FurnaceDoctor -Pro USER MANUAL
Contents
1. Enter the Data Add Comment Logging Enter Interval the Log Here 30 LD for 999 secs the ee es Ge data Click here to enter a log file comment h for a log file Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 27 of 67 You must first enter a Log I D name for the file that will contain the data To enter the Log I D simply touch the filename field and the alpha numeric keyboard will appear The Log I D field allows you to enter a message that will be data logged with the I R data For example you may name the log file May2109 for May 21 2009 Then in the Log I D field you type the furnace name As you move from furnace to furnace you change the Log D field The ogfile assigns a name to the file This is the name you will see when you insert the USB drive into your computer and open Lexar H File Edit View Favorites yg J S Search Key Folders Gz Address H Tools Help Size Type Name File and Folder Tasks x NOV1108 2KB Text Document mi Rename this file ty Move this file D Copy this file Publish this file to the Web E mail this file amp Print this file XX Delete this file Other Places a My Computer E My Documents J My Network Places NOV1108 Text Document Date Modified Today November 11 2008 11 23 AM Size 1 64 KB Copyright2. FDPRO V2 0 Rev 002 Page 37 of 67 Follow the instructions to calibrate the touch screen After completion of touch screen calibration the cross will disappear It may take several tries You will see this screen Rew Canario se rrrigs have heen Teas red Hress the Sober kev bo ac leper the new settings Fress the Esc key to keep the old settings Touch anywhere on the screen to finish the touch screen calibration You will then be prompted to save Calibration Settings Touch Save You will then see this screen Calibrate Touch Screen roup upc com Do you want to save Calibration Settings Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 38 of 67 Calibrate Touch Screen roup upc com Touch Close and the touch screen calibration will be saved The new setting will apply the next time the unit is turned back on Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 39 of 67 DATE AND TIME Touch the Set Date and Time check box and the following screen will appear Change Date Time ka Use Date Time Panel n Enter Date Time H i lesesessssssssssesssssnsnssssssssssssssssnssansnsnsssnecssesssssssssesesesssesssssssassssessssssssssnsnsnens need roup upc com Here to Close the Window Use the up and down arrows to change t
3. d j m i te gl WWW GROUP UPC COM PROCESS CONTROLS FurnaceDoctor Pro V2 0 USER MANUAL Revision Number 002 Pnited AFFILIATED MEMBERS PROCESS CONTROLS Furnace Control Corp Marathon Monitors Inc Process Electronic Waukee Engineering Co FDPRO V2 0 Rev 002 Page 2 of 67 Manual 006 Rev No 002 Date 01 Feb 2015 COPYRIGHT No part of this publication may be reproduced transmitted transcribed stored in a retrieval system or translated into any language or computer language in any form or by any means electronic mechanical magnetic optical chemical manual or otherwise without prior written permission of United Process Controls Inc DISCLAIMER The FurnaceDoctor Pro V2 0 is to be used by the industrial operator under his her direction United Process Controls Inc is not responsible or liable for any product process damage or injury incurred while using the FurnaceDoctor Pro V2 0 United Process Controls Inc makes no representations or warranties with respect to the contents hereof and specifically disclaims any implied warranties or merchantability or fitness for any particular purpose For assistance please contact United Process Controls Inc TEL 1 513 772 1000 FAX 1 513 326 7090 Toll Free North America 1 800 547 1055 upc support group upc com www group upc com C AU TION DO NOT CLOSE CHARGER IN LID SCREEN CAN BE DAMAGED NOT COVERED BY WARRANTY Copyright United Pro
4. EXHAUST FLOW INDICATOR X P NPTF All rights to copy reproduce and transmit are reserved Copyright United Process Controls FDPRO V2 0 Rev 002 Page 16 of 67 Connect one end of the sample tube to the inlet Connect the other end to the furnace sample port Do not connect to a port with a lamb s wool or angel hair filter already installed Be sure to properly vent exhaust We strongly recommend a small diameter 1 2 id or less non metallic sample tube that can be inserted at least 2 past the refractory wall hot face to ensure an accurate sample Connect Sample Tube Here Be sure to properly vent exhaust CO is toxic Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 17 of 67 Rotate Handel CCW and remove cover Lift Filter to upright position take note of O ring and insure it is properly seated at all times Be sure that the filter is clean and free from moisture Soot build up or discoloration in the sample element requires the element to be replaced Caution re insert the filter element with the same orientation or risk damaging the FDPRO by introducing contaminants into the gas stream Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 18 of 67 Turn on the power switch Depress the Pump button to start sampling Your F
5. FDPRO V2 0 Rev 002 Page 5 of 67 EQUIPMENT RATINGS Supply Voltage 110 240 VAC Supply Frequency 90 60 Hz Power Consumption 3 2 1 8 Amps Certifications Compliance C c Range Resolution Accuracy CO 0 30 0 45 0 02 2 of range CO2 0 2 20 ppm 1 of range CH4 0 10 0 02 2 of range Operating Temperature 40 F 120 F Relative Humidity 5 90 non condensing Atmospheres Suitable for Carburizing Carbonitriding Carbon Correction Neutral Hardening Austempering Martempering Precipitation Hardening Annealing Normalizing Stress Relieving call FCC if your process is not listed NH3 ammonia is strictly prohibited in the sample NH3 filters available upon request Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 6 of 67 THEORY Why Infrared By purchasing your new FurnaceDoctor Pro you have obviously made the decision that your current process measurement methods require some enhancement This may be due to customer requirements for back up process verification to your existing oxygen probe based system or simply a matter of answering the question is that probe really working You might be looking for more complete information of what is happening with respect to your furnace atmosphere Whatever your reasons the use of I R analysis and the FurnaceDoctor Pro will satisfy these requirements Since most Furnac
