 23 OxyTrak 390 Flow Gas Analyzer User s Manual Site Preparan sado ia dba 17 SEIEClION se Barren 14 Specifications Calibradores a deo O O O DUE A SS BE 89 FunctHonal ue cdi Gand aula a deka ewes ka 88 Per OrMane etdan hE Spo wl aoe wow eae dba 87 Physical amas na ld abre 89 T Temperature O A 13 He ter Block we a ici 8 Sensor Furnace oidos ocd bk aw we ee wa ae 8 Test Calibration Gas Flow Rate 109 RESPONSE ss E EAs GA ho Mee eons 109 U US 41 45 71 NEE SS Y a eee ced ook Gas Ba eed Gees 37 e els y toe gh saam eae aed kunkan hos a
48. Calibrate menu press ESC until you return to normal run mode 6 4 2 Combustibles Tolerance This section 1s very similar to the previous section except that 1t 19 used to program the tolerance for the combustibles calibration Proceed as follows AY CALIBRATE Autoca1 Use the arrow keys to select the Comb Tolerance option and press ENTER 4 J2 a HU Toler 18 Comb HU 2B Ae me e Tolerance Hex Use the arrow keys as indicated to enter the desired tolerance value in ppm combustibles When done press ENTER Save changes Undo changes move Cursor chanse value When you have finished programming the Calibrate menu press ESC until you return to normal run mode OxyTrak 390 Flow Gas Analyzer User s Manual 73 Chapter 6 Advanced Programming 6 5 Setup Menu The Setup menu has several additional options that become available at this passcode level Proceed to the appropriate section to program any of these new options Note Ifnecessary see Chapter 5 General Programming for instructions on navigating to this menu 6 5 1 O gt Sensor Temp This option is used to specify the operating temperature of the zirconium oxide oxygen sensor factory default 700 C At the Setup submenu of the Main Menu use the arrow keys to select the 02 Sensor Temp option and press ENTER eater oc Clock Cal Method Blow Back Comb Frem C1lame _SETUP Oe Sensor Temp Use the arrow keys to selec
49. Deadband 0 00 Diag Errors O2 Over Range Setpoint 100 00 O2 Under Range Setpoint 0 01 120 OxyTrak 390 Flow Gas Analyzer User s Manual Appendix E Default Settings O2 Cal Error Comb Over Ranee Setpoint 30000 00 ppm Comb Under Range Setpoint 0 00 ppm Comb Cal Error System Faults Furnace Temp Over Range Furnace Temp Under Range Furnace Low Temp Block Temp Over Range Block Temp Under Range Block Low Temp Active RTD Over Range Active RTD Under Range Ref RTD Over Range Ref RTD Under Range Normal Failsafe Normal Failsafe Relay E Test Reset Trip Normal Failsafe Normal Failsafe Relay F Test Reset Trip Normal Failsafe Normal Failsafe Relay G Test Reset Trip OxyTrak 390 Flow Gas Analyzer User s Manual 121 Appendix E Default Settings Normal Failsafe Normal Failsafe Relay H Test Reset Trip Normal Failsafe Normal Failsafe 122 OxyTrak 390 Flow Gas Analyzer User s Manual Appendix E Default Settings E 6 Communications Defaults Note Default settings are in bold text COMMUNICATIONS Select Port RS232 RS485 Node ID NodeID 16 Port Settings Baud Rate 2400 9600 19200 38400 57600 Parity None Stop Bits 1 Data Bits 3 Ethernet Settings IP Addr Port 0 Gateway Addr OxyTrak 390 Flow Gas Analyze
50. GE Meosurement amp Control Gos Analysis OxyTrak 390 Panametrics Flue Gas Analyzer User s Manual 910 264 Rev C imagination qt work er odo OxyTrakTM 390 Panametrics Flue Gas Analyzer User s Manual 910 264 Rev C November 2012 www ge mcs com 2012 General Electric Company All rights reserved Technical content subject to change without notice no content intended for this poge Contents Chapter 1 General Information deb 1 2 HOGI nta iee A ee O ests Saran eae io ee ee 1 ss E oo AAA Sn SSS sss 1 La SOM SS en ea er RON rn oup NA than ashi 3 PAD pay CORO uruya AT EE aap baykun z us miays muq ab 7 e Price p OL ODE a T a a Gd ces a a ee ee ee ee 8 Chapter 2 Installation 2 1 2 2 2 3 2 4 2 5 3 1 5 2 5 5 5 4 3 5 3 6 3 lO rl risotto rosso 13 Da A ee ee 13 el TTT 14 A E DNA 14 ARAS NS E 15 Me TTT 17 WA L TTT 18 Eel Ten else ea L o A O O eU Ua as o 19 23 WINO nia Tees OUTPUTS AG u uu u n ts ss taria 20 Alar lO Ess aaa AFON O Od aah ONIG Geese shaya 20 25 2 Wiring the Calibration lal llus uu su 588 Dn GO GEDYRN Wn ae era 21 2 55V ING INERS2 32 OU DU Ener ee ee ee ee eur 22 2 5 6 WINING Ine RSS QUINN or AS A ASS ASS ee 22 2 5 7 Remote Display Option 23 250 AIAG A u uuu usa as T_ NR qa Haa banta CN CN RR NN b eens sues aB aa 25 Chapter 3 Operation MFTO sp di
51. Gas Gas Points Gas 1 Gas 2 Gas 3 Gas 4 Gas 5 Gas 6 Type Ocal Perform Non Aspirator Aspirator Temp 1 CalGas 1 CalGas 2 CalGas 3 CalGas 4 CalGas 5 CalGas 6 Temp 2 Edit 126 CalGas 1 CalGas 2 CalGas 3 CalGas 4 CalGas 5 CalGas 6 5 Mins 0 0000 mV 600 0 DegC 2 220 DegC 240 DegC 5 0 ppm 3000 ppm 6000 ppm 12000 ppm 21000 ppm 1500 ppm 240 cc m OxyTrak 390 Flow Gas Analyzer User s Manual Appendix E Default Settings E 8 1 Aspirator Temp 1 CalGas 1 Ref ohms Act ohms CalGas 2 Ref ohms Act ohms CalGas 3 Ref ohms Act ohms CalGas 4 Ref ohms Act ohms CalGas 5 Ref ohms Act ohms CalGas 6 Ref ohms Act ohms Temp 2 CalGas 1 Ref ohms Act ohms CalGas 2 Ref ohms Act ohms CalGas 3 Ref ohms Act ohms CalGas 4 Ref ohms Act ohms CalGas 5 Ref ohms Act ohms CalGas 6 Ref ohms Act ohms OxyTrak 390 Flow Gas Analyzer User s Manual 1810 81 1811 17 1819 36 1838 11 1827 91 1865 04 1845 00 1918 91 1870 64 1999 72 1000 00 1000 00 1849 34 1849 78 1857 90 1876 38 1866 46 1902 98 1883 59 1956 18 1909 28 2035 98 1000 00 1000 00 127 Appendix E Default Settings E 8 2 Non Aspirator Temp 1 CalGas 1 Ref ohms Act ohms CalGas 2 Ref ohms Act ohms CalGas 3 Ref ohms Act o
52. Index Installation Blow Back Sample System 21 MGUNUING Runen 17 Site Preparations ars ss eden sad tar 17 Site Selecion na ua are 14 Wie roo 18 Integration Time Value 11 K A aah ae dee oe ee eae 36 L Line Power Wiring 25 LVD Compliance 18 19 NID Direc Cesa niae dada ra 36 M Measure Options ee RR RR a 55 Measurement Units 44 Measurements Lino rara L 39 Mounting the OxyTrak 17 N Namur Analog Output 56 Nernst Equation 91 Graphical Form 92 Numene Forms 2255 34 2 a ee 39 Non Aspirator Defaults 128 O Operation Principlesof 8 Output Detalle rai ras aa sa 114 Ni si u ami Spy nodos 55 72 Optio ia tando wn ON 55 56 57 58 60 Oxy Sel SENSO cards Ea 1 9 OxyTrak Clean a bog oan wand arten 36 Model Number 90 AIDS aba 17 Ordering Information 90 Powenne Unreal 36 Standard Configurations 2 Mon aa en ee aa 18 136 p Parameters Customizing 41 45 PASSCOUES ua bee aa da 41 45 71 Password A zu tote mack Oe O YO eth oe eaters 37 U seriProstam uds we haya ee 37 PID Heater Controls sas aa 11 Power UD 36 Principles of Operation 8 Programming
53. J8 in the display controller 1 Connect the NC pin to the alarm device input for failsafe operation or leave this pin unused for non failsafe operation Relay A J7 4 NC b Relay B J7 1 NC c Relay C J8 4 NC d Relay D J8 1 NC 2 Connect COM pin to the alarm device return Relay A J7 6 COM b Relay B J7 3 COM c Relay C J8 6 COM d Relay D J8 3 COM 3 Connect the NO pin to the alarm device input for non failsafe operation or leave it unused for failsafe operation Relay A J7 5 NO b Relay B J7 2 NO c Relay C J8 5 NO d Relay D J8 2 NO 20 OxyTrak 390 Flow Gas Analyzer User s Manual Chapter 2 Installation 2 5 4 Wiring the Calibration Relays E H To wire a warning device to any of the OxyTrak 390 calibration relays E H refer to Figure 12 on page 24 and Figure 17 on page 32 or Figure 18 on page 33 and make the following connections to terminal blocks J9 and J10 in the display controller 1 Connect the NC pin to the alarm device input for failsafe operation or leave this pin unused for non failsafe operation b c d Relay E J9 3 NC Relay F J9 6 NC Relay G J10 3 NC Relay H J10 6 NC 2 Connect the COM pin to the alarm device return a b c d Relay E J9 1 COM Relay F J9 4 COM Relay G J10 1 COM Relay H J10 4 COM 3 Connect the NO pin to the alarm device input for non failsafe operation or leave this pin unused f
54. O2 Using the BLACK wire from the white black pair connect junction box terminal J2 2 O2 to display controller terminal J1 2 O2 3 Wire the furnace thermocouple a b Using the BLUE wire from the blue black pair connect junction box terminal J1 3 T C FURN to display controller terminal J6 3 T C FURN Using the BLACK wire from the blue black pair connect junction box terminal J1 4 T C FURN to display controller terminal J6 4 T C FURN 4 Wire the manifold thermocouple a Using the BROWN wire from the brown black pair connect junction box terminal J1 5 T C MAN to display controller terminal J6 5 T C MAN b Using the BLACK wire from the brown black pair connect junction box terminal J1 6 T C MAN to display controller terminal J6 6 T C MAN OxyTrak 390 Flow Gas Analyzer User s Manual 23 Chapter 2 Installation 2 5 7a Wiring the Signal Cable Assembly 704 1104 cont 5 Wire the cold junction compensation d Using the YELLOW wire from the yellow black pair connect Junction box terminal J1 1 CJC to display controller terminal J6 1 CJC Using the BLACK wire from the yellow black pair connect Junction box terminal J1 2 CJC to display controller terminal J6 2 CJC 2 5 70 Wiring the AC Cable Assembly 704 1102 1 Wire the manifold and furnace heaters a 24 Using WIRE 1 connect junction box terminal J5 1 MANIFOLD to display contr
55. Programming 5 4 3 Range The Range option 1s used to specify the zero and span points of the analog output range as a percentage of the output variable range _PLAY OUTPUT Outrut A Use the arrow keys to select the Range option and press ENTER Heasure TYFe 1m Cal Setting lITPLlT Dutrut G Farnge Use the arrow keys to select the Zero option and press ENTER Elke Fan l Eid Use the arrow keys as indicated to enter the desired Zero point of the output range When done press ENTER save changes Unda chan e move CuUP Oor chan e Value uteut ArTure Srpecia Use the arrow keys to select the Span option and press ENTER ero H Hem A ema Use the arrow keys as indicated to enter the desired Span point of the output range When done press ENTER Save changes Undo changes move Cursor change value OxyTrak 390 Flow Gas Analyzer User s Manual 57 Chapter 5 General Programming 5 4 4 Trim The Trim option is used to fine tune the analog output parameters _PLAY OUTPUT Outeut A Use the arrow keys to select the Trim option and press ENTER Heasure TYFe Range a ettimd DLITPLlT Dutrut ArTrim Use the arrow keys to select the Base Trim option and press ENTER BEIMA Fan Ir m B B mA 120 na Mode Use the arrow keys as indicated to specify the Zero point of the analog output When done press ENTER
56. R Baud Fate Parity Stor Bits bate Bits Use the arrow keys to select the desired number of data bits and press ENTER When you have finished programming the Communications menu press ESC until you return to normal run mode 5 6 2 Ethernet Port To configure an Ethernet port proceed as follows 4 CCOMMUHICATIONS sp Use the arrow keys to select the Ethernet Settings option and press ENTER Ore Hode ID Port Settings _MUHICATIOHNS Ethernet Use the arrow keys to select the Port option and press ENTER IF Addr a ME Addr Use the arrow keys as indicated to enter the value for the Port When done press ENTER save changes undo changes move CURSO change Value Note The Port is the only programmable parameter at the 2719 passcode level When you have finished programming the Communications menu press ESC until you return to normal run mode OxyTrak 390 Flow Gas Analyzer User s Manual 69 Chapter 5 General Programming no content intended for this page 70 OxyTrak 390 Flow Gas Analyzer User s Manual Chapter 6 Advanced Programming Chapter 6 Advanced Programming 6 1 Introduction Although the OxyTrak 390 is set up at the factory with default values that are suitable for many applications the User Program provides a means for customizing many of the meter parameters IMPORTANT This chapter discusses only those additional
