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model 3030pm portable heated voc analyser operating manual

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1. These codes normally prevent analyser operation SIGNAL GROUP LTD 3030PM MAN Page 55 of 64 Issue 1 01 3030PM OPERATION MANUAL 10 10 1 10 1 1 10 1 2 10 1 3 10 2 10 2 1 10 3 10 3 1 TECHNICAL DESCRIPTION The Flame Ionisation Detector The Model 3030PM Portable Heated Hydrocarbon Analyser is based on the Flame Ionisation Detector FID The flame ionisation detector works by ionising the sample gas using combustion in a hydrogen flame Ions produced in this process are collected at a polarized electrode outside the combustion zone The polarizing voltage across the detector must be high enough to stop any recombination of the electrons and positive ions produced in the flame Ifthe voltage is too low all of the electrons may not reach the collector electrode causing insensitivity and with larger samples non linearity The resultant electrical current proportional to the mass of carbon present in the flame is in the order of 1 pA 10 12 A to 100 nA 10 7 A It is then amplified to produce the analyser signal When the sample gas is composed of gases of different carbon number the detector will respond to the number of carbon atoms present As an example air containing 10 ppm methane and 10 ppm propane will produce a reading of 40 ppm carbon atoms and is numerically equal to 40 ppm methane equivalent The user may calibrate the analyser with a methane or propane standard all readings will then be either methane
2. Press and hold the button marked IGN for four seconds This will ignite the detector flame and cause the IGN light to flash Allow a further ten minutes for the flame temperature to stabilise The IGN light will be on continuously once the flame has been detected If the IGN light goes out after about five minutes the flame either did not light or could not be maintained SIGNAL GROUP LTD 3030PM MAN Page 20 of 64 Issue 1 01 3030PM OPERATION MANUAL 4 2 6 1 If this is the first time the analyser has been switched on since it was plumbed up it is possible that there is air in the fuel lines Repeat the ignition procedure up to five times to ensure that the fuel path is purged of air 4 2 7 Insert the sample probe into your sample point Select SAMPLE 4 2 7 1 If the oven is not at temperature sample will not be selected The SAMPLE light will flash showing that SAMPLE gas is required but ZERO gas will remain selected Wait until SAMPLE is automatically selected when the oven reaches its working temperature 4 2 8 Press RANGE then UP repeatedly until the display shows Auto Wait for the display to change back to concentration You are now able to read hydrocarbon concentration directly from the display in Carbon Number Methane equivalence 4 2 9 If you have the Non Methane option select TOT for total hydrocarbon CH4 for methane or NON for non methane measurement 4 2 10 Unless the analyser was recently calibrated
3. 5 4 3 OPERATION Introduction This section explains how to access all the features analyser s features The fundamentals for basic operation are given in section 4 which should be used as a quick start to getting your concentration measurements The operational function of each key is given in section 6 Use it to find the full and exact key presses required to access a particular function A fast method for setting values is explained in section 6 4 The RS232 port is normally used when the analyser is part of a system and controlled by the Signal Host Controller The commands for remote control via this port use the AK protocol and are detailed in section 8 Those wishing to control the analyser from a PC or other computer and have the facility for creating their own software should study that section Start Up Follow the instructions in section 3 for electrical and pneumatic installation Follow the instructions in section 4 for making the analyser operational Display The front panel will show the concentration in the best possible units for the selected range automatically setting the decimal point as required The bar graph under the numerical display shows the approximate fraction of the range used by the concentration value This is a quick way to determine the need for a change in range The concentration has exceeded the basic range if the numerical display and the bar graph are flashing There is a 15 over range capabilit