6. and carbon potential Endo from Natural Gas which will use a 40 H2 to calculate dew point and carbon potential Endo from Propane which will use a 31 H2 to calculate dew point and carbon potential Gas Generators Allows the user to select which type s of generator gas will be measured Other Please specify H2 content which will use a manually entered H2 to calculate dew point Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 43 of 67 Vv Show Atmosphere v Show CH4 Co CH4 F 5 To Enter the Alloy Factor CH4 Factor and the H2 for Dew Point and carbon potential calculations touch the corresponding box An alpha numeric keyboard will appear to enter the value Touch OK when done Fe ee a ee OW ER eeee ie ee es ee SRaennnaae Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 44 of 67 After you have configure the I R Screen touch OK and you will be taken to the main menu Cancel will discard any changes you have made Tal Show Steel Surface Carbon Tal Show CH4 Corrected Carbon Potential Non equilibrium atmosphere V Show 02 Probe Calculated Signal Touch Here after completion of the I R Screen configuration Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDP
7. for the process to work High free methane content is usually a product of the control system calling for too much natural gas due to an air leak unusually high surface area in the load Check for air leaks Check for burner tube leaks Check for furnace fan water jacket leaks Check generator or nitrogen methanol system Be sure that the probe control system is working properly Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 13 of 67 OPERATIONS Precautions before operations 1 Dew point of sampling gas must be lower than the ambient temperature to avoid occurrence of drain in the gas analyzer If vapor is contained in the sampling gas dew point should be lowered to 0 C by using a dehumidifier 2 Temperature of sampling gas should be within O to 50 C Provide a means that prevents entry of hot gas directly into the instrument 3 Absolute pressure of sampling gas should be 926 1024 mb Avoid flow or pressure fluctuation during measurement Observe the flow reading by a flow meter provided 4 Avoid installing this instrument near an electrical unit high frequency furnace or electric welder that generates much electrical noise 5 Allow 20 minutes warm up for stabilized readings SAMPLE GAS The condition of the sample must conform to the following requirements to ensure that the performance of the product meets the stated technical specificati
8. United Process Controls Date Modified 11 11 2008 11 23 AM All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 28 of 67 Starting and Stopping Data logging To start data logging insert the USB flash drive in to the top of the FurnaceDoctor Pro Insert USB flash drive here Compatible USB FLASH Memory Sticks Dane Electric DA ZMP 02G CA W1 R PQI Mr Flash U172 Model BB55 B1G3 0221 Corsair Model CMFUSBSF2 0 128 Viking Interworks Model USB0O0256L2 Kingston DataTravlier Model DTI 1GBKR PNY Technologies Attache 256 or 512 Lexar JumpDrive Viking Model USB0032L sony Model Microvalt Dell Model Memory Key Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Touch the Change button next to the LOGGING OFF text FurnaceDoctor Pro www group upc com Co C02 CH4 20 7 CP 0 07 ones DPT F Alloy Factor Change CH4 Factor Furnace Mode Change Endo Mode Change Touch here to start and stop data logging A window will pop up Enter the Log I D log file name and Data Log Interval by touching the appropriate area Touch the Start Logging button and touch OK Log File Name Data Log Interval secs Add Comment Page 29 of 67 Copyright United Process Controls All rights to copy reproduce and
9. can access the VNC server using the Ethernet port To access the Set Ethernet button you can start by navigating to the Utilities Menu FurnaceDoctor Pro Calibrate Touch Screen Set Date and Time Configure I R Screen U te Fir ar tae Calibration Accumulated Runtime OCESS CONTROLS Calibrate Touch Screen i r es Main Menu Proc Calc Utilities Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 58 of 67 Please enter the password Bees BR eeeeee LLL LLL e a EEN EN N S N E R E a e Password for this screen is 0401 Contact your local network administrator for setup information to use this interface properly on your internal network Interface eto Use DHCP ho IP Address 10 101 1 91 Network Mask 255 255 255 0 Gateway 10 101 1 1 Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 59 of 67 VNC VEIWER TightVNC viewer software comes with your FDPRO on the included Flash drive What is TightVNC TightVNC is a free remote control software package With TightVNC you can see the desktop of a remote machine and control it with your local mouse and keyboard just like you would do it sitting in the front of that computer TightVNC is e useful in administration tech support education and for many other purposes e cross platform
10. port and it appears unobstructed the port may leak somewhere behind the hot face of the refractory This may cause the sample to be drawn from between the brick and the furnace shell or even outside of the furnace It is also necessary to keep the sample velocity high in order to quickly stabilize the CO2 For this reason we strongly recommend the use of a non metallic sample probe that will penetrate the furnace wall at least 2 past the hot face of the refractory lf you are unable to use a non metallic probe and if you are getting numbers that just do not make sense I E Extremely low CO values or high CO2 then try taking a sample from the oxygen probe burn off port not the reference airport Only use this method if no other working port is available This method will affect the probe reading The following display is shown on the LCD when power is applied to the unit FurnaceDoctor Pro www group upc com H2 1 Alloy Factor CH4 Factor Furnace Mode Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 21 of 67 Measurement begins approximately 1 min after start up and is continuous after the process temperature is entered The unit will not correctly display O mV Carbon or Dewpoint until temperature is entered The display includes actual CO CO CH as readings calculated theoretical carbon and dewpoint and milli volts for the com