57. Save changes Undo changes move Cursor change Value OUTPUT Outeut A Trim Use the arrow keys to select the Span Trim option and press ENTER Base Trim m A GEMA 141 Use the arrow keys as indicated to specify the Span point of the analog output When done press ENTER ave changes ndo changes move CURSO change Value The option is used to output a signal at a specified percentage of the analog output range during a Test cycle DLITPLlT Dutrut ArTrim Use the arrow keys to select the option and press ENTER Base Trim B 4bmA Sram Trim amp 4 amp mA 16h ode 58 OxyTrak 390 Flow Gas Analyzer User s Manual Chapter 5 General Programming 5 4 4 Trim cont Use the arrow keys as indicated to specify the to be output during a Test cycle When done press ENTER save changes Undo chanses move CURSO change Value The Mode option is used to test the analog output DLITPLlT Dutrut ArTrim Use the arrow keys to select the Mode option and press ENTER i mA Base Trim Sean Trim Q Dgn aU 144 _T outeut A Trim Hode Use the arrow keys to select the Test option and press ENTER normal The analog output should now be reading a value equal to the percentage of full scale programmed into the 96 option above if 1t does not contact the factory for assistance After you verify this continue as follows T llutrut A Trim Hode Use the arrow keys to se
58. Under equilibrium conditions the potential gradient exactly balances the concentration gradient Porous coatings of a platinum catalyst on both surfaces of the ceramic cell serve as electrodes while still allowing the oxygen molecules to penetrate the coating and diffuse into the ceramic The measured voltage drop across the cell can be directly related to the ratio of the two oxygen partial pressures by means of Equation A 1 the Nernst Equation below m ea 1 Pia P s QE A 1 where F the Faraday 96 484 56 coulombs T absolute temperature K R gas constant 8 31441 volt coulomb mole K n electrons transferred per molecule 4 mole In natural logarithm 2 303 log jg p O partial pressure on reference gas side 0 209 P2 O partial pressure on flue gas side E gt voltage on reference face with respect to the flue gas face OxyTrak 390 Flow Gas Analyzer User s Manual 91 Appendix A The Nernst Equqtion A 3 The OxyTrak 390 Equation The Nernst Equation specifically applicable to the OxyTrak 390 analyzer is obtained by substituting the above values into the general equation converting the natural logarithm to the common logarithm base 10 and converting the units for E to millivolts This results in Equation A 2 below 0 A 2 E mV 0 049605 e T e al The OxyTrak 390 measures the temperature at the sensor and automatically inserts the correct value into the Nernst Equation
59. a type and press ENTER to select it as indicated by a to its left Repeat Measure to select as many types as desired then press ESC The current OxyTrak 390 alarm relay will now respond to the types of parameters chosen above Note The next section provides instructions for selecting the specific parameters to be included in each of the three categories above OxyTrak 390 Flow Gas Analyzer User s Manual 61 Chapter 5 General Programming 5 5 16 Setting The Setting option 1s used to choose the specific parameters that are included in each Type category for triggering the alarm relay Also the details for the alarm s response may be programmed SPL AY FELGYS Relay A Use the arrow keys to select the Setting option and press ENTER JFE Ee afe The Measure submenu Ow Rel aw Arsettina Use the arrow keys to select the Measure option and press ENTER 133 Errors System Faults au ArSettina Measure Use the arrow keys to select the Type option and press ENTER O2 l 4 Combustibles Fem Combustibles Settimg Peaszure Turel Use the arrow keys to select the desired option and press ENTER Ci Note The alarm setpoint is the signal value at which the relay will be triggered A High relay is triggered when the signal exceeds the setpoint a Low relay is triggered when the signal drops below the setpoint pa Meacure Ture Hia Use the arrow k
60. al 129 Appendix E Default Settings E 8 130 Factory Defaults cont Cal Factor Comb Cal Slope Comb Cal Intercept Fast Cal Limit Thermal Cal Limit Comb ppm Avg Start Span Cal PID SpanCal PID Status Service Busy 1 0000 1 0000 0 0000 20 0 50 0 lt OxyTrak 390 Flow Gas Analyzer User s Manual Appendix F Blow Back Sample System Appendix F Blow Back Sample System F 1 Installation To install a Blow Back Sample System see Figure 26 on page 132 and complete the following 1 Mount the sample system near the OxyTrak 390 using the four mounting holes located at each corner of the plate 2 Close all valves 3 Using 4 tubing with compression fittings connect the Solenoid Valve to the Blow Back Calibration Port the Flowmeter to the Aspirator Port and the Gas Inlet to the gas source 4 When compression fitting connections have been secured connect the sample system to its electrical source and open the valves F 2 Settings 1 Set the Inlet Pressure Regulator to 4 5 bars 2 Adjust the Blow Back Needle Valve for 125 cc min and remove the handle 3 Adjust the Aspirator Needle Valve to set the aspirator gas flow at 10 SCFH OxyTrak 390 Flow Gas Analyzer User s Manual 131 Appendix F Blow Back Sample System 0 875 _ 22 2 0 875 22 2 typ 27 00 685 8 Mounting Plate Blow Back Needle Valve Inlet Pr
61. alue Arrow Keys N NN SS N N Escape Key Enter Key A Figure 19 Digital Controller Display and Keypad Note The OxyTrak M 390 digital controller has an integral keypad which permits programming of the instrument without opening the cover Thus all programming procedures may be performed while the unit is installed in a hazardous environment 56 OxyTrak 390 Flow Gas Analyzer User s Manual Chapter 3 Operation 3 5 Entering Programming Mode The OxyTrak 390 software enables the operator to configure the meter for his specific requirements To accomplish this 1t 1s necessary to leave normal run mode and enter Programming Mode as follows Make sure you are at the normal run mode screen The closed black padlock indicates that the user program is currently locked zaan While in normal run mode press the ESC ENTER and ESC keys in sequence Notice that the black padlock is now open US aen Use the arrow keys to select the padlock it will change to white on a black backeround Then press the ENTER key US aer DISPLAY Set Lock Use the arrow keys to select the Passcode option Then press the ENTER key oc eu ad Lock Menus There are two different passcodes that can be used at the next screen e User Level passcode 2719 see Chapter 4 Setting Up the Display and Chapter 5 General Programming for instructions e Service Level Access passcode 7378 see Chapter 6 Adv
62. ance When you have finished programming the Factory menu press ESC until you return to normal run mode OxyTrak 390 Flow Gas Analyzer User s Manual 85 Chapter 6 Advanced Programming no content intended for this page 86 OxyTrak 390 Flow Gas Analyzer User s Manual Chapter 7 Specifications Chapter 7 Specifications 7 1 Performance Accuracy Oxygen 0 1 0 10 O 0 2 10 25 O Combustibles Optional 20 ppm or 5 of reading whichever 1s greater Repeatability Oxygen 0 05 0 10 O 0 1 10 25 O Combustibles Optional 10 ppm or 2 of reading whichever is greater Output Resolution Oxygen 0 01 Combustibles Optional 1 of full scale Stability Oxygen variation lt 0 2 O per year Combustibles Optional lt 200 ppm per year Measurement Range Oxygen 0 1 to 0 100 user selectable Combustibles Optional 0 500 2000 5000 10000 ppm 0 2 OxyTrak 390 Flow Gas Analyzer User s Manual 87 Chapter 7 Specifications 7 2 Functional Display 64 x 128 pixel graphical with backlight Analog Output 3 linearized isolated 4 20 mA outputs user selectable field programmable for O or combustibles over any range Alarm Output 8 relay user programmable for high low O or combustibles AutoCal or AutoVerify 2 for O and or 2 for combustibles system fault blowback feature Digital Output Standard RS232 or RS485 user selectable Power
63. anced Programming for instructions Use the arrow keys as indicated to enter the desired Passcode Then press the ENTER key save changes Unda changes move Cursor change value OxyTrak 390 Flow Gas Analyzer User s Manual 31 Chapter 3 Operation 3 5 Entering Programming Mode cont DISPLAY CALIBRAT Regardless of the password that was entered at the previous screen this will be the first programming screen 1 F1 ad 3 6 Exiting Programming Mode The are two different ways to leave the OxyTrak 390 programming mode These are described in the following sections 3 6 1 Temporary Exit To temporarily leave Programming Mode proceed as follows HT From any point in the user program press the ESC key repeatedly until the run mode screen appears Uae Notice that the padlock is open to indicate that programming mode is unlocked Also the current programming level is indicated just below the padlock e MI indicates that the 2719 passcode is in effect e M2 indicates that the 7378 passcode is in effect To reenter programming mode use the arrow keys to select the M1 or M2 symbol and press the ENTER key 3 6 2 Locking Programming Mode To lock programming mode use the arrow keys to select the padlock symbol and press the ENTER key Then proceed as follows DISPLAY Set Lock Use the arrow keys to select either the Lock Keypad option or the Lock Menus option Then press the
64. ar ess Pal l Use the arrow keys to select the Trip option and press ENTER Reset Physically verify that the relay has in fact been tripped If 1t has not been tripped contact the factory for assistance E lt CTRLI Process bal l Use the arrow keys to select the Reset option and press ENTER r1F IMPORTANT Be sure to Reset the relay before leaving the Reloys menu If you have finished programming the Relays menu press ESC until you return to normal run mode 66 OxyTrak 390 Flow Gas Analyzer User s Manual Chapter 5 General Programming 5 6 Communications Menu The Communications menu is used to configure the OxyTrak 390 communications port RS232 RS485 and Ethernet ports are supported To configure your port proceed to the appropriate section 5 6 1 RS232 RS485 Port As an example the programming of an RS232 port with the factory default settings 1s illustrated here The programming of other configurations 1s done in a similar manner 4 CCOMMUNICATIONSI Sp At the Main Menu use the arrow keys to select the Communications menu Then T use the arrow keys to select the Select Port option and press ENTER ode G Port Settings Ethernet Settings ICATIONS Select Par Use the arrow keys to select the desired option and press ENTER IMPORTANT The choice you make above must correspond to the actual wiring the was made to the meter during installation see Chapter 2
65. b Tolerance Auto Cal Now Figure B 3 OxyTrak 390 Flow Gas Analyzer User s Manual 100 Appendix B Menu Mops MAIN MENU a a Hm Sm E He ron lt lt lt lt lt Figure B 1 Figures B 3 B 4 Figures B 2 B 4 Figure B 2 Figure B 3 any Figures B 4 700 E 4 O2 Sensor Temp O2 1 CYL ENT Enter Value EN M N ENT M N N N ENT 770 Enter Value ENT ENT Heater Block Temp O2 2CYL ENT vA d d Enter Value am Fores co MIRA vA vA YA easton fo Cal Mead MT YA VA Brow Back aR VA MIA Comb pom Came MITO Enter Value m Z 3 m 3 m Z 3 m z 3 easton Je ervan gt Enter Value Figure 25 Setup Menu Map 7378 passcode gt Enter Value ren zero Blow Back Now Select Yes or No OxyTrak 390 Flow Gas Analyzer User s Manual 101 Appendix B Menu Mops OxyTrak 390 Flow Gas Analyzer User s Manual 102 Appendix C Calibration Standard Convection Appendix C Calibration Standard Convection C 1 Introduction To meet a variety a application requirements The OxyTrak 390 has been designed for calibration using a number of different methods The available methods include