4. 2 1 3 2 2 1 4 2 2 2 2 22 D222 2 2 2 2 3 Getting Started Unless you are familiar with the installation of gas analysers we recommend that you read Section 3 up to and including section 3 4 Install the analyser to include all the facilities that you require Read all of section 4 and follow the instructions This will take you through a step by step sequence to allow the measurement of the VOC concentration in your sample gas SPECIFICATION Safety The instrument has been constructed in accordance with prescribed safety standards All hazardous circuits are shielded within the instrument The detector and fuel lines are in ventilated areas A flame sensor overrides the fuel supply turning it off when no flame is present Power Analyser Switchable between 115 Vac and 230 Vac 15 50 Hz or 60 Hz Maximum power consumption 400 W Fuse rating 5 A 115 Vac or 3 15 A 230 Vac Fuse type T HBC Fused IEC 320 plug on rear panel accepts IEC320 sockets Heated line and Controller Fixed 115 Vac or 230 Vac 115 50 Hz or 60 Hz Maximum power consumption 600 W for a 5 m line and 1200 W for a 10 m line Approximately 10 W 120 W m for other line lengths Fuse rating 115 Vac 16 A for both 5 m and 10 m lines 230 Vac 10 A for 5 m and 16 A for 10 m lines Fuse type T HBC Pneumatics SIGNAL GROUP LTD 3030PM MAN Page 8 of 64 Issue 1 01 3030PM OPERATION MANUAL 2 3 1 2 3 2 2 3 2 1 2
5. 6 12 Set Propane Cut Percentage 37 6 13 Set Methane Cut Percentage 37 6 14 Enable Automatic Ignition 37 6 15 Restore Factory Defaults 37 6 16 Indicators 38 7 LOGIC REMOTE CONTROL 41 7 1 Description 41 7 2 Range Control and Indication 42 7 3 Gas Path Control and Indication 42 7 4 Analyser Mode Control and Indication 43 7 5 Calibration Control and Indication 43 7 6 High and Low Concentration Alarms 44 7 7 Sleep Mode Control 44 7 8 Fault Relay 44 SIGNAL GROUP LTD 3030PM MAN Page 5 of 64 Issue 1 01 3030PM OPERATION MANUAL 8 SERIAL PORT CONTROL 45 8 1 Description 45 8 2 General Packet Format 45 8 3 AK Command Packet 46 8 4 AK Acknowledgement Packet 46 8 5 AK Codes 47 9 FAULT CODES 8 6506 6s 6e tee eee 35 9 1 Health Check 55 9 2 Digital logic 55 9 3 Analogue 55 9 4 Internal control 55 9 5 Hardware faults 55 10 TECHNICAL DESCRIPTION 56 10 1 The Flame Ionisation Detector 56 10 2 Catalytic Air Purifier 56 10 3 Detector Gas Control 56 10 4 Sample Bypass System 57 10 5 Heated Sample Manifold 57 10 6 Safety and Flame out Alarm 58 10 7 Methane Non methane Measurement 58 11 ROUTINE MAINTENANCE 59 11 1 Filter Replacement 59 11 2 Calibration 59 11 3 Cutter Efficiency 60 12 ROUTINE SERVICING 61 12 1 Schedule 61 12 2 Service Manual 61 DIAGRAMS Figure Pipe Fitting Assembly 15 Figure 2 Chart Connections 17 Figure 3 Remote Connections 17 Figure 4 Remote Examples 18 Figure 5 RS232 Connections 19 Fi
6. Gases x Serial xxxx Used by Analyser 8 5 28 GRAV Read average max and min concentrations data NA results AV fffff fff MX gegg gggg MN hhhhh hhhh ffff fff average reading gggg ggg Minimum reading hhhh hhh Maximum reading Used by Analyser 8 5 29 GRAD Read average and alignment delay data NA results Av X D0 X D1 X X time in 0 1 seconds Used by Analyser 8 5 30 data GSAD Set average and alignment delay Av X D0 X D1 X results NA X time in 0 1 seconds Used by Analyser 8 5 31 GRLG Read the alarm limits Gx data results Gx Low xxx High xxxx x 0 1 2 for the gas xxx limit in ppm Used by Analyser SIGNAL GROUP LTD 3030PM MAN Page 50 of 64 Issue 1 01 3030PM OPERATION MANUAL 8 5 32 GSLG Set the alarm limits data Gx Low xxx High xxxx x 0 1 2 for the gas xxx limit in ppm results NA Used by Analyser 8 5 33 GRAL Read alarms high low span zero temperature data NA results LA a HA b ZA c SA d TA e a low concentration alarm status b high concentration alarm status c zero cal alarm status d span cal alarm status e temperature alarm status Used by Analyser 8 5 34 GRCL Read calibration state data NA results CS a ZS b SS c a calibration status 0 Not calibrating 1 Zero calibrating only 2 Span calibrating only 3 Zero calibrating before span 4 Not calibrating Basic data installed b zero calibration status 0 No zero calibration 1 Last Zero