11. safe to remove your USB memory stick g Log to USB Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 33 of 67 Press OK to acknowledge Remove the USB drive and insert into your PC to read the data of the encrypted file on the standalone chart viewer p FDOClogChartViewersA El view Logs T View Charts De Exit Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 34 of 67 THE MENU SYSTEM FurnaceDoctor Pro www group upc com CO 20 7 CP C C CH4 Co2 CH4 DPT F H2 gt F Change Alloy Factor CH4 Factor Furnace Mode Main Menu Button FurnaceDoctor Pro www group upc com 1 R Gas Values View Chart Calibration UJnited PROCESS CONTROLS Proc Calc Utilities Touching the Main Menu button will take you to the system main menu Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 35 of 67 The following options are available on the main menu I R Gas values This is the display that you see when the instrument is first powered up Data includes CO CO CH and user entered temperature Expected O2mv dew point Carbon will be determined in the Configure I R Screen page 45 The checked items will be displayed and log
12. transmit are reserved FDPRO V2 0 Rev 002 Page 30 of 67 A window pops up stating Please insert an USB memory stick Insert the USB stick and touch OK to start data logging AER IS se Mera lA aA eA A Log File Name FILE NAME Please insert an USB memory stick Data Log Interval secs Hit After Touching OK the text next to the Change button will state Logging ON and will display the logfile name in green FurnaceDoctor Pro www group upc com cCoO CO2 CH4 H2 Alloy Factor Change CH4 Factor Furnace Mode Change Endo Mode Change Log file Name Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 31 of 67 To stop Data Logging push the Change button FurnaceDoctor Pro www group upc com CP C C CH4 DPT F Co CoO2 CH4 20 7 H2 Alloy Factor Change CH4 Factor Furnace Mode Change Endo Mode Touch the Change button to stop Data Logging Change You will see this screen Touch on the StopLogging and then touch OK Log File Name Add Comment a Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 32 of 67 A window will pop up stating Data Logging Stopped Touch OK and another window will pop up stating t is now
13. Dew point Calculation Modes The instrument will compute dew point using either a temperature based calculation used when measuring furnace atmospheres where you can identify the process temperature or a simplified table look up method based on CO to be used when measuring the dew point of endothermic generators If you use the furnace calculation when measuring your endothermic generator and enter a process temperature of 1900F or so you will get meaningless values for dew point If you have the generator calculation selected it is not necessary to enter a process temperature You must select the correct carrier gas from the Configure I R Screen From this screen you can select the correct carrier gas for you process FurnaceDoctor Pro www group upc com CP c C CH4 O2 mV DPT F co 20 CoO2 CH4 0 0 y H2 170 Change Alloy Factor CH4 Factor 65 0 Furnace Mod g Main Menu a Change Touch here to toggle between furnace and generator dew point calculation madac Touch here to toggle between endo and exothermic modes If applicable Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 24 of 67 Touch the Change button next to the Furnace DPT mode text and the instrument will toggle to Gen Dpt Mode Touch the button again to return to the furnac
14. EY CURRENT USER Software TightVNC Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 61 of 67 FILTER MAINTENANCE 4 filters with various rates of use all 4 should be changed the filter bowl cleaned out and new filter element installed Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 62 of 67 This is typical use after a few months This filter is starting to get soot buildup and should be changed before use again Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 63 of 67 This filter used with dirty natural gas notice the yellowish tint A filter looking like this should be replaced with a clean filter Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 64 of 67 This filter has been taken out and re inserted not recommended Notice the multitude of additional indentations in the top This filter is past due for replacement Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 65 of 67 This filter is in horrible condition and is way overdue for replacement This filter cannot do its job properly any longer and contamination has resu
15. F Last Factory Calibration 9 25 2009 12 00 0 er Restore Touch Yes on the dialog box or touch CANCEL or NO to cancel the calibration After YES is pressed you will see this screen Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 50 of 67 Mainbenance After nitrogen has been connected and there is adequate flow press OK to Start the calibration SS Ea Cell Pressure mb Cell Temp F 6 72 6 Last Factory Calibration 9 25 2009 12 00 0 Calibration count will show here The FurnaceDoctor Pro will count up to 120 When it has reached 120 connect and turn on the span gas Be sure that you have adequate flow and touch the Span button The following screen will appear Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 51 of 67 You have to have calibration gas ready Are you sure you want to proceed Last Factory Calibration 9 25 2009 12 00 0 Connect and turn on the span gas be sure that you have adequate flow and touch OK on the dialog box Follow the same procedure as Zero calibration calibration Gas CO 25 00 sof of 1 fo mona 0 o 4 0 Cell Pressure mb Cell Temp F Last Factory Calibration 9 25 2009 12 00 0 7 Main Menu Restore Copyright United P
