H2SMART USER MANUAL - United Process Controls
Contents
1. E0ie 4 Te INTRODUCTIONS E 5 1 1 WU VT 5 2 SPECIFICATIONS eege deeg dk a RP ER ARCU ERR AUR EUN ues DRAUF an o RA arva 6 2 1 duin 6 2 2 d Jib urn NEEN 6 2 3 Operating TET NIQC I C E ouunt ssdesuecsensevtssscesuctsdenadsssvetedssseceueessees 6 2 4 Recommended Calibration eee eese eee eene eene eene nnns nete ttntiss hasse sese tensis sns EEN 6 Be INSTALLATION ustrik vesc tn EEENREEURR OE CP OFQUEERVE QU UUFER URGERE CKREFRUKU E VER DER EFQU UMRURE IE CFR CEU MEER SNR HK DAR UR 7 3 1 WU VT 7 3 2 Physical Characteristics 1 orto tern Age EE EESE EEES 8 3 3 Installations Steps E 11 4 ELECTRICAL INSTALLATION E 15 4 1 H2Smart digital input and output signals eese entente tnnt nntn tn tn tn snnt tt nnns 19 4 2 H2Smart hEID II pce 20 4 3 Heat tracing sensor connector Optional eee KREE KREE eene eene e enne nnn nnn nnn nnn nnn nnn 21 4 4 Oxygen Probe card optional 00 1 tine ore riore anra r ee eege 21 5 OPERATING INSTRUCTIONG ssccccsssssccccssssccccssssccccescsccecaccsscescssscsssansessesccusssssccesssssccossssecees 22 Gs PREVENTIVE e 23 6 1 Sample Bas DU Dee HA2. KN and Kc Calculation The KN and KC calculations run internally in the unit based on the furnace volume the inlet gas flows and the reading from the H2Smart sensor To ensure a correct furnace atmosphere calculation the process flows into the furnace must be updated whenever they are changed The updates must be made at all times during the recipe even during non nitriding stages These changes can be made via the communication adaptor MODBUS ProfiBus or CANBus or via the H2Smart software The communication data register assignments can be found in the respective communication appendix The furnace atmosphere is continually updated based on the flow rates and the stored furnace volume Valid KN and Kc calculated values require the furnace to be at nitriding temperature as well as the H2Smart sampling enabled When the sampling is disabled the KN and KC calculations are disabled and will return a 0 00 value If sampling is enabled under non nitriding conditions the KN and KC calculations will not return valid KN and Kc values Copyright O United Process Controls All rights to copy reproduce and transmit are reserved H2Smart User Manual Rev 17 Page 23 of 25 6 PREVENTIVE CARE All maintenance and preventive care must be carried out by trained personal only in compliance with the applicable safety standards 6 1 Sample gas pump The life time of the sample gas pump is dependent on the composition of Maintenan
3. LO Optional amp mm Adapter 3 8in 97 5MM Figure 3 Side View All rights to copy reproduce and transmit are reserved Copyright United Process Controls H2Smart User Manual Rev 17 Page 11 of 25 3 3 Installations Steps 3 3 1 Step 1 Two support brackets and four screws are used to secure the H2Smart unit Attach unit to a panel wall using four 10 M5 screws H2Smart Intelligent Hydrogen Sampling System 30 2 96DIS United PROCESS CONTROLS Figure 4 Step 1 3 3 2 Step 2 Pre measure and bend the tubing accordingly Pre swage Swagelok ferrules to the tubing s using Swagelok Pre swaging tool or spare Swagelok fitting A CAUTION Do not swage the tubing in the H2Smart connectors Copyright United Process Controls All rights to copy reproduce and transmit are reserved H2Smart User Manual Rev 17 Page 12 of 25 Attach tubing to Exhaust H2Smart Side View Exhaust to atmosphere 1 4 6mm 1 4 6mm Sampling SS in Filter Exhaust from furnace Figure 5 Step 2 3 3 3 Step 3 Connect 1 4 tubing to Swagelok connector using a 9 16 wrench or metric equivalent do not over tighten Follow Swagelok instruction to assemble piping with tube fitting 4 E e OUT IN 2 Cp Figure6 Step 3 Copyright O United Process Contr
