User Manual OMS420
Contents
1. 3 Transmitter TOM 420 The transmitter for oxygen monitor TOM 420 is a 4 20 mA intelligent transmitter type with on board micro controller It is used to continuously measure oxygen concentrations in stacks of industrial boilers or furnaces ideally suited for combustion monitoring and control The transmitter is e compact and reliable rugged industrial design e no need for reference air true wet gas analysis e low response time and low energy consumption e micro controller based electronics with on board small LCD for O value and error message e linearized 4 20mA signal output for direct transfer to process PLC or RS485 digital data transfer optionally both analog and digital data transfer e HART interface superimposed to 4 20mA option no local display at HART communication e 2x pushbuttons for calibration and changing of measuring range in 0 5 O steps e field replaceable transmitter and servicing without removing the probe from the stack e dust tight and water proof enclosure easy operation and maintenance 3 1 Specifications measuring task measuring principle life time of ZrO cell warm up time measuring range repeatability linearity accuracy response time output signal power supply ambient temperature ambient humidity case protection dimensions MRU Ltd oxygen contained in non combustible flue gas wet gas analysis direct insertion zirconium cell into the sampl2. Oxygen Monitoring System OMS 420 5 1 MRU ordering numbers for spare parts OMS 420 Prices upon demand 1 O ring Viton 500 60x3 mm 59104 a i 7 Sintered metal filter 18x2 mm CrNi steel 59447 6 Assembly of probe OMS 420 to the stack Connect TOM 420 with flange DN100 PN6 by means of a wrench 36 Please observe correct fit Don t forget copper seal bushing 11 Before installing the probe refer to the drawings to determine the mounting configuration and the hardware re quirements for your installation Vertical mounting of the probe can be used Cut a 110 mm diameter hole in the stack breeching where the probe is to be mounted Measure the thickness of the wall through the hole and add 8 mm Weld a DN 100 carbon steel raised or flat faced flange to the end of the pipe see pipe flange assembly Insert the pipe flange assembly into the hole until the flange facing is 8 mm from the stack wall Tilt the pipe flange assembly approx 5 from horizontal to allow condensation to drain into the stack Weld the pipe flange assembly in place IMPORTANT Insulate the mounting flange to prevent condensation from forming The probe can now be installed Slide the flange gasket over the sensor end of the probe and bring the gasket to the mounting flange Carefully insert the sensor end of the probe through the pipe into the stack and bolt the probe mounting flange and the pipe flange assembly together Caution Whenev
3. until alternates with oud Measurement with a multi meter above the onboard test load resistor 100 Ohm and set the voltage with or to 400 mV Press Mm or g to set the 4 mA exactly read value on the digital multi meter Range of adjustment 0 5 mA The analog output current has to drive a load resistor 0 to 500 Ohms Press Mm and simultaneous leave 4 mA output setting MRU Ltd 18 Oxygen Monitoring System OMS 420 7 8 Adjustment 20 mA output After leaving 4 mA adjustment display alternates with Measurement with a multi meter above the onboard test load resistor 100 Ohm and set the voltage with Mm to 2 000 mV or or Press g to set the 20 mA exactly read value on the digital multi meter Range of adjustment 1 mA The analog output current has to drive a load resistor 0 to 500 Ohms Press Mm and g simultaneous leave 20 mA output setting 7 9 Adjustment measuring range After leaving 20 mA adjustment display alternates with Default setting 25 0 gt 0 O 4 0 mA 25 O 20 mA Press or g to set the range between 4 0 and 32 0 in steps of 0 5 Press Mm and g simultaneous to store and leave adjustment menu back to measurement MRU Ltd 19 Oxygen Monitoring System OMS 420 8 Emergency maintenance 7 ini u no display check power supply check connector E 1 Heating current lt 0 5A New adjustment required Configuration not ok Checksum wrong Please conta
4. EMISSIONSMESSTECHNIK Manufacturer Address MRU Emission Monitoring Systems GmbH Fuchshalde 8 D 74172 Neckarsulm Obereisesheim Tel 49 71 32 99 62 0 Fax 49 71 32 9962 20 Service Hotline 49 7132 9962 59 E Mail info mru de Homepage http www mru de Street address P O Box 2736 D 74017 Heilbronn Express station Heilbronn Hbf self collect 2003_01_17 MRU Ltd 23