7. Page 53 of 64 Issue 1 01 3030PM OPERATION MANUAL 8 5 52 GRXS Return Temperature catalyst set point data NA results T xxx xxx in degrees kelvin Used by Analyser 8 5 53 GSXS Set Temperature catalyst data T nnn nnn in degrees kelvin results NA Used by Analyser 8 5 54 GTEM Return Temperature catalyst data NA results T xxxx xxxx in degrees kelvin Used by Analyser SIGNAL GROUP LTD 3030PM MAN Page 54 of 64 Issue 1 01 3030PM OPERATION MANUAL 9 FAULT CODES 9 1 Health Check 9 1 1 The microprocessor continuously monitors the state or health of the analyser If a condition is detected that the user should be made aware of a warning will be displayed in the form ofan E number Some warnings are not due to an analyser failure but indicate that the analyser is not ready 9 2 Digital logic El Flame out E2 Watchdog timer reset E3 Invalid Linearisation Data E4 Error writing to EEPROM E5 ADC Calibration fault E6 Invalid Configuration Data E30 Manual Function Inhibited 9 3 Analogue E9 Battery failure E10 FID bias voltage error Ell Power supply error 9 4 Internal control E20 Oven temperature outside working limits E21 Internal temperature outside working limits E24 Catalyst temperature outside working limits 9 5 Hardware faults E64 E79 Fault in PIO E144 E159 Fault in ADC E160 E175 Fault in EEPROM E901 Fault in RAM E902 Fault in EPROM E903 Checksum error in EEPROM
8. Relay Relay contacts are available for warning of a fault condition within the analyser The FRCOM common contact will be connected to the FRNC normally closed contact when there is no power to the analyser and when there is a fault or error condition The FRCOM common contact will be connected to the FRNO normally open contact when power is present and there is no fault or error condition detected SIGNAL GROUP LTD 3030PM MAN Page 44 of 64 Issue 1 01 3030PM OPERATION MANUAL 8 2 8 2 1 SERIAL PORT REMOTE CONTROL Description A Signal Host or other computer with at least one serial port and running dedicated software can be used to control and interrogate the analyser An RS232 serial port on the computer is connected to the serial port on the analyser and is used to transfer commands from the computer to the analyser and the responses from the analyser to the computer Up to eight analysers can be connected to the computer provided that there are enough serial ports and drivers The computer and analyser talk to each other using a very structured protocol to ensure that commands cannot be misunderstood The remote control protocol follows the standard known as AK which has been specified by the German automobile industry It is based on the master slave principle The host computer is the master and the analysers are the slaves Each analyser is connected to the host via an individual RS232 link The host master issue
9. SET LO AL HI AL UP and DOWN keys to set alarm trip levels for this mode Non Methane is the difference between the Total and CH4 modes The analyser is automatically sequenced between these modes and the difference is calculated This is transparent to the user The key is disabled if the Nonm Methane option is not fitted IGN This key ignites the detector flame While held it enriches the fuel air ratio for optimum ignition It should be pressed for about four seconds to allow the enriched mixture to come in contact with the igniter Ignition is not possible if the oven temperature is below 120 C The key is inhibited until the oven temperature is above 120 C RANGE Press to show the full scale range of the concentration display and chart recorder output Used with the UP and DOWN keys to change the range The displayed units will be PPM CAL 6 2 10 1 Press for three seconds to start a calibration A zero calibration will be performed if zero gas path is in use a span calibration will be started if the span gas path is in use and both a zero and span calibration will be started if the sample gas path is in use Any calibration can be cancelled by pressing CAL for a further three seconds Calibration is inhibited if the flame is not lit Used with the SET UP and DOWN keys to set an automatic calibration interval SIGNAL GROUP LTD 3030PM MAN Page 30 of 64 Issue 1 01 3030PM OPERATION MANUAL 6 2 11