4. 23 Fe ee ET Kg el 24 8 CUSTOMER SUPPORT eese esee eee e eese eee snnt RENE n sete N Arao S asse sess sa KEE sess estates ana 24 Copyright United Process Controls All rights to copy reproduce and transmit are reserved H2Smart User Manual Rev 17 TABLE OF FIGURES Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 7 Figure 8 Figure 8 Figure 9 Bottom View Front View Side View Step 1 Step 2 Step 3 Step 4 Heat trace cable installation Electrical Installation Figure 10 Connectors Figure 11 Connectors Figure 12 LAN Connector Figure 13 CAN Connector Copyright United Process Controls Page 4 of 25 10 11 12 13 14 14 15 16 17 18 18 All rights to copy reproduce and transmit are reserved H2Smart User Manual Rev 17 Page 5 of 25 1 INTRODUCTION 1 4 Overview The H2Smart is an integrated thermal conductivity sampling system designed to measure the concentration of a gas sample in binary or quasi binary mixtures It is especially suitable to measure hydrogen content or dissociation level with high accuracy in nitriding and nitrocarburizing atmospheres and to calculate the parameters necessary for nitriding process control A unique measuring cell design and advanced electronics eliminate the need for a reference gas cell thus simplifying the installation An integrated sampling pump with variable output and a flow monitoring circuit with pump saturation wa
5. be configured as type K or S It is crucial that the appropriate setting is factory configured Please inform your sales rep Copyright United Process Controls All rights to copy reproduce and transmit are reserved H2Smart User Manual Rev 17 Page 22 of 25 5 OPERATING INSTRUCTIONS After power on the system heats up the measuring cell to operational temperatures nominally 65 C Flow measurement is disabled and the sampling pump is off during heat up to avoid contamination of the system with condensation Depending on ambient temperature heat up takes about 30 minutes Full accuracy is reached after 1h It is recommended to keep the system powered up at all times and use the Sampling enable digital input or digital communication to activate or deactivate the sampling flow When the operating temperature is reached the Sampling enable digital input or digital communication command must be active to start sample gas pump enable sampling flow control and gas composition measurement Display The display shows the following information depending on the system status Display shows Status Flashes Temp Heat up or sampling disabled Pump Off Process Variable i e diss Kn etc Sampling enabled Filter Sampling pump nearing saturation most probably due to a clogged gas filter or sampling line contamination Alarm Sampling enabled but the sample gas flow is outside the flow tolerance band
6. cally isolated from ground and each other Max Input voltage is 28VDC input Current is 6mA 24VDC Digital outputs are open collector outputs referred to pins 8 and 15 of connector X1 0V external load supply Be aware that pins 8 and 15 of X1 are internally connected to OV of the system power supply input Copyright O United Process Controls All rights to copy reproduce and transmit are reserved H2Smart User Manual Rev 17 4 2 H2Smart analog outputs Page 20 of 25 Connector X2 is a 9pin DSUB female connector Pin Signal name Signal function L TANANI Analog output 1 2 AnaOut1 Analog output 2 5 Shield GND Cable shield connection connected to PE 6 Reserved 7 Reserved Pins are reserved for future use make no connections to 8 Reserved them 9 Reserved KKK Caution AnaOut1 Pin 1 and Anaout2 Pin 3 are internally connected To avoid interference between both outputs do not connect externally The analogue outputs of H2Smart are internally powered 4 20mA current sources with common positive supply able to drive a maximum loop resistance of 500 ohms Output assignment scaling and electrical output range 0 20mA or 4 20mA may be configured using the H2Smart service software To ensure proper functioning isolated analogue inputs shall be used to read H2Smart analogue signals Factory default configuration Output valu