16. RO V2 0 Rev 002 Page 45 of 67 PROCESS CALCULATOR This feature has several options for computing carbon potential dew point and probe millivolts Input fields include CO the carbon monoxide percentage CO2 the carbon dioxide percentage CH4 the methane percentage H2 the hydrogen percentage and F or C temperature To change from F to C touching the F button will change it to C and vice versa Other inputs are O2MV the carbon probe millivolts DPT the dew point Alloy Factor the Alloy Factor is a process factor that can be determined by a shim stock test The FurnaceDoctor Pro can then be adjusted to match you shim stock tests 100 is nominal CH4 Factor the CH4 Factor is a process factor that corrects for the catalytic effect that is happening in the furnace from free CH4 O turns this feature off Once an input percentage has been changed the CALCULATE button will turn red Touch the CALCULATE button to calculate the changes To input a value touch on the appropriate input box O o prm z 20 0 2 Calculation Method Set to Use Gas Input Use mV Input Use DPT Input Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 46 of 67 Options Use Gas Input By entering the CO CO2 CH4 Alloy Factor CH4 Factor and process temperature the O2MV DPT CP atm C C t ch4 Sat C and Oxygen will be compute
17. available for Windows and Unix with Java client included e Compatible with standard VNC software conforming to RFB protocol specifications Install TightVnc on your local machine Running TightVNC Viewer To view and control a remote desktop where a TightVNC Server is running you need to run the TightVNC Viewer To run the viewer choose start gt Programs gt TightVNC gt TightVNC Viewer Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 60 of 67 You will see a window allowing choosing a server to connect to i New TightV NC Connection Connection Remote Host Enter a name or an IP address To specify a port number append it after two colons for example mypc 5902 Reverse Connections Listening mode allows people to attach your viewer to eos j their desktops Viewer will wait For incoming connections Ustening Tight VNC Viewer Tight VNC is cross platform remote control software tight Its source code is available to everyone either freely x i IC GNU GPL license or commercially with no GPL restrictions To connect to remote server enter its host name or IP address in the field Remote Host and click Connect Port number is optional you need to specify it only if it differs from the default value 5900 Default destination Program Files TightVNC miinaan Registry keys HKEY LOCAL MACHINE Software TightVNC HK
18. cess Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 3 of 67 TABLE OF CONTENTS cet esac ge casas esac coma E E oat seaunbeda senerastaeveresontteaapepena nau 4 eee ea WEL Co eee ce ne ee ee ee ee ee 5 THEORY sees ecg cate an ecg E nue eo ecac Ge aesaeoerien obee eset eben wots aentecasevecwrss 6 OPERATIONS reac wet ose E E nes arte anne E E 13 DATA COGGING eea sac eres two cqteestnne as E E A E E O E EE E 24 1HE MENU SYST M ooer E E E E E 33 UTT reer er ern E T E ee ee 36 DATE AND TIME peer E E ee ee 39 GONFIGURE THE IR SCREEN eiccen ae E E EEE 39 PROCESS CALCULATOR eeepc n E e a EE eer 45 CACIBRA TION erer E E E ET 47 RESTORING FACTORY CALIBRAT ION aaaeeeeeeesensseessesssssereserssressessressresressressressreses 52 BATIERY CHARGER ecen en ee E E E O EE 54 ETHERNET SETUP oeron scorns cs ewe A E A EN EEE TENE E EEEE E EO A 56 VNG VEIWER ceee ene a a E E E E E E E E E E S 59 FECLERMAINTENANGE rrr E a E eee eae 61 SPARE PARIS en eee ee ne eee 66 Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 4 of 67 SAFETY Please read the instructions before operating the instrument This instrument complies with accepted industrial safety standards Do NOT operate this instrument with the internal top cover removed Copyright United Process Controls All rights to copy reproduce and transmit are reserved
19. d Touch the CALCULATE button to calculate Use mV Input By entering the oxygen probe millivolts Alloy Factor CH4 Factor and process temperature the DPT CP atm C C ch4 Sat C and Oxygen will be computed CO2 is also calculated Changing the CO will calculate the H2 This will change the calculated DPT CP atm C and C ch4 Touch the CALCULATE button to calculate Use DPT Input By entering the dew point DPT Alloy Factor 7 CH4 Factor and process temperature the O2MV CP atm C C ch4 Sat C and Oxygen will be computed CO2 is also calculated Changing the CO will calculate the H2 This will change the calculated O2MV CP atm C C ch4 Touch the CALCULATE button to calculate Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 47 of 67 CALIBRATION You may calibrate your unit with certified grade span gas and nitrogen If you have plant nitrogen available be sure to regulate it to approximately 1 PSI Span bottle gas must have a bottle top regulator that will be capable or regulation at 1 PSI Be sure that your gas supplier provides you with a certified analysis of the gas in the bottle You may purchase span gas bottles from Furnace Control Corp Please contact your local Furnace Control Corp representative Values for span gas should be 20 25 0 CO 7 1 0 COz2 and 8 15 0 CH and 40 H2 with the balance of nitroge