10. TEMP 6 2 11 1 Used to monitor the oven and convertor temperatures A single press on this key shows either the oven or catalyst temperature a second press before the display reverts to concentration shows the other temperature The top right display will show units and the monitored item A display of C OV is the oven temperature in C and C CA is the catalyst temperature in C Used with the SET UP and DOWN keys to change a temperature control point Nominal oven and convertor temperatures and their adjustment ranges are given in section 2 6 2 12 UP 6 2 12 1 Used to increase a parameter value or to select a higher less sensitive range when used with the RANGE CAL TEMP SET HI AL or LO AL keys A fast set mode is available on most functions 6 2 13 DOWN 6 2 13 1 Used to decrease a parameter value or to select a lower more sensitive range when used with the RANGE CAL TEMP SET HI AL or LO AL keys A fast set mode is available on most functions 6 2 14 LO AL 6 2 14 1 Displays the low alarm trip point setting A display of means that the alarm is off Used with the SET UP and DOWN keys to set the trip point 6 2 15 HI AL 6 2 15 1 Displays the high alarm trip point setting A display of means that the alarm is off Used with the SET UP and DOWN keys to set the trip point 6 2 16 REMOTE 6 2 16 1 Allows or disables control from a host compu
11. a 5 m line and controller The sample manifold in the Model 3030PM is controlled to within 1 C of the set temperature by sensing with a thermocouple and using a proportional band temperature controller The control system is designed to maintain the sample capillary which is attached directly to the sample manifold at a very steady temperature in order to minimise detector drift SIGNAL GROUP LTD 3030PM MAN Page 57 of 64 Issue 1 01 3030PM OPERATION MANUAL 10 5 3 10 5 4 10 6 10 6 1 10 7 10 7 1 10 7 2 The sample manifold houses a 0 4 micron 0 4 um glass fibre filter secured with a bayonet type fixing The filter will prevent particulate matter entering the sample system The sample gas then passes through a solenoid valve which is attached to the sample manifold and therefore heated This valve is used to switch off the sample flow when calibration is required The sample pump head is also incorporated into the heated sample manifold to prevent sample condensation Bypass air is supplied by the second head of the sample pump Hydrocarbor free air for the FID and zero gas is supplied by passing a portion of the bypass air supply through the catalytic air purifier Safety and Flame out Alarm The analyser is designed to minimize the possibility of a dangerous build up of fuel gas It is ventilated so that any possible fuel leak cannot collect inside The fuel solenoid is also shut when the analyser is switched o
12. calibration Successful 2 Last Zero calibration Unsteady 3 Last Zero calibration Outside limits c Span calibration status 0 No Span calibration 1 Last Span calibration Successful 2 Last Span calibration Unsteady 3 Last Span calibration Outside limits Used by Analyser 8 5 35 GRGE Read cutter efficiencies data NA results FO aa Fl bb aa Gas 0 CH4 efficiency bb Gas 1 TOT efficiency 8 5 36 GSGE Set cutter efficiencies data FO aa Fl bb results NA aa Gas 0 CH4 efficiency bb Gas 1 TOT efficiency SIGNAL GROUP LTD 3030PM MAN Page 51 of 64 Issue 1 01 3030PM OPERATION MANUAL 8 5 37 GRAR Return Auto ignition state count max data NA results RS a RC b MR c a status ON OFF 1 0 b Current ignition count c Maximum allowable re ignition Used by Analyser 8 5 38 GSAR Set Auto ignition state data io 0 1 I ON results NA Used by Analyser 8 5 39 GSIS Set Ignition on or off data io 0 1 1 ON 0 OFF results NA Used by Analyser 8 5 40 GSPS Set Pump on or off data io 0 1 1 ON 0 OFF results NA Used by Analyser 8 5 41 GSTS Set Temperature oven data T nnn nnn in degrees kelvin results NA Used by Analyser 8 5 42 GSAC Abandon the calibration data NA results NA Used by Analyser 8 5 43 GRFS Return the Flameout state data NA results io 0 1 1 Flame out Used by Analyser 8 5 44 GRPS Return the Pump state data NA results io 0 1 1 ON Used by A