5. Q EMISSION MONITORING SYSTEMS We WM out the environment User Manual OXYGEN MONITORING SYSTEM OMS 420 Read and observe before commissioning Ex Situ oxygen analyzer based on ZrO sensor Measuring Instruments for flue gases and environmental protection Ltd Phone 49 7132 9962 0 Fuchshalde 8 Fax 49 7132 9962 20 74172 Neckarsulm Obereisesheim Internet http www mru de Germany E mail info mru de Oxygen Monitoring System OMS 420 ENGLISH Caution Please inspect in the presence of the transporting agent all consignments regarding damages removing possible packing All damages have to be confirmed by the transporting agent and have to be reported within 3 days Otherwise those cannot be accepted Advices Store original packing in order to prevent transportation damages if the device has to be sent in The products described in this manual are subject to a continuous development and amelioration Therefore this manual may be incorrect or incomplete We appreciate every customer feedback comments and suggestions re garding our product and its operation manual You can reach us MRU GmbH Fuchshalde 8 74172 Neckarsulm Obereisesheim GERMANY Tel 49 71 32 99620 Fax 49 71 32 996220 Email info mru de Homepage www mru de This manual is intended as instruction for the use of the product MRU is not liable for damages caused by incorrect interpretation of information taken of this man
6. corrosive gas silicone vapor alkaline metals P Pb high SO etc will shorten the life of the sensor MRU Ltd 4 Oxygen Monitoring System OMS 420 2 Principle of the ZrO2 sensing element Stabilized zirconium ZrOz is used as a ceramic solid electrolyte This ceramic is a good oxygen ion conductor at temperatures around 850 C generated by an on board low power heater element Zirconium oxide electrolyte Reference gas Electrocatalytic surface The electro motive force emf that is generated across the solid electrolyte by the passage of oxygen ions can be measured as a sensor voltage U U BI In Pan offset voltage for Pos rer Pozsampke 02 sample universal gas constant zirconium temperature Faraday constant Pore oxygen partial pressure reference side P o2sampie oxygen partial pressure sample side This voltage is measured by a local micro controller based transmitter electronics and translated into a stan dard 4 20 mA signal linearized for oxygen measuring range 0 25 Lifetime of this sensor is about 5 years and more and do not depends of the used fuel type but CAUTIONS e If combustible gas CO Hz HC exists in the sample gas error will occur due to local combustion at the sensors hot surface e The inclusion of corrosive gas silicone vapor alkaline metals P Pb high SO etc will shorten the life of the sensor MRU Ltd 5 Oxygen Monitoring System OMS 420
7. ct your dealer respectively the manufacturer Heating current lt 0 5A and configuration wrong Transmitter does not react with Clean the sintered metal filter sample gas from stack Transmitter does not react with test Please contact your dealer respectively the manufacturer gas MRU Ltd 20 Oxygen Monitoring System OMS 420 9 OMS 420 Ordering code OMS420 xD xx Tx x LX xX X X for low dust flue gas HD _ for high dust flue gas for flow guidance model AP for air jet pump model for sample pump model T1 for temp lt 600 C T2 for temp lt 1100 C T3 for temp lt 1700 C S for sintered metal filter 0 for no filter L1 for 500mm tube length L2 for 750mm tube length L3 for 1 m tube length L4 for gt 1m tube length Cc for control amp display unit AE1100 0 for no control unit transmitter probe only 1 for 4 20mA analog output 2 for RS485 digital output 3 for HART digital output for no pneumatic unit 1 for pneumatic unit automatic calibration for pneumatic unit high dust probe MRU Ltd 21 Oxygen Monitoring System OMS 420 10 Options 10 1 Control and display unit CU 420 Separate user manual 10 2 Pneumatic unit PU 420 Separate user manual MRU Ltd 22 Oxygen Monitoring System OMS 420 11 Appendix 11 1 Addresses Your contacts to MRU gt x