20. e dew point mode same for Endo and Exothermic modes if applicable Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 25 of 67 DATA LOGGING Your FurnaceDoctor Pro is equipped with a built in memory data logging system Data on all gas values is stored on 30 999 seconds intervals and is available for review from your PC on our Stand Alone chart viewer Data log data is stored on internally or on an industry standard USB memory stick File types are encrypted and are easily read by our Stand Alone chart viewer program S et oa Ss Se Sa ease i i CARRIER GAG2ENDO COMM Si REE eee E 00 00 01 00 02 00 03 00 04 00 05 00 CO CO2 CH4 DPT F Data saved will include time date Log Id co coz ch and user entered temperature Expected o2mv dew point Carbon will be determined in the Configure I R Screen The checked items will be data logged See Utilities Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 26 of 67 Starting the data logger FurnaceDoctor Pro www group upc com CO CP c oas erca oas moo Alloy Factor CH4 Factor 1 700 Change Touch here to start Data Logging Touch the Change button and this window will pop up Enter the for the file here
21. eDoctor Pro owners are either performing gas carburizing or neutral hardening in an endothermic atmosphere the following discussion will help to understand the meaning of the measured values Endothermic atmospheres in use for these applications have this basic composition CO 20 carbon monoxide H 40 Hydrogen CO Trace carbon dioxide CH Trace methane usually from natural gas O Trace oxygen H2O Trace water vapor N Balance nitrogen These ratios are typical whether you are producing gas by means of an endothermic generator or using prepared gasses such as nitrogen and methanol Ratios are slightly different if propane is used rather than methane for the production of carrier gas Obviously any increase in volume in one of the gasses means a decrease in one or more of the other gasses We often get asked the question Why is my generator producing 20 CO but am only measuring 17 at my furnace It is even lower when add ammonia One part of the answer to Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 7 of 67 this question is simple volumetric displacement There is only room in the furnace for 100 of the atmosphere How can the FurnaceDoctor Pro help me with my generator The basic chemical reaction taking place in an endothermic generator is as follows 2CH4 Oo 2 CO 4 Ho Ignoring the nitrog
22. en Remember you are mixing gas and air together and heating it up to produce the above described gas composition The reaction takes place in two stages First some of the methane burns with air and makes heat The by products of this combustion are H2O water vapor and CO In the second stage the remaining methane reacts with the CO and H20 It becomes obvious that we want this reaction to be as complete as possible This is the reason for the nickel catalyst in the generator Assuming that the main air gas ratio is set somewhere between 2 7 and 2 85 parts air to 1 part gas there are two considerations 1 The catalyst must be clean and free from soot If soot is present the efficiency of the above reactions goes down 2 You must have adequate temperature to keep the rate of the reactions high enough So how can the FurnaceDoctor Pro help First by measuring the generators methane content you can determine whether or not the catalyst is operating efficiently 6 CH is about the upper limit Above this level it is possible that the catalyst is laden with soot or the catalyst is simply spent Another indication of this condition would be a high COs or dew point The FurnaceDoctor Pro provides a convenient way to obtain dew point CO CO and CH Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 8 of 67 Check to see that the basic gas compositi
23. f carbon transfer is CO dependant What is really happening is that the ratio of CO to CO is much more accurate means of determining equilibrium carbon One problem is that we use CH as enriching gas What happens to the CH once it enters the furnace It decomposes mostly near the hot catalytic surfaces in your furnace It may be replenishing depleted CO based on equilibrium rules it may be making soot crumbs on your hearth or it may be reacting directly with the surface of the material CHyz gt Cy 2H gt How much of the above reaction is happening is dependent on how much methane is present in your furnace The reaction also happens faster at higher temperatures but is still slow compared to the equilibrium reactions For example at 1600 with an equilibrium carbon potential of 4 and methane content of 5 the theoretical carbon potential is actually 44 In reality the effect is usually about 6 10 of what the theoretical calculations deliver making the carbon potential closer to 42 By contrast if we were to up the methane content to 5 the actual carbon potential might be closer to 6 a significant difference Whether the work really ends up seeing this is dependent on a number of issues temperature governing the rate of reaction the surface area of the work and the level of saturation at the surface atmosphere circulation etc Copyright United Process Controls All rights to copy reproduce and transmi
24. ged Utilities This allows you to calibrate the touch screen set the date and time View internally stored data on a chart and configure the I R Gas Values screen Proc Calc Allows you to enter temperature oxygen probe millivolts or CO CO CH4 H2 Alloy Factor and CH4 Factor to compute carbon potential and dew point You can also enter the dew point and temperature to compute the above Calibration This option allows you to calibrate the instrument to certified grade gasses About tells about software version customer support and the members of United Process Controls View chart Allows the user to view internally stored data on a graphical chart Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 36 of 67 UTILITIES Touch the desired option to select A new window will pop up FurnaceDoctor Pro www group upc com Calibrate Touch Screen Set Date and Time i Configure I R Screen Update Firmware Proc Calc Utilities Calibrate Touch Allows you to calibrate the touch positions on the screen by locating a target for you to touch at various positions on the screen Darahli press acid Ane Py hald steke on rhe cerite af the taget kepest as the target riores around the seen Fress the Eze key to cancel Copyright United Process Controls All rights to copy reproduce and transmit are reserved