66. be installed and operated as described in this manual Also be sure to follow all applicable local safety codes and regulations for installing electrical equipment All procedures should be performed by trained service personnel only 2 2 Unpacking Remove the analyzer see Figure 9 below from its shipping container and make sure that all items on the packing slip have been received If anything is missing contact the factory immediately Note See Figure 14 on page 29 local controller or Figure 15 on page 30 remote controller for a complete outline and installation drawing of the OxyTrak 390 Figure 9 Typical OxyTrak 390 with Local Controller OxyTrak 390 Flow Gas Analyzer User s Manual 13 Chapter 2 Installation 2 3 Installation Site Environmental and installation factors should already have been discussed with a GE applications engineer or field sales person before the OxyTrak 390 arrives 2 3 1 Selecting the Site The tip of the probe is typically inserted into the stack to a distance of 1 3 of the stack diameter Also the flue gas flow direction should be either perpendicular to the probe or angled away from the open end of the probe see Figure 10 below IMPORTANT Never allow the flue gas flow to be angled directly into the end of the probe e For furnaces locate the analyzer close to the combustion zone typically within the radiant section and always before the convection section Make sure that
67. bration to continue until the new O and combustibles readings are within the programmed tolerances OxyTrak 390 Flow Gas Analyzer User s Manual 107 Appendix C Calibration Standard Convection C 9 Calibration Gases Table 4 below lists the acceptable specifications for the various OxyTrak 390 calibration gases Table 4 Calibration Gas Specifications Method Defoult 0 01 O 5 00 O 10 00 O 5 8 00 O 20 93 O 25 00 O 0 01 O 5 00 O 10 00 O 0 01 O 5 00 O 10 00 O U ppm Comb 0 ppm Comb 10 of Range 60 of Range Full Range 120 of Range l 8 00 O 2093 O 25 00 O 3 4 0 01 O gt 5 00 O 10 00 O U ppm Comb 0 ppm Comb 10 of Range 60 of Range Full Range 120 of Range 8 00 O 20 93 O 25 00 O 0 01 O 5 00 O 10 00 O U ppm Comb 0 ppm Comb 10 of Range 60 of Range Full Range 120 of Range 0 01 O 5 00 O 10 00 O U ppm Comb 0 ppm Comb 10 of Range ERE 8 00 O 20 93 O 25 00 O 7 0 01 O 5 00 O 10 00 O U ppm Comb 0 ppm Comb 10 of Range 108 OxyTrak 390 Flow Gas Analyzer User s Manual Appendix D Calibration Aspirated Flow Appendix D Calibration Aspirated Flow D 1 Response Test The response test is performed at the OxyTrak 390 s initial installation only The purpose of this test is to set the aspirator at a flow rate to achieve the desired response time Allow the unit to warm up fo
68. c Normal Failsafe The Normal Failsafe option is used to choose the mode of operation for the alarm relay being programmed Note A Normal relay uses the normally open contacts and must be energized when a fault occurs a Failsafe relay uses the normally closed contacts and is de energized when the fault occurs _SPLOY RELHYS Relau A Use the arrow keys to select the Normal Failsafe option and press ENTER Pe Settirs au O Hormal Failsate Use the arrow keys to select the desired option and press ENTER allsate If you have finished programming the Outputs menu press ESC until you return to normal run mode OxyTrak 390 Flow Gas Analyzer User s Manual 65 Chapter 5 General Programming 5 5 2 Relays E H Note The control relays are configured at the factory to perform their designated functions These relays may not be reprogrammed at the 2719 passcode access level However the relays may be tested for proper operation To test the control relays E H proceed as follows RELAYS COMMUNICA At the Main Menu use the arrow keys to select the Relays menu Then use the el u arrow keys to select the desired relay to configure and press ENTER Relay D elas Relay G CLIRLO Relay H CLTRLO Note The setup of Relay E is shown here as an example Relays F G and H are programmed in a similar manner To Test the relay press ENTER ormal Failsate E CTR N Br
69. calibrations according the settings programmed in this section OxyTrak 390 Flow Gas Analyzer User s Manual 49 Chapter 5 General Programming 5 3 3a _ Autocal Interval Program the time interval between Autocals as follows HY CHL IBRHTE Hutocal as bourrlu Mins settlins Tim Mins Hell Failure Oe A Toler 16 Comb R U 24 H rFrFme Auto Cal now HTEButocal Interval otocal interval Hours OUP Z 2 Hours UT oc al l nrterusal Das l rays art Time save changes Undo changes move Cursor change value 50 Use the arrow keys to select the Interval option and press ENTER Use the arrow keys to select the Hours option or see below for the Days option and press ENTER Use the arrow keys to select the desired number of hours between Autocals and press ENTER Use the arrow keys to select the Days option or see above for the Hours option and press ENTER Use the arrow keys to select the Days option and press ENTER Use the arrow keys as indicated to enter the desired value When done press ENTER OxyTrak 390 Flow Gas Analyzer User s Manual Chapter 5 General Programming 5 3 3a Autocal Interval cont utocal Interyal Dass Days Das Puyal Daus e art Time 5 ours L PUTS AMins save changes Unda changes move Cursor chanae value wYal Days Start Time our BHours AMins save changes Undo changes move Curs
70. can cause damage to the sensor Always allow the probe assembly to gradually heat up to normal operating temperature before subjecting it to hot flue gases e Be sure the unit has exited Warm up mode prior to use If any problems not covered in this manual are encountered contact a GE representative for assistance OxyTrak 390 Flow Gas Analyzer User s Manual 35 Chapter 3 Operation 3 3 Cleaning the Enclosure If the display window or the case of the OxyTrak 390 becomes soiled use a soft cloth dampened with water for cleaning Never use solvents or detergents to clean the OxyTrak 390 3 4 Powering Up the System Check the wiring connections and make sure all the OxyTrak 390 covers are closed and secured before applying power Then energize the external disconnect device to power up the OxyTrak 390 and allow the analyzer to warm up for at least 50 minutes before taking measurements IMPORTANT For compliance with the European Union s Low Voltage Directive 2006 95 EC the OxyTrak 390 requires an external power disconnect device such as a switch or circuit breaker The disconnect device must be marked as such clearly visible directly accessible and located within 1 8 m 6 ft of the unit 3 4 1 The Display and Keypad The front panel of the digital controller supplied with the OxyTrak 390 whether located locally or remotely includes the components shown in Figure 19 below Lock Indicator V
71. ceramic toward the outer electrode At the outer electrode they give up electrons to become oxygen molecules again and are swept away by the sample gas flow The lower the concentration of oxygen in the flue gas sample the greater the rate of ion migration through the ceramic and the higher the cell voltage due to electron exchange at the electrodes The cell voltage rises logarithmically as the amount of oxygen in the flue gas falls allowing the accurate measurement of very low levels of excess oxygen in the flue gas OxyTrak 390 Flow Gas Analyzer User s Manual 9 Chapter 1 General Information Platinum Catalyst Combustibles Sensor The combustibles sensor consists of two platinum thermistors mounted side by side in the sample stream One thermistor the active element is used to detect react partial combustion products while the other thermistor the reference element provides a baseline The active element is coated with a black platinum catalyst and the reference element has a white inert surface As the sample gas passes over the active element the platinum catalyst causes any combustibles to burn in the presence of excess oxygen thereby raising the temperature of the active element above that of the reference element see Figure 8 below Flue Gas Flow Reference _ Element Inert Coating Element Platinum Catalyst J DA x gt lt gt gt gt gt x O S N
72. d Figure 11 below Note Although a horizontal installation is shown in this manual other mounting angles are permissible n ie eee BENIN FRONT VIEW Q O 3 min Welds Masonry Wall 7 SEO GAS FLOW a 2 i N Mounting Plate 2 Sch 80 Pipe V Mating Flange Figure 11 A Typical Installation Setup OxyTrak 390 Flow Gas Analyzer User s Manual 15 Chapter 2 Installation 2 3 2 Preparing the Site cont 1 Atthe chosen analyzer location on the furnace or boiler wall or on the side of a horizontal or vertical flue duct drill a hole of the proper diameter to accommodate a short length of pipe having at least a 1 7 8 in 48 mm inside diameter A length of 2 Schedule 80 pipe is suitable for this purpose 2 Weld the short pipe into a mounting plate with welds on both sides of the plate The pipe length must be sufficient to meet the following requirements One end of the pipe should extend through the rear of the mounting plate sufficiently to enter the wall For installation in a masonry wall the pipe should extend entirely through the wall to prevent the probe from becoming trapped if the wall should crumble To provide clearance for installing the flange bolts the pipe must be long enough to provide 4 in 100 mm of clearance between the front surface of the mounting plate and the back surface
73. e appropriate section to program the option selected at the above screen 5 4 1 Measure The Measure option is used to specify the measured variable oxygen ppm oxygen combustibles or ppm combustibles that is sent to the output being programmed _PLAY OLTPUT OUtFut A Use the arrow keys to select the Measure option and press ENTER Ure kanae rim Cal Setting PliT Uutrut ArMeasure Use the arrow keys to select the desired output variable and press ENTER 4 Lombustibles Fem Combustibles The current OxyTrak 390 analog output will now display the data for the variable chosen above OxyTrak 390 Flow Gas Analyzer User s Manual 55 Chapter 5 General Programming 5 4 2 Type The Type option 19 used to specify the type of signal that Is used for the analog output being programmed _PLAY OUTPUT OUtrFut A Use the arrow keys to select the Type option and press ENTER Measure arise rim Cal Setting OUTPUT Outrut Ar Tupe Use the arrow keys to select the desired output type and press ENTER Him HAMLUF Sreci l Note The Namur NE43 specification requires a 4 20 mA output to be clamped in specific bands to indicate out of range errors If you select Special at the above prompt you will be able to specify the Zero and Span values of your choosing for the analog output range 56 OxyTrak 390 Flow Gas Analyzer User s Manual Chapter 5 General
74. ection you programmed the manner in which the OxyTrak 390 responds to an auto verification failure In this section you define what constitutes a failure by specifying the maximum amount of variation in the oxygen calibration reading that will be tolerated Proceed as follows _AY CHALIERATE RAutocal Use the arrow keys to select the 02 A V Tolerance option and press ENTER Interval Gas SUFFly 2Mins settlins Tim Mins HL Failure We Hel olerancle omb Hl A A THuto Cal now Use the arrow keys as indicated to enter the desired tolerance value in O When done press ENTER save changes Unda changes move CURSO change Value OxyTrak 390 Flow Gas Analyzer User s Manual 53 Chapter 5 General Programming 5 3 3f Combustibles Auto Verification Tolerance This section is very similar to the previous section except that it is used to program the auto verification tolerance for the combustibles measurement Proceed as follows AY CALIBRATE Autoca1 Use the arrow keys to select the Comb A V Tolerance option and press ENTER Interval Gas SUFFly 2Mins settlins Tim Mins Hu Failure 02 HU Toler 192 Use the arrow keys as indicated to enter the desired tolerance value in ppm combustibles When done press ENTER save changes Unda changes move Cursor change value 5 3 39 Auto Cal Now This option may be used to force an immediate Autocal using the currently programmed parameters