7. ce period the gas Action Send the unit in for service in case of a pump failure A WARNING Prevent liquids such as water or oil from entering the sampling line A WARNING Never use sharp objects wire screwdriver etc to check or unblock the H2Smart sampling Swagelok connectors and internal lines Never use compressed air to clean the H2Smart This may create a health hazard and permanent instrument damage d Copyright O United Process Controls All rights to copy reproduce and transmit are reserved H2Smart User Manual Rev 17 Page 24 of 25 7T CONFIGURATION Field configuration of the H2Smart is limited to setting the IP parameters selecting the temperature display unit C or F and configuring the analog outputs All configurations are done using the H2Smart service software installed on a PC running Windows XP Vista O S To connect to the H2Smart Use the LAN port on your computer with a special adapter included H2Smart P address is displayed during instrument power up procedure 8 CUSTOMER SUPPORT In the event of any major emergency situation please call United Process Controls customer support department upc support group upc com Phone 1 513 772 1000 Fax 1 513 326 7090 Copyright United Process Controls All rights to copy reproduce and transmit are reserved H2Smart User Manual Rev 17 Reach us at www group upc com United Pro
8. cess Controls brings together leading brands to the heat treating industry including Waukee Engineering Furnace Control Marathon Monitors and Process Electronic We provide prime control solutions through our worldwide sales and services network with easy to access local support UNITED PROCESS CONTROLS INC MARATHON MONITORS PLANT 8904 Beckett Rd West Chester OH 45069 USA Phone 1 513 772 1000 Fax 1 513 326 7090 E mail upc sales group upc com Copyright O United Process Controls Page 25 of 25 d KA United PROCESS CONTROLS a EX f WM aca GU Ss PIKE All rights to copy reproduce and transmit are reserved
9. e Measurement result as ordered Analog output 1 Scaling 0 100 Range 4 20mA Output value Sample gas flow rate l min Analog output 2 Scaling 0 1 l min Range 4 20mA Copyright United Process Controls All rights to copy reproduce and transmit are reserved H2Smart User Manual Rev 17 4 3 Heat tracing sensor connector optional Page 21 of 25 Connector X3 is a 9pin DSUB male connector It is exclusively used for the optional heat tracing temperature sensor that enables H2Smart to control the temperature of the sample gas tube heat tracing Do not connect anything else to this connector Note that the power source of the heat tracing circuit may require GFCI rating Please consult local laws with regards to this protection 4 4 Oxygen Probe card optional The optional oxygen probe card has two DB9 connectors one for the O5 Probe T C and one for the O2 Probe mV Signal connector These DB9 are used to directly connect an oxygen probe to the H2 Smart thus receiving the appropriate signals via optional serial data The wiring diagram is as described O Probe mV db9 female on cable O Probe T C db9 male on cable PIN signal colour signal colour 1 2 mV Depends on probe 3 4 mV Depends on probe 5 6 7 T C Depends on type 8 T C Depends on type 9 Note that the Oxygen Probe card s thermocouple input can
10. et and outlet connectors e Thermal insulation shall be in contact with inlets plate and be properly sealed e No gap shall exist between inlets plate and the insulation e Temperature sensor has to be attached to the tubing only it should not touch the heating cable HEAT TRACING CABLE IN FULL CONTACT WITH PIPING Copyright United Process Controls United United PROCESS CONTROLS X E n PROCESS CONTROLS HEAT TRACING CABLE ai NOT IN FULL CONTACT WITH PIPING Note Heat tracing insulation not shown Figure 8 Heat trace cable installation All rights to copy reproduce and transmit are reserved H2Smart User Manual Rev 17 Page 15 of 25 4 ELECTRICAL INSTALLATION Connect the system to a well regulated 24VDC power supply capable of supplying 2 5A minimum 3A typical Connect power cable to 24 V power supply e e mm Qe em D ESAN svc LAN ei X Opt Interface a Je d el 77 Egger we T M D g e G up Digital 1 0 Analoa Out Taux Figure 9 Electrical Installation A CAUTION The H2Smart will be permanently damaged if connected to 115 or 230VAC Within the specified limits the value of the supply voltage will not influence the accuracy but a power supply with bad stability may increase measurement noise of the system Use a well regulated power supply and do not operate other heavy loads from the same supply The specified