25. he Date and Time After the correct date and time are entered touch the Set Date Time button The new Date and Time will then be saved Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 40 of 67 CONFIGURE THE IR SCREEN This screen is for configuring the I R Gas Values screen Touch the Configure I R Screen box FurnaceDoctor Pro www group upc com Proc Calc Utilities A new window will pop up you will be asked for a password I R Gas Values Proc Calc Utilities Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 41 of 67 Touch OK and an alpha numeric keyboard will appear Enter the password and click OK Q w E R T Y U l o P A S D F G H J K L Back Zz x C v B N M Clear Ok Cancel Options include Show Atmosphere Carbon Potential This is displayed on the I R Gas Values screen as CP It is a carbon calculation that displays the carbon potential of the atmosphere using CO CO2 and manually entered process temperature Show Steel Surface Carbon This is displayed on the I R Gas Values screen as C It is a carbon calculation that displays the carbon potential of the steel surface using CO CO2 and manually entered process temperature with the option of an Alloy Factor The Alloy Factor is a process factor that can be determined by a shim stock te
26. lted very costly Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 66 of 67 SPARE PARTS Replacement Battery T LITHIUM BAT TERY Desktop Battery Charger T LITHIUM SMARTCHARGER Filter Element T FIL 04 Filter Housing T FIL 03E Extra Tubing T REDTUBE qty in feet Portable Battery Charger T AC ADAPTOR Barb Adaptor for tubing T AD1 TU BA 0 25 Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 67 of 67 L lt a y A Reach us at www group upc com s EFR ft Oy te S United Process Controls brings together leading brands e gt a ms to the heat treating industry including Waukee X X sf Engineering Furnace Control Marathon Monitors and 4 ad Process Electronic A w We provide prime control solutions through our 7 ya ta worldwide sales and services network with easy to gii access local support UNITED PROCESS CONTROLS INC A MARATHON MONITPORS PLANT 8904 Beckett Rd West Chester OH 45069 USA p nN te a PROCESS CONTROLS f WM ozs Wo Copyright United Process Controls All rights to copy reproduce and transmit are reserved
27. n It is recommended that you select span gas with values approximately 20 higher than typical observed process value Span gas values may be higher or lower but should not exceed the ranges of the measuring cells of 30 CO 2 COxz and 15 CH4 Be sure to keep the second stage regulator pressure around 1 2 PSI Your FurnaceDoctor Pro is equipped with good internal pressure regulation but too much pressure may override the regulator s ability to control the pressure in the cells It is important to understand the I R cells are very pressure sensitive by nature Realize that for a given species of gas there are more molecules of that gas present in a cell with a pressure of 1 5 PSI than in a cell with a cell pressure of 5 PSI This will lead to measurement error if the unit is calibrated at a high pressure and then applied to low pressure measurements You may observe this phenomenon by closing of the exhaust of the instrument while measuring a furnace Note the quick rise in the CO value Calibration Furnace Control Corp recommends the following procedure Connect the span bottle to the instrument and measure it on a weekly basis If the instrument measures the span bottle within 2 of the analyzed values on the bottle it is not necessary to calibrate the instrument Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 48 of 67 If calibration is required d
28. nges if it does you have a leak in the probe substrate If you change the probe or if you are sure that the probe is ok check to be sure you are obtaining a good sample at the FurnaceDoctor Pro Many times sample ports are the cause of the problem A good non metallic sample probe helps solve this One trick is to use the probe burnoff port to obtain a sample This has a few problems associated with it in furnaces running high methane contents The methane will crack near the alloy Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 11 of 67 surface of the probe creating a local reaction not representative of the overall furnace atmosphere Interpreting the gas value readings CO For most atmospheres in use this number should be around 18 20 If it is lower than 18 then observe the following Check generator for proper operation If you are using nitrogen methanol check the ratio of nitrogen to methanol Also be sure that the atmosphere sparger is in good condition If you are using nitrogen to push the methanol into the furnace be sure that the methanol is not getting nitrogen bubbles in it If you are using ammonia the ammonia additions will dilute the CO in the furnace Remember there is only room for 100 of the gas in the furnace Check for leaks This can be confirmed by a high CO2 If you are asking for a high carbon potential high methane conte
29. nt may also dilute atmosphere mix Check for leaks Air leaks typically cause the control system to add more natural gas to the furnace High surface area loads will be able to draw more carbon out of the atmosphere Typically the methane content will go up because of this CO This number can be anywhere between 05 to 1 and is dependent on temperature and gas composition It tracks inversely to carbon potential At 1600F a 4 C will be about 0 62 COs assuming 20 CO To achieve a 4 carbon at 1750 CO will be around 25 If the carbon potential is lower than expected the CO should be higher than expected Check for air leaks Check for burner tube leaks Check for furnace fan water jacket leaks Check generator or nitrogen methanol system If the probe system is in agreement with the FurnaceDoctor Pro be sure there is adequate carrier gas flow and adequate enriching gas flow Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 12 of 67 Is carbon controller turning on the natural gas when it should CH Most batch furnaces will operate with a CH content ranging from 1 to 4 5 At the start of the cycle this number is higher than when the atmosphere and the work approach equilibrium with each other Continuous furnaces performing carburizing will usually operate at higher methane levels In fact in some belt furnace applications this is necessary