75. er The display controller see Figure 6 below includes the terminal blocks for making all electrical connections and the furnace temperature control FTC circuit board Yhe FTC board maintains a constant sensor furnace temperature to improve the accuracy of the oxygen analysis and to extend the life of the oxygen sensor Figure 6 Display Controller Interior The display controller performs the following functions amplifies the oxygen and combustibles sensor outputs linearizes the oxygen signal e controls the sensor temperature outputs the reading on a 64 x 128 pixel graphic display e enables programming using an integral keypad e provides a linear 4 20 mA analog output e provides four alarm relays e provides four auto calibration relays e provides RS232 RS485 communications outputs OxyTrak 390 Flow Gas Analyzer User s Manual 7 Chapter 1 General Information Principles of Operation Ideally every furnace burner should mix a precise ratio of air to fuel and the mixture should burn efficiently to yield only heat water vapor and carbon dioxide However because of burner aging imperfect air to fuel mixtures and changing firing rates this rarely happens Monitoring the actual efficiency of the combustion process 1s easily accomplished with the OxyTrak 390 A flue gas sample is drawn into the probe by gaseous diffusion and a gentle convective flow The sample passes through the probe and into the sample sy
76. erms of the warranty or if the warranty has expired an estimate for the cost of the repairs at standard rates will be provided Upon receipt of the owner s approval to proceed the instrument will be repaired and returned OxyTrak 390 Flow Gas Analyzer User s Manual 139 Warranty no content intended for this page 140 OxyTrak 390 Flow Gas Analyzer User s Manual aail DECLARATION Sensing OF CONFORMITY DOC 0027 Rev A We GE Sensing 1100 Technology Park Drive Billerica MA 01821 USA declare under our sole responsibility that the OxyTrak 390 Flue Gas Oxygen Analyzer to which this declaration relates is in conformity with the following standards e EN 61326 1 2006 Class A Table 2 Industrial Locations e EN 61326 2 3 2006 e EN 61010 1 2001 Overvoltage Category II Pollution Degree 2 following the provisions of the 2004 108 EC EMC and 2006 95 EC Low Voltage Directives The unit listed above and any ancillary equipment supplied with it do not bear CE marking for the Pressure Equipment Directive as they are supplied in accordance with Article 3 Section 3 sound engineering practices and codes of good workmanship of the Pressure Equipment Directive 97 23 EC for DN lt 25 Billerica August 2010 Issued Mr Gary Kozinski Certification Standards Lead Engineer C TOV Customer Support Centers U S A The Boston Center 1100 Technology Park Drive Billerica MA 01821 U S
77. essure f SSK and c N Solenoid Valve TJ L _ 17 00 431 8 pa Dimensions are in inches millimeters 132 Sample Cylinder TO BLOWBACK CALIBRATION PORT Solenoid Valve Va Z 2 ay oy J N J Z Aspirator Needle Valve TO ASPIRATOR Flow Meter on gt OS N er NIZ x COB Figure 26 Blow Back Sample System ref dwg 733 366 OxyTrak 390 Flow Gas Analyzer User s Manual Appendix F Blow Back Sample System
78. est Normal Cal Setting Hold Last Value User Selectable Specific Value 1 0 mA Live Output 116 OxyTrak 390 Flow Gas Analyzer User s Manual Appendix E Default Settings E 5 Relays Defaults Note Default settings are in bold text RELAYS Relay A Type Measure Diag Errors System Faults Setting Measure 02 Combustibles ppm Combustibles Type High Setpoint 0 00 Deadband 0 00 Low Setpoint 0 00 Deadband 0 00 Diag Errors 02 Over Range Setpoint 100 00 O2 Under Range Setpoint 0 01 O2 Cal Error Comb Over Range Setpoint 30000 00 ppm Comb Under Range Setpoint 0 00 ppm Comb Cal Error System Faults Furnace Temp Over Range Furnace Temp Under Range Furnace Low Temp Block Temp Over Range Block Temp Under Range OxyTrak 390 Flow Gas Analyzer User s Manual 117 Appendix E Default Settings Block Low Temp Active RTD Over Range Active RTD Under Range Ref RTD Over Range Ref RTD Under Range Normal Failsafe Normal Failsafe Relay B Type Measure Diag Errors System Faults Setting Measure O2 9o Combustibles ppm Combustibles Type High Setpoint 0 00 Deadband 0 00 Low Setpoint 0 00 Deadband 0 00 Diag Errors O2 Over Range Setpoint 100 00 O2 Under Range Setpoint 0 01 O2 Cal Error Comb Over Range Setpoint 30000 00 ppm
79. eys to select the Setpoint option and press ENTER 4 BE eadbanod E1 He 62 OxyTrak 390 Flow Gas Analyzer User s Manual Chapter 5 General Programming 5 5 16 Setting cont srPleasure Ture Hiah Use the arrow keys as indicated to specify the value for the alarm relay setpoint When done press ENTER a save changes Undo changes move CUrSor Chanae Value The Deadband option is used to specify a range of values around the setpoint within which the relay will not reset after 1t has been triggered This is to prevent the relay from cycling on and off in response to minor fluctuations near the setpoint na Tleasure Ture Hianl Use the arrow keys to select the Deadband option and press ENTER l alaka Setpoint Q EFT 6 66 srPleasure Ture Hiam Use the arrow keys as indicated to specify the deadband value for the alarm relay G When done press ENTER save changes Undo changes move CUF ZO Chanae Value This completes the programming of the Type submenu Press ESC to return to the Measure menu au OeSettina Measure Use the arrow keys to select the desired measurement parameter to trigger the alarm orbitales relay O2 is shown as an example Then press ENTER Fem Combustibles TYFe OxyTrak 390 Flow Gas Analyzer User s Manual 63 Chapter 5 General Programming 5 5 16 Setting cont The Diag Errors subme
80. g this integration time reduces the offset more quickly e Derivative Action The derivative portion of the control loop applies a corrective signal based on the rate at which the actual temperature is approaching the set point In effect the derivative action reduces overshoot by counteracting the control signal produced by the proportional and integral parameters The heater control circuit is configured at the factory for optimum performance Because of the strong interaction between the three parameters involved properly setting up the PID loop is a very complex matter As a result randomly changing the P I and or D parameters can seriously degrade the performance of the OxyTrak 390 IMPORTANT Always contact the factory before attempting to change the default P I and or D values OxyTrak 390 Flow Gas Analyzer User s Manual 11 Chapter 1 General Information no content intended for this page 12 OxyTrak 390 Flow Gas Analyzer User s Manual Chapter 2 Installation Chapter 2 Installation 2 1 Introduction This chapter provides instructions on how to properly install and wire the OxyTrak 390 Be sure to observe all installation limits and precautions described in this chapter Pay particular attention to the specified ambient temperature range of 30 to 70 C 22 to 158 F for the analyzer and 30 to 60 C 22 to 140 F for the controller WARNING To ensure safe operation the OxyTrak 390 must
81. he Main Menu appears To adjust the contrast of the LCD display proceed as follows DISPLAY CALIBRATR Use the arrow keys to select the Display option and press ENTER Lewes _PLAY DISPLAY Diselas Use the arrow keys to select the Contrast option and press ENTER Horma nm Fener ZG dn Note The Normal and Reverse options in the above menu are used to toggle the display between the normal black text on a white background display and a reverse white text on a black background display Use the keypad as indicated to set the desired contrast percentage and press ENTER You will be returned to the previous menu save changes ungdo changes Move CuUr or change value Press ESC twice to exit the User Program and return to the normal run mode screen 4 4 Selecting the Measurement Mode and Units To select the measurement mode display parameter and measurement units from the run mode screen proceed as follows q Use the arrow keys to highlight the measurement mode display parameter and press ENTER OxyTrak 390 Flow Gas Analyzer User s Manual 43 Chapter 4 Setting Up the Display 4 4 Selecting the Measurement Mode and Units cont QY Measure Use the arrow keys to select the desired parameter to be displayed and press ENTER A les Furnace Temr DISPLAY Measure Unit Use the arrow keys to select the desired units for the selected measurement mode a mil see Table 2 belo
82. he initial programming screen 1 F 1 a a From the Main Menu screen above proceed directly to the appropriate section to perform the desired programming task OxyTrak 390 Flow Gas Analyzer User s Manual 41 Chapter 4 Setting Up the Display 4 2 Selecting the Number of Views The OxyTrak 390 can be easily configured to display 1 2 or 3 views To do so proceed as follows DISPLAY CALIBRAT Use the arrow keys to select the of Views option and press ENTER 1 F 1 37 Use the arrow keys to select the desired option and press ENTER You will then be e ISPLAY DISPLAY Lli ews g returned to the Display main menu LEWS 3 U1 euz After your selection press ESC to return to the standard run mode screen and depending on the option selected above your display will look like one of the following leuaen pr This is a display configured to show 1 view x4g3er This s a d splay configured to show 2 views 2 00 Combustible x4a3er This s a d splay configured to show 3 views B B x p Combustible a Ae FFM Furnace Teme H HA C Note Any of the measurement modes or measurement units in any of the displayed views may be programmed by selecting it with the arrow keys and pressing ENTER 42 OxyTrak 390 Flow Gas Analyzer User s Manual Chopter 4 Setting Up the Display 4 3 Adjusting the Display Contrast After entering the User Program as described on page 37 t
83. he operates all auxiliary equipment in accordance with local codes standards regulations or laws applicable to safety Working Area WARNING Auxiliary equipment may have both manual and automatic modes of operation As equipment can move suddenly and without warning do not enter the work cell of this equipment during automatic operation and do not enter the work envelope of this equipment during manual operation If you do serious injury can result WARNING Make sure that power to the auxiliary equipment is turned OFF and locked out before you perform maintenance procedures on the equipment Qualification of Personnel Make sure that all personnel have manufacturer approved training applicable to the auxiliary equipment Personal Safety Equipment Make sure that operators and maintenance personnel have all safety equipment applicable to the auxiliary equipment Examples include safety glasses protective headgear safety shoes etc Unauthorized Operation Make sure that unauthorized personnel cannot gain access to the operation of the equipment OxyTrak 390 Flow Gas Analyzer User s Manual VI Preface Environmental Compliance Waste Electrical and Electronic Equipment WEEE Directive GE Measurement amp Control is an active participant in Europe s Waste Electrical and Electronic Equipment WEEE take back initiative directive 2002 96 EC The equipment that you bought has required the extraction and use of natu