13. flame conditions exist the sample path will be selected Used with the CAL key to perform both span and zero calibration SPAN Selects the span gas port for measurement Used with SET and CAL keys to calibrate the analyser SIGNAL GROUP LTD 3030PM MAN Page 29 of 64 Issue 1 01 3030PM OPERATION MANUAL 6 2 4 6 2 4 1 6 2 5 6 2 5 1 6 2 6 6 2 6 1 6 2 7 6 2 7 1 6 2 8 6 2 8 1 6 2 9 6 2 9 1 6 2 10 ZERO Selects the air inlet port for measurement The air inlet port is fed to a catalytic convertor to remove hydrocarbons allowing normal ambient air to be used as a zero gas for most applications Used with SET and CAL keys to set the zero point of the analyser CH4 This key selects Methane as a measurement and display mode CH4 Itis used with the SET LO AL HI AL UP and DOWN keys to set alarm trip levels for this mode and with the SET UP and DOWN keys to set the Methane cut percentage The key is disabled if the Non Methane option is not fitted TOT This key selects Total Hydrocarbon as a measurement and display mode THC Itis the default mode if the Non Methane option is not fitted It is used with the SET LO AL HI AL UP and DOWN keys to set alarm trip levels for this mode and with the SET UP and DOWN keys to set the Propane cut percentage NON This key selects Non Methane as a measurement and display mode NMHC It is used with the
14. is past the upper limit for the range in use 6 16 2 Chart Recorder Bar Graph 6 16 2 1 This is a horizontal bar graph immediately underneath the General Numeric Display and within the same window It represents the fraction of the chart recorder range being used For the Non Methane option it can only show the fraction for the current displayed mode If NON is selected the bar graph will show the fraction of the Non Methane channel 6 16 2 2 The bar graph will flash if the concentration is above the upper limit for the range in use 6 16 3 Gas Type 6 16 3 1 This shows the gas or measurement mode in current use It is located in the bottom right of the window It will flash if a high or low alarm is detected 6 16 4 FAULT 6 16 4 1 This indicator glows when a fault or warning condition has been detected The code will be flashed on the General Numeric Display for a period of two seconds and revert to concentration for ten seconds 6 16 5 AUTO 6 16 5 1 This indicator glows when automatic range changing has been selected 6 16 6 SAMPLE 6 16 6 1 This indicator glows when Sample gas is selected and its concentration is displayed It will flash if Sample gas has been selected but due to a cold oven or loss of flame cannot be allowed Zero gas will be used until the correct conditions for Sample gas are present The gas path will return to Sample as soon as analyser conditions allow SIGNAL GROUP LTD 3030PM MAN Page 38 of 64 Issue 1
15. its working temperature the ZERO path will be selected The ZERO indicator will glow and the SAMPLE indicator will flash When the oven is at its working temperature the sample path will automatically change from ZERO to SAMPLE allowing sample measurement This protects the sampling system from hydrocarbons condensing in a cold oven Logic outputs and inputs available on the front panel REMOTE connector allow the analyser to report and control the gas path Refer to section 7 for full details on using this facility Gases entering via the SAMPLE path are filtered using a 0 4 micron 0 4 um glass fibre filter to remove particulate the might block the sample path This filter will require changing at intervals depending on the amount of particulate present in the sample Refer to section 11 1 for filter replacement instructions Calibration While in the SAMPLE mode a full calibration of both zero and span can be started by pressing CAL and is confirmed when the CAL light glows This will cause a zero calibration followed by a span calibration The CAL light will turn off when the calibration is complete During the zero calibration the ZERO light will glow and the display and chart outputs will show the offset on each range starting at the highest and working down prior to resetting them to zero This allows any offset to be recorded and taken into account when evaluating the results During the span calibration the display and chart ou