30. o it in the environment that the instrument will be used in If you calibrate the instrument in an office that is 70 degrees and then go use the instrument in a 110 degree heat treat you will probably experience some error in measurement To begin calibration The procedure for Span gas values only needs to be performed when a new span bottle is to be used Touch the Main Menu button from the main screen then the Calibration button to get to the calibration page Be sure that the span gas values on the calibration page match the certified gas values provided with the span gas bottle Be sure these values match the values supplied by the certification with your gas Last Factory Calibration cylinder 9 25 2009 12 00 0 Restore Cell Pressure mb Cell Temp F If these values need to be changed touch the appropriate field and enter the new value from the cylinder certification The offset and span values will be computed automatically during calibration The Reading fields are the actual measured values Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 49 of 67 Starting Calibration Connect and turn on the nitrogen gas Be sure that you have adequate flow and touch the Zero button The following screen will appear Maintenance You have to have calibration gas ready Are you sure you want to proceed Cell Pressure mb Cell Temp
31. on Contamination in the sample cell particularly on the windows will cause an error in the output reading Avoid degradation of the sample gas between sample point and the sensor by the introduction of unnecessary volumes or restrictions Eliminate transients which can cause pressure variations Maintain constant flow conditions Avoid the use of rubber compounds for the sample tubing adsorption effects Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 14 of 67 Particles The gas to be measured must be well filtered 100 of 3 um particles must be retained Humidity Prior to entry in the FDPRO the moisture in the gas must be adequately reduced This means that the dew point of the gas must be brought below the operating temperature of the FDPRO by some means No moisture can then condense in the ACCUBENCH Liquids The sample gas must be free of any liquid Entrained oil The sample gas must be free of any contamination Copyright United Process Controls All rights to copy reproduce and transmit are reserved Page 15 of 67 FDPRO V2 0 Rev 002 FURNACE SAMPLE Pad 12 PLE TUBE VALVE fi SAMPLE CAL I BRATION a en FOL n z ZERO WY NITROGEN ZERO GAS lt 10 PSI REGULATOR SPAN GAS Y NPTF gt K VALV SUBMICRON FILTER FURNACE DOCTOR PRO IZR CABINET VACUUM PUMP IN Our IZR CELL I R CELL
32. on is as expected CO should be around 20 Check the CH level and be sure that it is less than 8 observe the CO and the dew point readings Note the relationship between dew point and CO Carbon Dioxide VS Dewpoint 1 60 1 40 v 1 20 n 1 00 z 0 80 2 060 Q 3x 0 40 0 20 0 00 0 20 40 60 80 100 Dewpoint Make adjustments to either your oxygen probe control system or the generator carburetor to obtain the desired dew point How will the FurnaceDoctor Pro help me with my Furnace atmosphere If you are using oxygen probes the FurnaceDoctor Pro can supply independent traceable verification of your probes accuracy It will also give you a much more complete picture of what is happening in your furnace atmosphere The primary reactions involved in carbon transfer are well understood as 2CO gt Cy CO Hz CO gt Cy H2O Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 9 of 67 These reactions are assumed to be close to equilibrium The theory behind this is that a reaction sometimes called the water gas reaction is busy keeping the H2 and Oz in balance CO H20 CO2 H2 The measurement of Carbon in your atmosphere with an oxygen probe is based on the assumption that the above is true CO gt Cy 2 Oo Note that it is assumed that the primary mechanism o
33. our analyzer into Furnace Control Corp for calibration the calibration data and the factory calibration date are entered and stored in the analyzer s memory by the use of a password Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 55 of 67 BATTERY CHARGER Your FurnaceDoctor Pro includes a battery charger universal A C adaptor Charging Unit will operate continuously for approximately 6 hours without recharging A full charge will take approximately 2 hours to complete It is not necessary to completely discharge the battery before charging To charge the unit Connect the supplied Battery charger universal A C adaptor into the D C input port on the top of the Furnace Dr Battery Charging level Port indicator p Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 56 of 67 Note Unit is designed to operate with a charged battery or with the A C adaptor Using the charger as an AC adapter will not allow the battery to charge as quickly as it would otherwise It is a best practice to connect the charger with the unit s power off and fully charge the battery The unit will not operate with the battery removed Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 57 of 67 ETHERNET SETUP You