8. e gas more than 5 years in normal conditions min 10 minutes 0 to 25 change of measuring range in 0 5 0 steps within 1 0 of full scale better than 1 of full scale 0 2 or 2 of reading whichever is larger lt 10 sec from calibration gas inlet port 4 to 20 mA max 500R load or RS485 with PC software or HART 24 Vdc 1 A 20 C to 50 C 0 to 95 non condensing IP 65 NEMA 4 100 x 95 x 65 mm with tube 200 x 32 mm Oxygen Monitoring System OMS 420 3 2 Terminal assignment of plug in connector TOM 428 ROUND CONNECTOR FOR CABLE 4 20mA D R max 5808R ROUND PLUG JACK SCREN SIDE VIEN Wiring Remove probe cap cover and attach two pair 24 AWG cable to the four pin electrical connector drawings Terminate the other end of the 24 AWG cable at the control unit according to drawings The power should be bought in through separate conduit provide circuit breakers for the control unit 3 3 Connection to electronic board of the Zirconium sensor Sensor signal Sensor heater white Power supply Analog output MRU Ltd 7 Oxygen Monitoring System OMS 420 4 Illustration probe OMS 420 LD FG TOM 420 Flange DN 100 Calibration inlet port Outlet sample tube f Inlet sample tube MRU Ltd Oxygen Monitoring System OMS 420 5 Probe construction rn A ee PS SSOSSSSSSSSSSSSSSSSSSSSSSSS e INH MRU Ltd
9. er the probe is inserted or extracted in a hot stack it must be done a few cm s at a time to prevent damage due to thermal shock MRU Ltd 10 Oxygen Monitoring System OMS 420 6 1 Assembly at the exhaust channel The probe for oxygen monitoring system OMS 420 will be mounted to the stack by means of a mounting flange as shown in the drawing below flange DN 100 PN6 Steel stack Pipe DN 100 PN6 TOM 420 Calibration gas inlet illustration pipe flange assembly supplied by customer MRU Ltd 11 Oxygen Monitoring System OMS 420 6 1 1 Mounting guidelines vertical stack vertical stack correct 6 1 2 Mounting guidelines horizontal stack horizontal stack AZIZ ALAA Clean the surface of the tube and drill a hole with a diameter of 110 mm into the exhaust channel Fix the tube with few welding points adjust it correctly and weld it completely to the steel skin of the stack MRU Ltd 12 Oxygen Monitoring System OMS 420 7 Operation 7 1 Flow chart press press gt 10 sec gt 10 sec press gt 10 sec MRU Ltd 13 Oxygen Monitoring System OMS 420 7 2 Start up Before start up please verify with the following check list if all conditions are complied for the failure free opera tion of the transmitter Checklist transmitter e Cast cover closed and screwed e Transmitter well accessible and visibly mounted e Ambient temperature within range to 20 to 50 C e Correct locat
10. ion of transmission cable not beside power cable e Connection for power supply connected properly e Signal connection connected properly e Power supply factory provided mains fuse switched on e Start up considerations Incorrect wiring Most problems are due to incorrect wiring Please double check the wiring Shields must be grounded as shown in the drawings do not ground at any other points Leaks Check all air lines for any leaks especially the calibration gas lines The calibration gas inlet must be closed off to ambient air at all times other than when checking for 20 9 oxygen Insulation Check that the mounting flange has been well insulated to prevent condensation forming Check that all electronic boards are in place before the power is turned on 73 Warm up Duration of the warm up min 10 minutes During the warm up time in alternation the measured O value and a countdown of the Warm up is displayed gt H Heat In case of an error display will show F Error 1 Heating current gt 0 5 A sensor element defect E g Error 2 Configuration not ok Checksum wrong new adjustment required E J Error 3 Heating current gt 0 5 A and Configuration not ok Checksum wrong MRU Ltd 14 Oxygen Monitoring System OMS 420 7 4 Calibration 7 4 1 Adjustment of Oxygen Reference Value A testing gas cylinder will be connected to the calibration gas inlet port for adjustment of transmitter Manuall
11. m or W to adjust O to 20 9 Low calibration at O lt 10 O value low lt 15 mV value of sensor gt 0 Press Mm or to adjust O until the reading value is the same as in the gas cylinder Press Mm and g simultaneous to store adjustment and leave calibration mode back to measurement 7 5 Sensor mV Press g until the mV values are displayed This function is also available in the Warm up mode i mV approx 20 9 O ISU mV approx 0 0 O MRU Ltd 16 Oxygen Monitoring System OMS 420 7 6 Amplifier calibration Factory only Connect precision voltage source in place of sensor signal input Set mV values 100 Press Mm or g to set the factor of the amplifier Display value equal to source voltage value Range of adjustment 0 60 to 1 50 Set mV values 10 Press m or m to set the offset of the amplifier Display value equal to source voltage value Range of adjustment 10 mV Press Mm until the mV values of the sensor alternates with Offset and factor influence themselves therefore first factor setting then Offset setting and repeat proce dure once or twice Press and m simultaneous to store adjustment and leave amplifier calibration menu back to manaua ank MRU Ltd 17 Oxygen Monitoring System OMS 420 7 7 Adjustment 4 mA output Taster Power ON LED ie key up 400 0mVS 4mA 2 000 mV 20mA N E Taster y Displa y a key down Press