84. her implemented in manual mode or using the autocal process includes the following Steps 1 Obtain the one calibration gas a Gas 1 A gas with known oxygen and combustibles content to be used as both a span gas in a 1 gas oxygen calibration and a zero gas in a 1 gas combustibles calibration Install a system to deliver the calibration gases to the OxyTrak 390 at the proper flow rate and pressure Program all user programmable calibration parameters Initiate either manually or automatically the calibration process ae ee 49 Allow the calibration to continue until the new O and combustibles readings are within the programmed tolerances 106 OxyTrak 390 Flow Gas Analyzer User s Manual Appendix C Calibration Standard Convection C 8 Method 7 Calibration method 7 whether implemented in manual mode or using the autocal process includes the following steps 1 Obtain the two calibration gases a Gas 1 A gas with known oxygen content to be used as the span gas in a 2 gas oxygen calibration b Gas 2 A gas with known oxygen content to be used both as the zero gas in a 2 gas oxygen calibration and as a zero gas in a 1 gas combustibles calibration Install a system to deliver the calibration gases to the OxyTrak 390 at the proper flow rate and pressure Program all user programmable calibration parameters Initiate either manually or automatically the calibration process ot A A MS Allow the cali
85. hms CalGas 4 Ref ohms Act ohms CalGas 5 Ref ohms Act ohms CalGas 6 Ref ohms Act ohms Temp 2 CalGas 1 Ref ohms Act ohms CalGas 2 Ref ohms Act ohms CalGas 3 Ref ohms Act ohms CalGas 4 Ref ohms Act ohms CalGas 5 Ref ohms Act ohms CalGas 6 Ref ohms Act ohms 128 1933 47 1934 31 1936 90 1945 44 1940 34 1957 02 1947 01 1979 83 1956 89 2013 72 1000 00 1000 00 1968 50 1969 32 1972 40 1980 74 1975 94 1992 16 1982 53 2014 29 1992 31 2047 11 1000 00 1000 00 OxyTrak 390 Flow Gas Analyzer User s Manual Appendix E Default Settings E 8 Factory Defaults cont Development Furnace PID Setpoint 600 0 DegC PropBand 25 0 DegC IntTime 560 0 Secs Max Temp 950 0 DegC Manifold PID Setpoint 220 0 DegC PropBand 5 8 DegC IntTime 70 0 Secs Max Temp 350 0 DegC O2 Cal PID Setpoint 5 00 PropBand 0 30 IntTime 600 0 Secs GE Energy Start Purge 0 Calibration Cycle 24586 Start Cal Cycle 0 ZeroCal Duration 3 Mins SpanCal Duration 3 Mins LongPurge Duration 5 Mins Sample Delay Time 60 0 Secs Init Sample Delay Time 60 0 Secs Zero Cal Valve 0 Span Cal Valve 0 Purge Valve 0 Aspirator 0 Settling 15 Mins Span O2 5 00 Span HC 1500 0 ppm Comb Offset 0 Comb Cal Sample Duration 3 Mins Start Sample Time Delay 0 OxyTrak 390 Flow Gas Analyzer User s Manu
86. lect the Normal option and press ENTER e IMPORTANT Be sure to set the output to the Normall mode before you leave the Trim menu OxyTrak 390 Flow Gas Analyzer User s Manual 59 Chapter 5 General Programming 5 4 5 Cal Setting The Cal Setting option is used to specify the manner in which the OxyTrak 390 handles measurement readings during a calibration _PLAY OUTPUT OUtrFut A Use the arrow keys to select the Cal Setting option and press ENTER Heasure Tre kanae Teim Dlutrut ArCal Settinal Use the arrow keys to select the desired option see description below When done press ENTER Ser Elects m Live Outrut The available options at the above prompt are as follows e Hold Last Value The last valid measurement taken prior to the calibration 1s displayed while a calibration 1s in progress e User Selectable The user chooses the measurement value that is displayed while a calibration is in progress e Live Output The instrument continues to display the actual current measurement value while a calibration is in progress If you select Hold Last Value or Live Output you are immediately returned to the previous menu If you choose User Selectable continue as follows PRima Seecific Value At the Specific Value option press ENTER alue ia SFeCiTic Value Use the arrow keys as indicated to enter a value When done press ENTER tins
87. lect the Settling Time option and press ENTER Interval Gas Surrls 2Mins ins U Fal lure De AU Toler a 14 Comb Hl 24 hhirPme Auto Cal now Use the arrow keys as indicated to enter the desired time in minutes When done press ENTER save changes Unda changes move Cursor change value Now whenever the OxyTrak 390 performs an Autocal the settling time allowed for the calibration data will be as programmed above 52 OxyTrak 390 Flow Gas Analyzer User s Manual Chapter 5 General Programming 5 3 3d _ Auto Verification Failure As part of the Autocal process the OxyTrak 390 periodically verifies the current calibration You can program the manner in which the meter responds to an Auto Verification failure as follows _AYy CHLIERATE autocsl Use the arrow keys to select the A V Failure option and press ENTER Imterwal Gas Supp lQ 2hin Settlina TimeMins a oler 16 Comb HU 24 hhirrme Auto Cal now _BROATE Gutocal Gctior Use the arrow keys to select the desired option The press ENTER armtreLal If you selected Alarm above an auto verification failure will only trigger the auto verification alarm However 1f you selected Alarm ReCal above an auto verification failure will not only trigger the auto verification alarm but 1t will also initiate an immediate calibration of the instrument 5 3 3e Oxygen Auto Verification Tolerance In the previous s
88. lete combustion of the fuel by burning it in the presence of excess oxygen atemperature controlled sensor furnace to maintain the oxygen sensor at a stable operating temperature and to act as the engine for convective sampling e a convection loop to circulate the sample gases through the sample system an aspirator port to connect to an aspirated probe OxyTrak 390 Flow Gas Analyzer User s Manual 3 Chapter 1 General Information 1 2 1 Sample System cont Convection Loop Furnace T C Aspirator Port TE i NNN MN YN u NT WWW 1 444 I F gt Sensor Furnace WWW l l i L ASS N N Oxygen Sensor Ox 9 YTrak 390 Figure 2 The Sample System 4 OxyTrak 390 Flow Gas Analyzer User s Manual Chapter 1 General Information 1 2 1 Sample System cont Convection i Combustibles Sensor Sensor Furnace Combustibles Sensor Washers Oxygen Sensor Washer Zirconium Oxide Oxygen Sensor Figure 3 Sensor Locations ref dwg 705 1088 sht 3 OxyTrak 390 Flow Gas Analyzer User s Manual 5 Chapter 1 General Information 1 2 1 Sample System cont Figure 4 Combustibles Sensor Figure 5 Zirconium Oxide Oxygen Sensor u 6 OxyTrak 390 Flow Gas Analyzer User s Manual Chapter 1 General Information 1 2 2 Display Controll
89. manual 2 2 gas bottles O only auto amp Manual 3 2 gas bottles O amp combustibles auto amp manual O 1 gas shared combustibles 2 gases zero amp span 4 3 gas bottles O amp combustibles auto amp manual 5 4 gas bottles O amp combustibles auto amp manual 6 1 gas bottle O amp combustibles auto amp manual 7 2 gas bottles O amp combustibles auto amp manual O 2 gases combustibles 1 gas OxyTrak 390 Flow Gas Analyzer User s Manual 89 Chapter 7 Specifications 7 5 Ordering Information In order to ensure that the proper OxyTrak 390 configuration is supplied for the intended application a full and accurate model number must be specified at the time of purchase This model number should be constructed as follows IMPORTANT Some of the options listed in this section may not yet be available for purchase Please consult with your GE representative Ryn gt STER ALEA B Convection Loop Analyzer Package 1 Horizontal General Purpose e IP52 NEMA 2 3 Aspirated Horizontal General Purpose e IP52 NEMA 2 C Display Controller 1 Local General Purpose Enclosure e IP66 NEMA 4X Option B 1 Horizontal GP Only 2 Remote General Purpose Enclosure e IP66 NEMA 4X D Oxygen Sensor Fluxed Sane As FGA300 1 Standard Type 1 2 High CO Stoichiometric Type 2 3 Incinerator Type Applications Type 3 E Improved Combustibles Sensor 0 No
90. mounting of the OxyTrak 390 into a threaded hole using its mounting threads is not recommended Always use a mounting flange Note Rather than the use of a thread sealant a high temperature lubricant such as Molykote 1000 is recommended Refer to Figure 16 on page 31 and complete the following steps to mount the OxyTrak 390 convection loop analyzer package 1 Slide a suitable flange gasket over the probe and up against the mounting flange on the analyzer Note Be sure to use a suitable high temperature gasket for this application 2 Orient the analyzer so that the convection loop analyzer package is vertical and slide the probe through the hole in the mounting wall until the two flanges meet 3 Using suitable hardware make sure the gasket is properly positioned between them and bolt the two flanges together 4 Continue as follows a If you have a local display controller the physical installation is complete Proceed to the wiring section on the next page b If you have a remote display controller proceed to Step 5 5 Refer to Figure 15 on page 30 and mount the remote display controller in a convenient location Be sure to allow sufficient clearance for programming and operation of the unit 6 Install suitable cable glands and conduit for the environment to connect the junction box on the bottom of the convection loop analyzer package to the display controller 2 places OxyTrak 390 Flow Gas Analyzer User
91. n or an RS485 connection but not both at the same time 1 Connect J13 1 to Return on the RS485 system 2 Connect J13 2 to 12V on the RS485 system 3 Connect J13 3 to on the RS485 system 4 Connect J13 4 to on the RS485 system 22 OxyTrak 390 Flow Gas Analyzer User s Manual Chapter 2 Installation 2 5 7 Remote Display Option If you have a local display controller skip this section and proceed to the next page to wire your line power Otherwise wire the remote display controller to the junction box on the convection loop analyzer package as follows see Figure 12 on page 24 and Figure 18 on page 33 2 5 7a Wiring the Signal Cable Assembly 704 1104 1 Wire the combustibles sensor a Using the RED wire from the red black pair connect junction box terminal J3 1 CO ACT BLK to display controller terminal J4 1 ACT BLK Using the BLACK wire from the red black pair connect junction box terminal J3 2 CO REF GRN to display controller terminal J4 2 REF GRN Using the GREEN wire from the green black pair connect junction box J3 3 CO ACT RED to display controller terminal J4 3 ACT RED Using the BLACK wire from the green black pair connect junction box terminal J3 4 CO REF YEL to display controller terminal J4 4 REF YEL 2 Wire the oxygen sensor a Using the WHITE wire from the white black pair connect junction box terminal J2 1 O2 to display controller terminal J1 1
92. ne 1 Standard available for option B 1 only F Input Voltage 10 1 115 120 VAC 2 230 240 VAC G Communications 1 RS232 amp RS485 No Auxiliary Keypad H Tropicalization 0 None 1 Tropicalized I Special 0 None S Special For example a horizontal general purpose OxyTrak 390 with a local general purpose controller for use with 115 VAC input power and including standard oxygen and combustibles sensors RS232 amp RS485 communications and diffusion convection based sampling would be specified as Model OxyTrak 390 1111 1100 90 OxyTrak 390 Flow Gas Analyzer User s Manual Appendix A The Nernst Equqtion Appendix A The Nernst Equation A 1 Introduction The OxyTrak 390 Flue Gas Analyzer uses the Nernst Equation to calculate the oxygen content of the flue gas When a Yttrium doped zirconium oxide ceramic is heated to a temperature above 650 C it becomes an electrolytic conductor as vacancies in the crystal lattice permit oxygen ions to diffuse into the ceramic If there are different oxygen partial pressures on the two sides of the ceramic cell oxygen ions will migrate along the resulting concentration gradient This constitutes a transfer of electrons from one face of the ceramic to the other If the transferred charge is allowed to accumulate it gives rise to a potential gradient acting in the opposite direction thus tending to oppose further diffusion A 2 Equilibrium Conditions