16. load restrictions The pneumatic and electrical connectors are found on the front and rear panels If you do not have an analyser in front of you while reading this manual refer to the fold out diagrams on pages 53 and 54 SIGNAL GROUP LTD 3030PM MAN Page 13 of 64 Issue 1 01 3030PM OPERATION MANUAL 3 2 3 2 1 3 3 3 3 1 3 3 1 1 3 3 2 3 3 3 3 3 3 1 3 3 3 2 3 3 3 3 3 3 4 3 3 4 1 3 3 4 2 3 3 4 3 3 3 4 4 Location The analyser and heated line controller should be placed in a dry and sheltered location out of direct sunlight avoiding drafts and protected from rain All mains power connections must be protected from water ingress Mains Power Connection The analyser is supplied with a 2 m long mains lead with an IEC320 socket at one end for connection to the analyser The other end should be connected to a mains plug to suit the local supply Check the local mains voltage and set the Voltage Selector switch on the rear panel to 115 V or 230 V according to the supply The 540 heated line controller is factory set to suit the mains voltage requested on the order It comes with an attached mains lead The free end should be connected to a mains plug to suit the local supply Standard Wiring Connect the BROWN wire to the LIVE L pin Connect the BLUE wire to the NEUTRAL N pin Connect the GREEN amp YELLOW wire the EARTH E pin Portable Safety Isolating Transformer Supplies Connect the B
17. or propane equivalent respectively An important characteristic of the flame ionisation detector is the variation in detector response with changes in oxygen concentration in the sample gas This effect is normally only found in the analysis of combustion gases It requires a special fuel consisting of 40 hydrogen and 60 helium To compensate for the lower concentration of hydrogen an analyser using a hydrogen helium mix requires a greater x3 fuel flow Each analyser is built to be used witha specific fuel option A 100 hydrogen fuel is used for applications rich in oxygen The fuelcapillary may be changed to the alternative option and this may be arranged through the local Signal sales office or distributor Catalytic Air Purifier In order to give a stable signal the FID requires a supply of clean hydrocarbor free air As anaid to portability the analyser air is supplied from a built in pump As there is a possibility of the ambient air being contaminated with hydrocarbons it is passed over an internal platinum catalyst on an alumina substrate at high temperature Air passed through the catalytic air purifier is also used as zero gas during calibration Detector Gas Control The stability of the air and fuel flows to the detector are important to maintain detector stability and sensitivity The optimum performance of the detector is particularly dependent on the ratio of hydrogen to sample gas flow rate since this ratio affects the f
18. progress by taking the ACAL input Low for a minimum of two seconds the returning it High The calibration details will not be updated While calibration is in progress the CIP output will go Low and the READY output will go High If the calibration fails the CFAIL output will go Low and remain there until a satisfactory calibration is obtained or until the factory default values are restored SIGNAL GROUP LTD 3030PM MAN Page 43 of 64 Issue 1 01 3030PM OPERATION MANUAL 7 6 7 6 1 7 6 2 7 7 7 1 1 7 8 High and Low Concentration Alarms HIAL and LOAL are two outputs representing the state of the high and low alarms A Low level on the HIAL line indicates that the concentration is above the high alarm trip value and a Low level on the LOAL line indicates that the concentration is below the low alarm trip value When the Non methane option is fitted alarms can be set for each of the three modes TOT NON CH4 The HIAL and LOAL outputs refer to the selected mode only using the thresholds set for that mode Sleep Mode Control If the SLEEP input is taken Low the analyser is placed into a sleep or standby mode The pump and fuel will be turned off Oven and Catalyst temperatures will be maintained When the SLEEP input is released or taken High the pump and fuel will be switched on If auto ignition was enabled automatic re ignition will occur allowing the analyser to become active within a few minutes Fault