12. ual or by wrong use of these instructions MRU Ltd 2 Oxygen Monitoring System OMS 420 1 Security Instructions 4 2 Principle of the ZrO2 sensing element 5 3 Transmitter TOM 420 6 3 1 SPO CHICA ONS u nn anudedineatesnctinisladdevaainneinueuadvaanuncsuadeads 6 3 2 Terminal assignment Of plug in connector uussennenennennannnnunnannannnnunnunnununnunnannnn 7 3 3 Connection to electronic board of the Zirconium sensor uueusensnnennennonannennenn 7 4 Illustration probe OMS 420 LD FG 8 5 Probe construction 9 5 1 MRU ordering numbers for spare parts OMS 420 usenssusnnennannnnannannunnnnunnannunn 10 6 Assembly of probe OMS 420 to the stack 10 6 1 Assembly at the exhaust channel unnsennennanennannannnnannennanannunnannnnunnannnnunnannunnn 11 6 1 1 Mounting guidelines vertical stack mnunnnnnnnnnnnannnnnnnennannnnennanann 12 6 1 2 Mounting guidelines horizontal Stack ccceceeeeeceeeeeeceeeeeeeeeeeeeteeteeeeeetees 12 7 Operation 13 7 1 ehn E aT a A EEE a ha 13 7 2 Start Up eesin aaan a Taea aae aaa a aa E aaa pa aaaea aa naaa en aaan aaan i dabaea ai aiea aaia aiaia 14 1 3 Wal UP ee nee en Teen 14 7 4 Gallbralion sauce 15 7 4 1 Adjustment of Oxygen Reference Value uunnsnennsnnnnnnennnnnnennennnnnnnn 15 TDs 1 a E E E 16 7 6 Amplifier calibration Factory Only essensennanennannanunnennanunnunnannnnunnannnnnnannnnenn 17 7 7 Adjustment 4 MA OUtpUt sssssn
13. usennnnununennunennnnunununnunenunnunununnunenennununnnnunenennunennnn ennnen ennen 18 7 8 Adjustment 20 MA Output a ai hai 19 7 9 Adjustment measuring range unssuannensennennunnannunnunnunnnnnnunnunnannunnannunnunnnnnnnnnnnrannannunnn 19 8 Emergency maintenance 20 9 OMS 420 Ordering code 21 10 Options 22 10 1 Control and display unit CU 420 unuensensanennannanunnunnannnnunnannanunnannannanunnunnannnnunnannannn 22 10 2 Pneumatic unit PU 420 0 00 aa na 22 11 Appendix 23 11 1 Addresses Your contacts to MRU nsssenesensennannnnunnannannnnannunnanunnunnannnnunnannannn 23 MRU Ltd Oxygen Monitoring System OMS 420 1 Security Instructions e The O probe may only be used in faultless condition and in accordance with the operation manual e All persons dealing with the installation commissioning operation and maintenance of the device have to be qualified correspondingly and have to strictly observe this operation manual e Arbitrary reconstructions and modifications lead to considerable security risks and are prohibited due to security reasons e Do not let the probe get in touch with the condensate e The O probe may only be installed and put into service by trained qualified personnel e The O probe may not be reached by condensate or spray water e The O probe has always to be supplied with voltage Otherwise condensate formation may occur which will damage the probe e The inclusion of
14. y or automatically via solenoid valves of the optionally pneumatic unit The testing gas air or calibration gas inlets the interstice between sensor and sample tube and afterwards exits via the sintered metal filter If calibration is not used please tightly close the calibration inlet port after the calibration procedure by means of a plug K rper hinterer Klemmring Body back ferrule berwurfmutter nut Dichtring Vorderer Klemmring St tzh lse Conical nipple front ferrule tube insert Blindstopfen plug The transmitter should already have been powered up for at least one hour before Clean air serves as reference gas 20 9vol Os Perform adjustment 1 Purge transmitter with ambient air 30l h on the calibration gas inlet port or remove the transmitter from the probe 2 On fresh air the transmitter TOM 420 output signal should be 17 37 mA readout for 0 25 O measur ing range After commissioning 3 The adjusted value should be checked again after further 12 hours of operation 4 The Oxygen Transmitter TOM 420 now is ready for operation IMPORTANT Only authorized persons or manufacturers trained stuff are allowed to carry out adjust ments on the transmitters electronics MRU Ltd 15 Oxygen Monitoring System OMS 420 Calibration Press ify until the current O value e g and displayed in alternation High calibration O 20 9 O value high gt 15 mV value of sensor lt 0 Press M
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