93. nu lOS Re aw B Settinal Use the arrow keys to select the Diag Errors option and press ENTER Measure Lam FAULTS Note This submenu allows you to select one or more diagnostic error signals for triggering the alarm relay Highlight a diagnostic error type and press ENTER to select 1t as indicated by a to ettingoDiau Errors I 1ts left Repeat to select as many types as desired then press ESC nder kanae Detal Error Comb Over Range Comb Under Range CombLal Error Note All three oxygen and three combustibles diagnostic errors that are available are listed above The System Faults submenu LRYSRelau GeSetting Use the arrow keys to select the System Faults option and press ENTER Measure Note This submenu allows you to select one or more system fault signals for triggering the alarm relay etting Suctem Fault Highlight a system fault type and press ENTER to select it as indicated by a to its i left Repeat to select as many types as desired then press ESC urnace Tene Under Furnace Low Teme Block Teme Over Fani Block Teme Under Fa Black Low Teme T Active RID Over Fan Note In addition to the seven system faults listed above the Active RTD Under Rangel Ref RTD Over Range and Ref RTD Under Range options are available in the above list 64 OxyTrak 390 Flow Gas Analyzer User s Manual Chapter 5 General Programming 5 5 1
94. nual Chapter 1 General Information Zirconium Oxide Oxygen Sensor The inside and outside of the zirconium oxide oxygen sensor are coated with porous platinum forming two electrodes The sample gas flows past the outside of the sensor while atmospheric air circulates freely inside the sensor This atmospheric air 19 used as the reference gas for making oxygen measurements See Figure 7 below Oxygen ions migrate through the zirconium oxide along the concentration gradient Sample Outside Cell Inside Cell 20 9 Zirconium Oxide Ceramic with Lattice Imperfections From Outside Y x From Inside Electrode Volts Electrode When O concentration in sample gas falls the cell voltage rises with increased oxygen migration through the zirconium oxide Figure 7 Oxygen Migration in the Zirconium Oxide Sensor At the operating temperature of the oxygen sensor the atmospheric reference oxygen is electrochemically reduced at the inner electrode and the resulting oxygen ions seek to equalize with the lower oxygen concentration on the sample side of the cell by migrating through the porous
95. ny of the factory installed wiring To access the terminal blocks for wiring unthread the four screws on the front of the display controller and swing the cover open If you have a system with a remote display controller you must also unthread the three screws on the junction box and swing the cover open 18 OxyTrak 390 Flow Gas Analyzer User s Manual Chapter 2 Installation 2 5 1 CE Mark Compliance For CE Mark compliance the OxyTrak 390 must meet both the EMC and LVD directives IMPORTANT CE Mark compliance is required for all units used in EC countries 2 5 1a EMC Compliance For EMC compliance the electrical connections must be shielded and grounded as shown in Table below After all the necessary electrical connections have been made seal any unused cable entry holes with standard conduit plugs or equivalent Note If the instructions in this section are followed the unit will comply with the EMC Directive 2004 108 EC Table 1 Wiring Modifications for EMC Compliance Wiring Modification Power When connecting the power select the cable entry closest to the chassis ground 2 Use shielded cable to connect the power to the OxyTrak 390 enclosure Connect the shield to the nearest chassis ground terminal Connect the power line ground wire to the nearest chassis ground terminal Input Output 1 Use shielded cable to interconnect the OxyTrak 390 enclosure with any external I O devices Connect the
96. oller terminal J3 3 MANIFOLD Using WIRE 2 connect junction box terminal J5 2 FURNACE to display controller terminal J3 2 FURNACE Using WIRE 3 connect junction box terminal J5 3 COMMON to display controller terminal J3 1 COMMON Connect the ground wire from a ground standoff in the junction box to a boss in the display controller RS232 Comb Temp Remote a Sensor Control RS485 Relays Relays Heaters J4 J6 E J9 F G J10 H J3 i l I i ed bad _ di 35 J5 CTT A J7 B O2 Open Field 4 20mA Relays Relays bus Output wa Figure 12 Display Controller Wiring Connections OxyTrak 390 Flow Gas Analyzer User s Manual Chapter 2 Installation 2 5 8 Wiring the Line Power WARNING Before proceeding verify that the line power has been turned off at the external disconnect device To wire the input voltage to the OxyTrak 390 complete the following steps Make these connections only with wire that meets the following specifications e minimum 18 AWG individual conductor gauge max 12A current e voltage rating of 600V minimum e insulation temperature rating of 105 C minimum WARNING The wire insulation rating must be at least 15 C above the expected ambient temperature OxyTrak 390 Flow Gas Analyzer User s Manual 25 Chapter 2 Installation AI3SOAX3 WALI S NIAV31 q13IHS G3dIVH8 ANNOYV MNIHHS 1V3H S WAL HOVLLV S3HIAA t DNISOdXd 318VO 8 WALI 40 LFIMOVF YANNI ANY 07131HS
97. on Then press ENTER Use the arrow keys as indicated to enter the zero gas oxygen percentage When done press ENTER Use the arrow keys to select the Span O2 option Then press ENTER Use the arrow keys as indicated to enter the span gas oxygen percentage When done press ENTER When you have finished programming the Cal Method menu press ESC until you return to normal run mode OxyTrak 390 Flow Gas Analyzer User s Manual 77 Chapter 6 Advanced Programming 6 5 3c 1 Gas Oxygen and Combustibles This method is used to perform both an oxygen calibration and a combustibles calibration with one calibration gas Method iLYL 102 1H0 To program the O span gas press ENTER CE S HE Use the arrow keys as Indicated to enter the span gas oxygen percentage combustibles must be U ppm When done press ENTER save changes ungdo chan e move Cursor change value When you have finished programming the Cal Method menu press ESC until you return to normal run mode 78 OxyTrak 390 Flow Gas Analyzer User s Manual Chapter 6 Advanced Programming 6 5 3d 2 Gas Oxygen and Combustibles This method is used to perform both an oxygen calibration and a combustibles calibration with two calibration gases Note This method has two variations One of the calibration gases is always used for one of the oxygen points and the low combustibles point However the second calibration gas may be used fo
98. on Sheet is lost contact the factory IMPORTANT This chapter discusses only those programming options available at the 2719 passcode access level For additional options available at the 7378 passcode level see Chapter 6 Advanced Programming The following submenus are included in the Main Menu of the OxyTrak 390 User Program e Display see Chapter 4 for instructions e Calibrate e Output e Relays e Communications Setup Factory Note While in the User Program press ESC at any time to abort the current operation and return to the previous menu level Access the User Program as described on page 37 at the 2719 passcode level and refer to Figure 21 on page 97 Figure 22 on page 98 and Figure 23 on page 99 in Appendix B while programming the OxyTrak 390 features described in this chapter Proceed to the appropriate section to program the desired meter function s OxyTrak 390 Flow Gas Analyzer User s Manual 45 Chapter 5 General Programming 5 2 Setup Menu Real Time Clock The options available in the Setup menu at the 2719 passcode level are the Clock submenus and Comb_ppm Clamp To set the OxyTrak 390 real time clock proceed as follows IMPORTANT The real time clock must be set before programming an automatic calibration schedule At the Main Menu use the arrow keys to select the Setup submenu Press ENTER to Ts Fem Clame access the Clock option DISPLAY SETUP Clock
99. or change Value Use the arrow keys to select the Start Time option and press ENTER Use the arrow keys to select the Hour option and press ENTER Use the arrow keys as indicated to enter the desired value When done press ENTER Use the arrow keys to select the Minute option and press ENTER Use the arrow keys as indicated to enter the desired value When done press ENTER The OxyTrak 390 is now programmed to automatically perform calibrations at the interval programmed in this section Press ESC until you return to the initial Autocal menu OxyTrak 390 Flow Gas Analyzer User s Manual 51 Chapter 5 General Programming 5 3 50 Gas Supply Time Program the length of time that the calibration gas will flow during an Autocal as follows _Oy CHLIEFROTE Gutocal Use the arrow keys to select the Gas Supply Time option and press ENTER Interwal ins imens Hl Failure UE A U Toler 16 Comb HU Zi Bee me THuto Cal now Use the arrow keys as indicated to enter the desired time in minutes When done press ENTER save changes undo changes move Cursor change Value Now whenever the OxyTrak 390 performs an Autocal the calibration gas will flow for the length of time programmed above 5 3 3c Settling Time Program the length of time allowed for the calibration data to settle during an Autocal as follows AY CALIBRATE Autacal Use the arrow keys to se
100. or failsafe operation Note Relay E J9 2 NO Relay F J9 5 NO Relay G J10 2 NO Relay H J10 5 NO The OxyTrak 390 relays do not provide power To use the Blow Back process connect a power supply in series with Relay H and the Blow Back solenoid valve OxyTrak 390 Flow Gas Analyzer User s Manual 21 Chapter 2 Installation 2 5 5 Wiring the RS232 Output To wire the OxyTrak 390 to the RS232 serial port on a PC refer to Figure 12 on page 24 and Figure 17 on page 32 or Figure 18 on page 33 and make the following connections to J14 in the display controller IMPORTANT You may make either an RS232 connection or an RS485 connection but not both at the same time Note This connection may be made with a GE 704 668 xx cable If this cable is used pin 1 is the white wire pin 2 is the red wire and pin 3 is the green wire 1 Connect J14 1 OUT to the transmit pin on the computer 2 Connect J14 2 IN to the receive pin on the computer 3 Connect J14 3 EN to the return pin on the computer Note See GE document EIA RS Serial Communications 916 054 for a detailed discussion of serial port connections 2 5 6 Wiring the RS485 Output To wire the OxyTrak 390 to a remote RS485 controller refer to Figure 12 on page 24 and Figure 17 on page 32 or Figure 18 on page 33 and make the following connections to terminal block J13 in the display controller IMPORTANT One may make either an RS232 connectio
101. r User s Manual 123 Appendix E Default Settings E 7 Setup Defaults Note Default settings are in bold text SETUP O2 Sensor Temp 700 DegC 770 DegC 812 DegC Custom Custom 700 DegC Heater Block Temp Custom 220 DegC Clock Year 2004 Month 12 Day 15 Hour 12 Minute 59 Cal Method O2 ICYL Span O2 5 00 O2 2CYL Zero O2 20 93 Span O2 5 00 O2 HC 1CYL Span O2 5 00 O2 HC 2CYL O2 HC 2CYL 102 2HC Span O2 5 00 Span HC 1500 0 ppm O24 HC 2CYL 202 1HC Zero O2 20 93 Span O2 5 00 O2 HC 3CYL Zero O2 20 93 Span O2 5 00 Span HC 1500 0 ppm 124 OxyTrak 390 Flow Gas Analyzer User s Manual Appendix E Default Settings O2 HC 4CYL Zero O2 20 93 Span O2 5 00 Zero HC 0 0 ppm Span HC 1500 0 ppm Blow Back Interval 0 Mins Duration 2 Secs Settling 60 Secs Blow back now Yes No Comb_ppm Clamp Clamp negative ppm Yes No E 8 Factory Defaults Note Default settings are in bold text FACTORY Versions Upgrade Are you sure Yes No Default Analyzer Are you sure Yes No Thermal Cal Thermal Cal Temp Limit 20 DegC O2 Tolerance 0 02 OxyTrak 390 Flow Gas Analyzer User s Manual 125 Appendix E Default Settings Cal Delay Air Offset Furnace Temp Comb Cal Setup Block Temp Temp Setpoints Temp 1 Temp 2 Cal