34. puted Carbon and manually entered temperature To compute the correct C associated with the CO CO and CH4 measured gasses you must enter the process temperature FurnaceDoctor Pro www group upc com DPT F ome Main menu Touch here to Enter Process change to C Temperature and back to F Here Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 22 of 67 Touch the temperature field and a numeric key pad will appear Enter the process temperature and press the OK button 1 700 Enter a value between 760 amp 2 000 1654 re ee ee ee ee es ee ea ee Le d Jee LLL LL Le IL es Le JL LL Ls Lt eee Lz l Ie y Je Jn J I Ai o O The instrument displays the carbon dewpoint for the measured CO CO CH gasses and entered probe temperature Additionally it displays calculated probe millivolts Calculated prove mV uses an algorithm that assumes CH4 is equal to zero The instrument will take at least 60 seconds from cold start to display any meaningful information Ensure that sample flow is adequate It s always a good idea to allow at least 3 minutes of operation to obtain a meaningful reading The FurnaceDoctor Pro can be switched between Deg F and Deg C by touching the F C box Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 23 of 67 Selecting the
35. rocess Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 52 of 67 Once the unit has counted up to 120 the calibration is complete You can now return to the I R Gas Values screen The instrument should read the values in the bottle within 2 of the cell range l e 30 CO should be 6 CO Annual Factory Calibration is suggested Retain original box and custom packing foam for return shipment to FCC Annual factory calibration will ensure your analyzer performs at a high degree of accuracy throughout its life Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 53 of 67 RESTORING FACTORY CALIBRATION If you wish to restore the calibration performed at the factory then touch the Restore Factory Cal button Cell Pressure mb Cell Temp F Touch here to restore factory calibration You will be prompted with Are You Sure you want to restore factory calibration Touch OK on the dialog box and the last factory calibration data will be restored Are you sure that you want to restore factory calibration Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 54 of 67 You will see this screen next Touch YES to complete the restoration of factory calibration n Menu Restore Calibration date When you send y
36. st The FurnaceDoctor Pro can then be adjusted to match you shim stock tests 100 is nominal Unchecking this option will invalidate the C CH4 calculation Show CH4 Corrected Carbon Potential This is displayed on the I R Gas Values screen as C CH4 It is a carbon calculation that displays the carbon potential of the atmosphere using CO CO2 CH4 and manually entered process temperature with the option of a CH4 Corrected Carbon Potential The CH4 Corrected Carbon Potential is a process factor that corrects for the catalytic effect that is happening in the furnace from free Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 42 of 67 CH4 The c CH4 box that will be displayed on the I R Gas Values page will turn red if the furnace is not in equilibrium 65 is the recommended default setting if you choose to use this feature Show O2 Probe Calculated Signal This is displayed on the R Gas Values screen as O2MV It is a calculated O2 Probe millivolt using CO CO2 and manually entered process temperature Show Calculated Dew Point This is displayed on the I R Gas Values screen as DPT It is a calculated Dew Point using CO CO2 and manually entered process temperature and H2 There are 4 selections of carrier gasses available Nitrogen Methanol which calculates the amount of H2 from the amount of CO that is present in the atmosphere to calculate dew point
37. t are reserved FDPRO V2 0 Rev 002 Page 10 of 67 Using the FurnaceDoctor Pro to analyze furnace atmosphere Probe condition Carbon is computed using actual gas values so it is more accurate than the assumptions made by the probe Compare the C calculated by the FurnaceDoctor Pro to C displayed on the Carbon Control instrument Your carbon controller is set up with some assumptions about the content of the furnace atmosphere Most controllers assume a CO to be 20 out of the box you may use the FurnaceDoctor Pro to correct this situation by adjusting this factor to the correct CO Observe the probe millivolts as computed by the FurnaceDoctor Pro and displayed by the carbon controller These should be within 1 2 of each other If not and you have entered the process temperature into the FurnaceDoctor Pro correctly you probably have a problem with the probe or the controller First check the millivolt reading at the back of the probe with a meter to eliminate any possible instrument problems Next be sure that the probe is free of soot by burning the probe off If the numbers still do not agree perform an impedance test on the probe to help determine the electrode condition You will also want to check to see how fast the probe recovers after this test Recovery time should be in seconds not minutes Finally disconnect the probes reference air tube and see if the millivolts reading on the controller cha
38. urnaceDoctor Pro is equipped with a battery monitor When a battery level monitor is low it is time to charge your FurnaceDoctor Pro Power Battery Level Pump Switch Indicator Button The LCD display will illuminate and the internal pump will start after pump button is depressed Manually input fields are in grey live and calculated fields are in white Buttons are grey FurnaceDoctor Pro www group upc com co 20 7 CP cC C CH4 O2 mv DPT 2F co2 CH4 H2 Change Alloy Factor CH4 Factor Main Menu Furnace Mode Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 19 of 67 After 30 seconds gas values will be measured and displayed FurnaceDoctor Pro www group upc com CP C C CH4 Co 20 N CO2 CH4 DPT 2F oma o Alloy Factor CH4 Factor Furnace Mode Ensure that sample flow is adequate If you are sampling a generator keep the flow rate below 9 SCFH so you do not compress the gas leading to an incorrect reading Copyright United Process Controls All rights to copy reproduce and transmit are reserved FDPRO V2 0 Rev 002 Page 20 of 67 A note about sample ports In a large percentage of heat treating environments we have found that the furnace sample ports are either plugged or leaking Even if you can look into the
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