19. state The highest point is 15 above the highest range 11500 ppm A further press on the DOWN key when a value of O is set will turn the low alarm off and the display will show 6 11 1 2 The Non Methane option allows a low alarm trip point for each mode TOT NON and CH4 Use mode SET LO AL SET as required SIGNAL GROUP LTD 3030PM MAN Page 36 of 64 Issue 1 01 3030PM OPERATION MANUAL 6 11 1 3 A fast way to turn the low alarm off is to reset to the factory default Press SET LO AL lt UP amp DOWN together gt SET 6 12 Set Propane Cut Percentage 6 12 1 SET TOT SET 6 12 1 1 Set the propane cut percentage PERC as calculated during a cutter calibration procedure or as given in the test sheet A display of 2 means that 2 of the propane was left after passing through the cutter 6 13 Set Methane Cut Percentage 6 13 1 SET CH4 SET 6 13 1 1 Set the methane cut percentage PERC as calculated during a cutter calibration procedure or as given in the test sheet A display of 98 means that 98 of methane was left after passing through the cutter 6 14 Enable Automatic Ignition 6 14 1 SET IGN SET 6 14 1 1 Use the UP or DOWN keys to toggle between enable and disable modes A display of shows that automatic ignition is disabled A display of 0 to 4 shows that automatic ignition is enabled and the value shows the number of ignition attempts made so far The value i
20. the concentration value may not be as accurate as you require Press SET CAL Check that the displayed value agrees with the span calibration certificate If the value is the same press SAMPLE to return to measurement mode If not press UP or DOWN to change the displayed value then press SET as confirmation There is a faster way of changing the value if the required value is very different from the required one Refer to section 6 4 for full instructions 4 2 11 After checking the calibration value press CAL Calibration always occurs using the TOT mode A full zero and span calibration will occur During this time the CAL light will glow and the ZERO and SPAN lights will glow as each type of calibration is performed If the CAL light flashes at the end of the calibration procedure a fault in calibration was encountered and corrective action is required 4 2 11 1 If a zero calibration failure occurred check that catalyst temperature has reached its working temperature by pressing TEMP If the top right display shows C OV press TEMP again until C CA is displayed Check that the analyser is not located where a high hydrocarbon background is present The analyser can remove up to 500 ppm Methane equivalent from the ambient air but higher concentrations will cause a zero offset Use bottled air connected to the air inlet port if necessary 4 2 11 2 If a span failure occurred check that the SPAN cylinder valve has been opened a
21. used in all future calculations If no change to a digit is required press the parameter key to move to the next less significant digit 6 4 3 Some parameters have maximum or minimum values that can be set If a digit is changed that would take the value above the maximum or below the minimum the display will show the maximum or minimum value 6 4 4 To abandon a change for either method press SAMPLE instead of the final SET Any value on the display is ignored and the original value will be used in all future calculation 6 4 5 A parameter value can be viewed by pressing SET param The display will show the current value Press SAMPLE to revert to the concentration display SIGNAL GROUP LTD 3030PM MAN Page 33 of 64 Issue 1 01 3030PM OPERATION MANUAL 6 4 6 6 4 7 6 5 6 5 1 6 5 1 1 6 5 1 2 6 5 1 3 6 5 1 4 If no key is has been pressed within the last thirty seconds the operation is cancelled and the original value used in all future calculations Parameters can have special requirements or limitations to their use All settable parameters are detailed below All follow the general setting routines above unless otherwise stated Set Range RANGE or SET RANGE The display shows the full scale concentration for the current range Use the UP and DOWN keys to select a range The display will show the full scale range in units of PPM It is not necessary to press the SET key a final time to conf