102. r either the high oxygen point or the high combustibles point Only one of the variations is shown here as an example CYL CalMethod Use the arrow keys to select the 102 2HC option Then press ENTER dl JE CFL 7 1Method 20YL 102 2H0 Use the arrow keys to select the Span O2 option Then press ENTER Far 2066 APPM Use the arrow keys as indicated to enter the span gas oxygen percentage combustibles must be U ppm When done press ENTER save changes Undo changes move cursor change value Span Ue a HHA E WI SA Dir Fm Use the arrow keys to select the Span HC option Then press ENTER Use the arrow keys as indicated to enter the span gas combustibles ppm When done press ENTER save changes Unda chan e move CURSO change Value When you have finished programming the Cal Method menu press ESC until you return to normal run mode OxyTrak 390 Flow Gas Analyzer User s Manual 79 Chapter 6 Advanced Programming 6 5 3e 3 Gas Oxygen and Combustibles This method uses three calibration gases to perform the oxygen and combustibles calibrations One of the gases is used for both an oxygen point and the 0 ppm combustibles point 25 ar Use the arrow keys to select the Zero O2 option Then press ENTER a Fan a HE Sram HU 1564 Seem Use the arrow keys as indicated to enter the zero gas oxygen percentage When done press ENTER save changes Unda chan e
103. r installation the use of unauthorized replacement parts or operating conditions outside the guidelines specified by GE Sensing the repairs are not covered under this warranty The warranties set forth herein are exclusive and are in lieu of all other warranties whether statutory express or implied including warranties or merchantability and fitness for a particular purpose and warranties arising from course of dealing or usage or trade Return Policy If a GE Sensing instrument malfunctions within the warranty period the following procedure must be completed 1 Notify GE Sensing giving full details of the problem and provide the model number and serial number of the instrument If the nature of the problem indicates the need for factory service GE Sensing will issue a RETURN AUTHORIZATION NUMBER RAN and shipping instructions for the return of the instrument to a service center will be provided 2 If GE Sensing instructs you to send your instrument to a service center it must be shipped prepaid to the authorized repair station indicated in the shipping instructions 3 Upon receipt GE Sensing will evaluate the instrument to determine the cause of the malfunction Then one of the following courses of action will then be taken Ifthe damage is covered under the terms of the warranty the instrument will be repaired at no cost to the owner and returned e _ If GE Sensing determines that the damage is not covered under the t
104. r two hours before beginning the response test Supply air to the aspirator and set 1t to 4 SCFH Standard Cubic Feet per Hour Record the excess O measurement from the stack once it is stable Switch the air supply from the aspirator port to the purge port at 300cc min until the O reading is stable Switch the air supply back through the aspirator port Record the 90 step change from 21 O to process the O recorded in step 2 This is the unit s response time mu A A A ASE Repeat steps 1 5 increasing the aspirator flow rate by 1 SCFH until the desired response time 1s achieved IMPORTANT DO NOT EXCEED 10 SCFH Doing so may affect the analyzer s performance D 2 Calibration Gas Flow Rate Test The calibration gas flow test is performed after the Response Test is complete The purpose of this test is to set the calibration gas flow to a rate sufficient enough to perform field calibrations Refer to Figure 14 on page 29 for port locations Set the aspirator flow rate to the desired flow rate setpoint 1 2 Record the excess O measurement from the stack once it is stable 3 Supply air 21 O through the calibration port at a rate of 0 5 SCFH until the reading is stable 4 If the unit s reading is a mix between the 21 O and the excess O from the process increase the flow rate by 0 5 SCFH 5 Repeat step 4 until the reading measures 21 Note Increase the calibration gas flow rate an additional 0 5 SCFH to
105. ral resources for its production It may contain hazardous substances that could impact health and the environment In order to avoid the dissemination of those substances in our environment and to diminish the pressure on the natural resources we encourage you to use the appropriate take back systems Those systems will reuse or recycle most of the materials of your end life equipment in a sound way The crossed out wheeled bin symbol invites you to use those systems If you need more information on the collection reuse and recycling systems please contact your local or regional waste administration Visit http www qe mcs com en about us environmental health and safety 1741 weee reg html for take back instructions and more information about this initiative viii OxyTrak 390 Flow Gas Analyzer User s Manual Chapter 1 General Information Chapter 1 General Information 1 1 Introduction Process plant managers are usually looking for ways to reduce expense and increase profitability When combustibles are burned as part of the operation and that combustion 1s incomplete allowing unburned fuel to escape costs go up and profits go down A reliable system for analyzing flue gas can provide the necessary information to adjust the flow of oxygen increase the efficiency of the combustion e gain significant cost savings for the overall operation To meet these specific needs GE provides the OxyTrak 390 Flue Gas Analy
106. ry simple to operate Once it has been properly installed and set up 1t simply begins taking readings However the analyzer should be allowed to warm up for at least 50 minutes prior to use Refer to Chapter 2 Installation if all of the required installation requirements have not yet been completed WARNING To ensure safe operation the OxyTrak 390 must be installed and operated as described in this manual Also be sure to follow all applicable local safety codes and regulations for installing electrical equipment This chapter includes discussions of the following topics e preventing common problems e powering up the system e programming the analyzer taking measurements 3 2 Preventing Common Problems Due to the extreme conditions in monitoring flue gases and the complexity of the OxyTrak 390 s measurement techniques some simple precautions should be taken Failure to observe these basic procedures can lead to operational difficulties Compliance with the following instructions will help to eliminate such common problems Do not use pipe thread compounds on any part of the OxyTrak 390 Many pipe thread compounds emit combustible vapors that may cause inaccurate readings e Do not handle the oxygen sensor any more than is absolutely necessary Scratches on the platinum electrode or the transfer of skin oils to the electrode can cause erroneous readings Installing a cold probe assembly into a hot flue gas stream
107. s Manual 17 Chapter 2 Installation 2 5 Wiring WARNING To meet CE Mark requirements install all cables as described on the next page IMPORTANT For compliance with the European Union s Low Voltage Directive 2006 95 EC the OxyTrak 390 requires an external power disconnect device such as a switch or circuit breaker The disconnect device must be marked as such clearly visible directly accessible and located within 1 8 m 6 ft of the unit WARNING To ensure safe operation the OxyTrak 390 must be installed and operated as described in this manual Be sure to follow all applicable local safety codes and regulations for installing electrical equipment All procedures should be performed by trained service personnel only To wire the OxyTrak 390 see Figure 17 on page 32 for a local assembly or Figure 18 on page 33 for a remote assembly and connect the following items to the display controller do not run the line power through the same conduit as the other connections alarm relays A D calibration relays E H e 4 20 mA analog output e RS232 or RS485 output e line power connect through the right hand port If you have a remote display controller you must also make the following connections between the controller and the junction box oxygen and combustibles sensors furnace and manifold thermocouples thermocouple cold junction compensation e furnace and manifold heaters IMPORTANT Do not alter a
108. save changes Unda chan e move Cursor change Value Method 46 2 HL ero Oe cH 33 SF arn Oe Ell A Beem Pan 1566 Beem Use the arrow keys to select the Zero HC option Then press ENTER Use the arrow keys as indicated to enter the zero gas combustibles ppm When done press ENTER save changes Undo chan e move Cursor chan e value OxyTrak 390 Flow Gas Analyzer User s Manual 81 Chapter 6 Advanced Programming 6 5 3f 4 Gas Oxygen and Combustibles cont Use the arrow keys to select the Span HC option Then press ENTER Use the arrow keys as indicated to enter the span gas combustibles ppm When done press ENTER save changes Undo changes move Cursor change Value When you have finished programming the Auto Cal Method menu press ESC until you return to normal run mode 6 5 4 Blow Back The OxyTrak 390 uses a process called Blow Back to purge its sample system by initiating a temporary reversal of the sample gas flow direction This menu option is used to configure the parameters for that process Note The Blow Back programming opens and closes Relay H only Relay H is a switch only and does not provide power To use the Blow Back process connect a power supply in series with Relay H and the Blow Back solenoid valve At the Setup submenu of the Main Menu use the arrow keys to select the Blow I HS sensor Teme _ Back option and press ENTER ock
109. stem where it is maintained at a temperature above 200 C 392 F by the heater block In the presence of oxygen this sample temperature 1s high enough to burn any partial combustion products that reach the active platinum coated element of the combustibles sensor The resulting temperature differential between the two combustibles sensor elements is related to the concentration of partial combustion products in the test sample Note The sampled gas is maintained above 200 C 392 F to prevent flue gas acids from condensing in the analyzer and causing corrosion The sample then passes into the sensor furnace which heats the sample gas and the oxygen sensor to 700 C 1 292 F a temperature above 650 C 1 202 F is required for proper operation of the oxygen sensor The oxygen sensor 1s covered with a platinum catalyst that causes the burning of all remaining combustibles enabling the sensor to measure the excess oxygen or fuel in the flue gas The sensor furnace also generates the convective flow that circulates the sample gas through the sample system The hot sample gas in the sensor furnace rises out of the furnace and cools as it is pushed from behind by the hot gases still in the furnace The cooled sample gases then drop down the other branch of the convection loop and into the annular space between the probe and probe sleeve where they are carried away by the gas flow in the flue 8 OxyTrak 390 Flow Gas Analyzer User s Ma