11. g LU n il te d WWW GROUP UPC COM PROCESS CONTROLS H2SMART USER MANUAL Version 17 H2Smart intelli gent Hydro sampling Syst m United PROCESS CONTROLS Hs www group upc com H eme C a Weg Jinited AFFILIATED MEMBERS PROCESS CONTROLS Furnace Control Corp Marathon Monitors Inc Process Electronic Waukee Engineering Co H2Smart User Manual Rev 17 Page 2 of 25 Manual 003 Rev No 017 Date 30 March 2015 THIS MANUAL IS SUPPLIED IN ONE 1 COPY COPYRIGHT No part of this publication may be duplicated copied and or transmitted without the prior written permission of United Process Controls The information contained in this document is STRICTLY CONFIDENTIAL and PROPRIETARY to United Process Controls and shall not be i reproduced or disclosed in part or in whole ii used for any design or manufacturing of heat treating and or control equipment or any other purpose except for that which it is supplied under the terms of the Contract unless the express written authorization is obtained from United Process Controls Drawings and photographs included in the documentation are the property of United Process Controls and it is strictly forbidden to reproduce them transmit them to a third party or use them for manufacturing and or design of equipment Sub licensing of any technical information contained in this Documentation is strictly forbidde
12. hm Outputs nputs Working pressure ambient 70mbar 1PSI ae Maximum Continuous Vacuum generated 350mbar abs 5 psi 2 4 Recommended Calibration Polynomial calibration 12 months 000000000000 Copyright United Process Controls All rights to copy reproduce and transmit are reserved H2Smart User Manual Rev 17 Page 7 of 25 3 INSTALLATION 3 4 Overview The H2Smart unit is to be installed away from the furnace and the sample gases are tapped from the exhaust lines Ensure that the source and dump lines are at the same pressure A CAUTION The sampling gas temperature entering the H2Smart must be lt 90 C 195F Usually this condition is easily accomplished by selecting the proper length and heat dissipation condition of the sampling supply line Necessary heat dissipation for the sampling flow of 0 5 Ipm 1 cfh and temperature difference 500 C 932 F is less than 10 W 35 Btu hr and depend on the sampling gas composition A CAUTION Handle with care do not drop The sensor is susceptible to shock and it is a static sensitive device use proper handling procedures A CAUTION Installations with dirty exhausts powder residues injections Malcomizing masking furnaces with oil seals require a supplementary pre filter we suggest a 5um or as required for your particular condition with a surface area of not less than 200 cm 30 in For fe
13. n under the terms of the Contract United Process Controls reserves the right to modify this document without prior notice WARRANT Y United Process Controls UPC warrants its goods as being free of defective materials and faulty workmanship Contact your local sales office for warranty information If warranted goods are returned to UPC during the period of coverage UPC will repair or replace without charge those items it finds defective The foregoing is Buyer s sole remedy and is in lieu of all other warranties expressed or implied including those of merchantability and fitness for a particular purpose Specifications may change without notice The information we supply is believed to be accurate and reliable as of this printing However we assume no responsibility for its use CE Conformity Europe This product conforms to 73 23 EEC the Low Voltage Directive and 89 336 EEC the EMC Directive AMS Conformity North America This product conforms to SAE Aerospace Material Specifications AMS 2759 10 for nitriding and 2759 12 for nitrocarburizing For assistance please contact United Process Controls Inc TEL 1 513 772 1000 e FAX 1 513 326 7090 Toll Free North America 1 800 547 1055 upc support group upc com www group upc com Copyright United Process Controls All rights to copy reproduce and transmit are reserved H Smart User Manual Rev st 17 Page 3 of 25 TABLE OF CONTENTS TABLE OF FIGURES M
14. ols All rights to copy reproduce and transmit are reserved H2Smart User Manual Rev 17 Page 13 of 25 OwA Assembly Instructions a Insert tubing into the Swagelok tube fitting b Make sure that tubing rests firmly on the shoulder of the tube fitting body and that the nut is finger tight c Scribe the nut at 6 o clock position Figure 7 Step 3 d While holding fitting body steady tighten the nut 1 1 4 turns to the 9 o clock position Reassembly Instructions a Insert tubing with pre swaged ferrules into fitting body until the front ferrule seats b Rotate the nut with a wrench to the previously pulled up position At this point a significant increase in resistance will be encountered c Tighten slightly with the wrench Note don t use the gap inspection gauge with reassembled fittings 3 3 4 Step 4 Heat tracing the sample gas tubes for Ferritic Nitrocarburizing furnace In order to avoid clogging of the sample gas tubes by ammonium carbonate and condensation the sample tubing piping should be kept at temperatures within the range of 85 90 C 185 195 F by external heat tracing For this purpose typically a heat trace cable is run close to the tube bundle tightly pressed against the tubes by appropriate cable ties The whole assembly is then wrapped in thermal insulation material Use pipe insulation whenever you run heat tracing Try to run the in and out tubing side by side such that the heat
15. power consumption is only true during start up after operating temperature is reached the power consumption will decrease to 20 40 of the specified value depending on ambient temperature Copyright United Process Controls All rights to copy reproduce and transmit are reserved Page 16 of 25 H2Smart User Manual Rev 17 Ap spw yo uoneinjes qe eje1wo 4 Ui M HE aan imo isuid yoq 12euuoo S P NV Addins peoj jeuiax3 20 0 Duren eH zanosa uonenes dung wely enobig swur yo eje1o14 oSA zujbig zujbig Luj6ig LujBig Suidwes ejqeu3 JO OSUUOD jew gNSA Udg esf sjndur ey6iq sindino jey 6ig LX pesn JON Figure 10 Connectors KAjddns 19Mod qieuiszH 2GA 0 Ajddns samod pneuiszH DAA P All rights to copy reproduce and transmit are reserved Copyright United Process Controls H2Smart User Manual Rev 17 Page 17 of 25 5 S D G 2 o O5 2529 8 3 28g SESS SS 9 amp 8 2328 a 3 S99 GER 5 EK o92c9 53 x 2tE xrcooc xa 3 3 z THE 2 i 3438 i Note that the 3AMP fuse is o customer Ed SV EEN E responsibility Power cable Ver 3 Lu 2 a a Pin 3 gt gt 1 24VDC 2 SCH 2 ov 5 PE YELLOW GREEN 2 Es s 3 n O EN i Figure 11 Connectors Copyright O United Process Controls All rights to copy reproduce and transmit are reserved H2Smart User Manual Rev 17 VB1 RD RD TD TD Figure 13 CAN Connec
16. rning and flow alarm insure fresh and reliable sampling flow The pump provides a continuously controlled flow despite possible sampling line obstructions or filter contaminations thus assuring accurate measurements and better process control A sample gas pump with variable output and a digital flow regulator are used to form a closed loop sampling system that ensures constant gas flow through the analyzer The measuring block is maintained at a preset temperature with high accuracy to provide stable measuring conditions and protect the system from moisture formation and cell contamination during nitrocarburizing The system status and measured results are displayed on a large easy to read alphanumerical display Copyright O United Process Controls All rights to copy reproduce and transmit are reserved H2Smart User Manual Rev 17 Page 6 of 25 2 SPECIFICATIONS 2 1 Physical mounting bracket 209 mm 8 T Height 201 mm 8 37 Depth 193 mm 7 6 2 2 Performance _ 0 5 of reading plus 0 3 of full scale cun ced 0 5 of full scale per Sampling flow 0 5 Ipm 1 cfh controlled _ Response time 95 in 30 sec 0 5 Ipm 1 efh Accuracy Linearity Repeatability 2 3 Operating Power requirements 24VDC 2 5 Amps max Use only well regulated power supply 2x analog sourcing with common positive supply 4 20 mA R 500 O