110. t either Yes to proceed or No to abort Then press HFE YOU SURE ENTER Yes When you have finished programming the Factory menu press ESC until you return to normal run mode 84 OxyTrak 390 Flow Gas Analyzer User s Manual Chopter 6 Advonced Programming 6 6 3 Default Analyzer This option is used restore all programmable parameters to their factory default values 4 CFACTORY At the Factory submenu of the Main Menu use the arrow keys to select the ee ae Default Analyzer option and press ENTER Terms al Hir UT A BEBcEmM Furnace T 769 99 C T Comb Sens Cal _PLAY FACTORY Confirm Use the arrow keys to select either Yes to proceed or No to abort Then press T HFE YOU SURE ENTER Yes When you have finished programming the Factory menu press ESC until you return to normal run mode 6 6 4 Additional Menu Options In addition to the previously discussed options the following menu options are available at the 7378 passcode level CAUTION Improper reprogramming of the parameters in these menus will seriously degrade the performance of the OxyTrak 390 e Thermal Cal e Air Offset e Furnace Temp e Comb Cal e Development As the parameters programmed in these menus are critical to the proper operation of the OxyTrak 390 detailed instructions are not provided here If 1t becomes necessary to change any of these parameters you must contact the factory for assist
111. t the desired operating temperature from the list or I choose the Custom option Then press ENTER ala C Custom ca Sensor Teme Custoam If you chose the Custom option above press ENTER to program this option PARP If you chose the Custom option above use the arrow keys as indicated to enter the desired operating temperature When done press ENTER save changes Unda changes move CURSO change Value When you have finished programming the Setup menu press ESC until you return to normal run mode 74 OxyTrak 390 Flow Gas Analyzer User s Manual Chapter 6 Advanced Programming 6 5 2 Heater Block Temp This option is used to specify the operating temperature of the heater block factory default 220 C At the Setup submenu of the Main Menu use the arrow keys to select the Heater Block Temp option and press ENTER gz Sensor Teme ack Cal Method Blow Back Comb_rem Llame _UP Hester Block Teme To program the Custom option press ENTER Use the arrow keys as indicated to enter the desired heater block temperature When done press ENTER save changes Unda changes move Cursor change value When you have finished programming the Setup menu press ESC until you return to normal run mode OxyTrak 390 Flow Gas Analyzer User s Manual 75 Chapter 6 Advanced Programming 6 5 3 Auto Cal Method This option is used to configure the OxyTrak 3
112. te is entered in the analyzer by using the Factory Menu Comb Cal Setup O Cal After ten minutes press ENTER Supply span gas at the same flow rate After ten minutes press ENTER Press ENTER again to save calibration data Shut off the span gas o A 9 Press ESC as required to return to the main menu 48 OxyTrak 390 Flow Gas Analyzer User s Manual Chapter 5 General Programming 5 3 3 Automatic One Gas Oxygen Calibration To perform an automatic one gas O calibration access the user program as described on page 37 and proceed as follows IMPORTANT As an example these instructions assume the factory default settings of a 5 00 calibration gas a 0 02 O calibration tolerance and a maximum allowable furnace temperature change of 20 C See Chapter 6 Advanced Programming for instructions on changing these values At the Display submenu of the Main Menu press the gt key At the Calibrate submenu of the Main Menu use the arrow keys to select the Autocal option and press ENTER AY CALIBRATE Autaca1 Seven options are now available for programming Proceed to the appropriate Plu 2Mins section to program the desired option Sattlins TimcMins HL Failure 02 HU Tolera 18 Comb All CB HAE me Auto Cal now After you have completed the programming of the OxyTrak 390 Autocal process Press ESC until you return to normal run mode and the meter will perform automatic
113. ter 6 Advanced Programming OxyTrak 390 Flow Gas Analyzer User s Manual 103 Appendix C Calibration Standard Convection C 2 Method 1 Calibration method 1 whether implemented in manual mode or using the autocal process Includes the following steps 1 Obtain the one calibration gas a Gas 1 A gas with known oxygen content to be used as the span gas in a 1 gas oxygen calibration Install a system to deliver the calibration gas to the OxyTrak 390 at the proper flow rate and pressure 2 3 Program all user programmable calibration parameters 4 Initiate either manually or automatically the calibration process 5 Allow the calibration to continue until the new 900 reading is within the programmed tolerances C 3 Method 2 Calibration method 2 whether implemented in manual mode or using the autocal process includes the following Steps 1 Obtain the two calibration gases a Gas 1 A gas with known oxygen content to be used as the zero gas in a 2 gas oxygen calibration b Gas 2 A gas with known oxygen content to be used as the span gas in a 2 gas oxygen calibration Install a system to deliver the calibration gases to the OxyTrak 390 at the proper flow rate and pressure Program all user programmable calibration parameters Initiate either manually or automatically the calibration process ME 19 Allow the calibration to continue until the new O reading is within the programmed tolerances 1
114. tput in Millivolts at 700 C Figure 20 Oxygen Sensor Output at 700 C OxyTrak 390 Flow Gas Analyzer User s Manual 93 Appendix A The Nernst Equqtion A 3 The OxyTrak 390 Equation cont Table 3 mV to O Conversion at 700 C 30610 90 13456 11 103300 o s as s mas 9 tees 00s on 7s 203 s 100204 ooi x x x E 936 090 2 w 030 gt 94 OxyTrak 390 Flow Gas Analyzer User s Manual Appendix B Menu Mops Appendix B Menu Maps OxyTrak 390 Flow Gas Analyzer User s Manual 95 96 no content intended for this poge OxyTrak 390 Flow Gas Analyzer User s Manual MAIN MENU ow i Son Denen me ee ae le Me A ee ee E a Figure B 3 Figure B 2 Figure B 2 Figure B 3 al Figure B 4 ENT Passcode Exits to Run Mode m Z 3 Enter Passcode m Z 3 Enter Value OxyTrak 390 Flow Gas Analyzer User s Manual Exits to Run Mode Minute Enter Value Appendix B Menu Maps Figure 21 Display and Setup Menu Map 2719 passcode 97 Appendix B Menu Mops MAIN MENU uns a Figure B 1 Figure B 3 Figure B
115. uation for more details on how to perform similar calculations at other operating temperatures Although percent oxygen can still be measured without the LCD Display the measurement of combustibles can NOT be accomplished without the LCD Display OxyTrak 390 Flow Gas Analyzer User s Manual 39 Chapter 3 Operation no content intended for this page 40 OxyTrak 390 Flow Gas Analyzer User s Manual Chapter 4 Setting Up the Display Chapter 4 Setting Up the Display 4 1 Introduction Although the OxyTrak 390 is set up at the factory with default values that are suitable for many applications the User Program provides a means for customizing many of the meter parameters IMPORTANT This chapter discusses only those programming options available at the 2719 passcode access level For additional options available at the 7378 passcode level see Chapter 6 Advanced Programming The following procedures for configuring the LCD Display are described in this chapter e selecting the number of display views e adjusting the display contrast e selecting the measurement mode display parameter e selecting the measurement units Note While in the User Program press ESC at any time to abort the current operation and return to the previous menu level Access the User Program as described on page 37 and refer to the menu map in Figure 21 on page 97 while programming the OxyTrak 390 display DISPLAY CALIERAT This 1s t
116. ve finished programming the Blow Back menu press ESC until you return to normal run mode OxyTrak 390 Flow Gas Analyzer User s Manual 83 Chapter 6 Advanced Programming 6 6 Factory Menu All of the Factory menu options become available at this passcode level Proceed to the appropriate section to program these options Note Ifnecessary see Chapter 5 General Programming for instructions on navigating to this menu 6 6 1 Versions This option is used to display the versions of the instrument software currently installed in your analyzer 4 FACTORY At the Factory submenu of the Main Menu use the arrow keys to select the Versions option and press ENTER Parade Default Analyzer Thermal Cal Hir UT A Kam Furnace T 769 99 C T Comb Sens Cal amp 20605 BE SEHSIHG The current versions of your instrument serial number and software are displayed SAH KM When done press ESC PUI e e Ox b ARR s d EZ ARN Ps d AR ARA Ps d When you have finished programming the Foctory menu press ESC until you return to normal run mode 6 6 2 Upgrade This option is used update or restore the instrument firmware 4 CFACTORY At the Factory submenu of the Main Menu use the arrow keys to select the Vers ions Upgrade option and press ENTER au Anal zer Thermal Cal Hir UT E1 beam Furnace T 769 99 LC T Comb Sens Cal _PLAY FHCTORY Confirm Use the arrow keys to selec
117. w and press ENTER to return to run mode Table 2 Available Measurement Units Measurement Mode Measurement Units Oxygen a Sens mV C Note Ifyou only wish to change the measurement units you may use the arrows to highlight the units on the run mode screen to go directly to the Units menu for the current measurement mode 4 5 Measurement Units Description As indicated in Table 2 on page 44 there are several measurement units available for the various measurement modes Although some of these options are obvious others require a bit of explanation The available units are as follows this is the percentage of the specified parameter by volume in the sample gas Sens MV this is the raw oxygen sensor millivolt output which indicates the condition of the oxygen sensor ppm this is the parts per million of the specified parameter by volume in the sample gas e Cor F this is the furnace temperature on the scale indicated 44 OxyTrak 390 Flow Gas Analyzer User s Manual Chapter 5 General Programming Chapter 5 General Programming 5 1 Introduction Although the OxyTrak 390 is set up at the factory with default values that are suitable for many applications the User Program provides a means for customizing many of the meter parameters Note See the Calibration Sheet included with the OxyTrak 390 and Appendix F in this manual for the factory default settings If the Calibrati
118. zer which monitors the efficiency of a furnace or boiler by measuring excess oxygen and or ppm unburned combustibles in the flue gases To measure these two parameters the OxyTrak 390 uses e a zirconium oxide oxygen sensor aplatinum catalyst combustibles sensor optional The oxygen sensor measures excess oxygen or in a fuel rich environment equivalent combustibles The combustibles sensor monitors partially combusted fuel only in the presence of excess oxygen 1 e there must be enough oxygen present to burn the fuel Each OxyTrak 390 may be equipped with an oxygen sensor a combustibles sensor or both 1 2 Physical Description The standard GE OxyTrak 390 Flue Gas Analyzer is provided in a general purpose weatherproof IP52 NEMA 2 enclosure The analyzer consists of a convection loop analyzer package and a display controller which may be mounted either locally or remotely Figure 1 on page 2 shows the OxyTrak 390 with local and remote display controllers OxyTrak 390 Flow Gas Analyzer User s Manual 1 Chapter 1 General Information 1 2 Physical Description OxyTrak 390 Panametrics Flue Gas Analyzer

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OxyTrak™ 390 Panametrics Flue Gas Analyzer User`s Manual