17. rritic nitrocarburizing we suggest that this pre filter is also heat traced End user must ensure that gases entering the unit are free of contaminants such as water oil or other Copyright United Process Controls All rights to copy reproduce and transmit are reserved H2Smart User Manual Rev 17 3 2 Physical Characteristics Page 8 of 25 BOTTOM VIEW 6 8in 172 5mm 37 5m Figure 1 Bottom View 1 Optional Interface for Profibus or Modbus 7 Taux temp sensor 2 CAN 8 Power 3 SVC service 9 Voltage Fuse 4 LAN 10 Oxygen probe signal 5 Digital I O 11 Oxygen probe thermocouple 6 Analog Out 12 In Out Connectors Copyright United Process Controls All rights to copy reproduce and transmit are reserved Page 9 of 25 H2Smart User Manual Rev 17 FRONT VIEW 6 7in a 170mm 4 9in 125mm E E ES i SE d H2Smart Intelligent Hydrogen Sampling System 30 290DIS E D c c E CH amp ON O SOLA N N United PROCESS CONTROLS 2 2in Optional 6mm Adapter 3 9in 98 6mm Figure 2 Front View Copyright United Process Controls All rights to copy reproduce and transmit are reserved Page 10 of 25 H2Smart User Manual Rev 17 SIDE VIEW Vv 6 8in 172 5mm i i st cE TE K 5 Os Ox ES EX LA E CN LO
18. tor GNCAN CANH CANL GNCAN GND Copyright United Process Controls Page 18 of 25 LAN 10BaseT Female DB 9 Connector Figure 12 LAN Connector CAN Cable Female DB 9 connector Colour RED BLACK WHITE BLACK SHIELD Note There is a 1200 across 2 7 All rights to copy reproduce and transmit are reserved H2Smart User Manual Rev 17 Page 19 of 25 4 1 H2Smart digital input and output signals Connector X1 is a 15pin DSUB male connector Pin Signal name Signal function l Digni A 24VDC signal on Digln1 enables sampling 2 Digln1 3 DigIn2 A Digln2 Reserved 5 DigOut4 Open collector output A low output signal indicates the status Flow rate off limits flow alarm 6 DigOut3 Open collector output A low output signal indicates a pump saturation status pump alarm 7 DigOut2 Open collector output Outputs a 10Hz pulse width modulated signal used to control the power of the heat tracing heater via a solid state relay Caution Do not use an electromechanical relay for this purpose 8 OV external load supply Connect to negative terminal of the external load power supply 9 Reserved 10 Reserved TE Reserved Pins are reserved for future use make no connections to them 12 Reserved 13 Reserved 14 Reserved 15 OV external load supply Connect to negative terminal of the external load power supply Digital inputs are electri
19. tracing sensor and the cable all fit nicely in one tightly packed bundle This will ease the installation of the insulation and maximize efficiency Mount the optional heat tracing temperature sensor to the tube bundle inside the thermal insulation at a distance of 30 60 cm 1 2 ft from the H2Smart connectors Use an appropriate solid state relay controlled by the heat tracing control output to switch power to the heat tracing cable Copyright O United Process Controls All rights to copy reproduce and transmit are reserved H2Smart User Manual Rev 17 United PROCESS CONTROLS Figure 8 Step 4 Page 14 of 25 Due to the high probability of dirty gas sharp bends in the piping should be avoided Try to keep the piping as smooth and as straight as possible as this will aid in the heat tracing insulation later Avoid unnecessary loops fittings or traps in piping See the wiring diagram section for more information The H2Smart will regulate the heat tracing temperature to 149 F 65 C as long as it is powered up without further user action Important consideration e Digital l O s and H2 Smart main power shall be powered from the same source e Arrange the heat tracing cables and the temperature sensor as shown e 20 W foot 60 W meter is good for typical installations with average insulation e Heating cable has to be placed up to the inlets plate of the H2Smart e Cable has to heat both inl
Download Pdf Manuals
Related Search