22. 01 3030PM OPERATION MANUAL 6 16 7 SPAN 6 16 7 1 This indicator glows when Span gas is selected and its concentration is displayed and while setting the span gas concentration It will flash if the last span calibration failed 6 16 8 ZERO 6 16 8 1 This indicator glows when Zero gas air inlet port is selected and its concentration is displayed It will flash if the last zero calibration failed 6 16 9 RANGE 6 16 9 1 This indicator glows when the display is showing range information 6 16 10 CAL 6 16 10 1 This indicator glows when either manual or automatic calibration is in progress and while setting the auto cal interval It will flash if the last calibration zero or span failed and until a valid calibration is achieved or the factory default calibration values are restored 6 16 11 TEMP 6 16 11 1 This indicator glows when the display is showing temperature information and flashes if the displayed temperature oven or catalyst is outside the working limits 6 16 12 SET 6 16 12 1 This indicator glows while parameter values are being changed 6 16 13 LO AL 6 16 13 1 This indicator glows if a low limit has been set for the current mode and flashes if the measured value is less than the set value The alarm is inhibited during calibration 6 16 14 HI AL 6 16 14 1 This indicator glows if a high limit has been set for the current mode and flashes if the measured value is greater than the set value The alarm is inhibited
23. 2 11 Repeatability 10 2 12 Response 10 2 13 Bypass Flow Sensitivity 10 2 14 Zero Drift 10 2 15 Ambient Temperature Effect 10 2 16 Detector Noise 10 2 17 Linearity 11 2 18 Carbon Number Correlation 11 2 19 Oxygen Synergism 11 2 20 Methane Cutter optional 11 2 21 Analogue Outputs 11 2 22 Fault Relay 12 2 23 Digital Inputs 12 2 24 Digital Outputs 12 2 25 Serial Interface 12 3 INSTALLATION swo 6 were 13 3 1 Introduction 13 3 2 Location 14 3 3 Mains Power Connection 14 3 4 Gas Connections 15 3 5 Chart Connections 17 3 6 Remote Connections 17 3 7 RS232 Socket Connections 19 3 8 RS232 Defaults 19 3 9 RS232 Configuration 19 SIGNAL GROUP LTD 3030PM MAN Page 4 of 64 Issue 1 01 3030PM OPERATION MANUAL 4 BASIC OPERATION 20 4 1 Installation 20 4 2 Operation 20 4 3 Decommissioning 22 5 OPERATION 4 46 5 00646s4 23 5 1 Introduction 23 5 2 Start Up 23 5 3 Display 23 5 4 Range Controls 23 5 5 Sample 24 5 6 Calibration 24 5 7 Concentration Alarms 25 5 8 Non Methane Option 25 5 9 Fault Relay 26 5 10 Converting To Other Units 27 5 11 Remote Control 28 5 12 Hydrogen Fuel 28 6 ANALYSER CONTROLS 29 6 1 Philosophy 29 6 2 Basic Key Functions 29 6 3 Calibration Key Sequences 32 6 4 Set Parameter Key Sequences 33 6 5 Set Range 34 6 6 Set Span Gas Concentration 35 6 7 Set Automatic Calibration Period 35 6 8 Set Oven Temperature 36 6 9 Set Catalyst Temperature 36 6 10 Set High Alarm 36 6 11 Set Low Alarm 36
24. 30PM OPERATION MANUAL 5 11 Remote Control 5 11 1 The analyser can be placed in remote control by pressing REM The REM light will flash unless a remote enable has been received via the RS232 line or a logic enable line has been taken Low Full descriptions of the remote operation are given in sections 8 for RS232 and 7 for logic control Also refer to section 3 for installation requirements 5 12 Hydrogen Fuel 5 12 1 Pure hydrogen may be used as a fuel where the oxygen content of the sample is close to that of normal air and where it does not vary significantly during the monitoring period 5 12 2 The use of hydrogen fuel requires changes to the sample and fuel flow rates which can only be done at the factory Contact our Service department or local representative SIGNAL GROUP LTD 3030PM MAN Page 28 of 64 Issue 1 01 3030PM OPERATION MANUAL 6 6 1 6 1 4 6 2 6 2 1 6 2 1 1 6 2 2 6 2 2 1 6 2 3 6 2 3 1 ANALYSER CONTROLS Philosophy The front panel controls are based on function There are no menu structures to complicate the display or set procedures Most functions allow a parameter to be read and using a second key allow the parameter value to be changed or to perform a task As an example a typical function is the SPAN key If SPAN is pressed the span gas is selected and the display will show the concentration To perform a span calibration press SPAN followed by CAL To enter the actual
25. 322 2 3 3 2 3 3 1 2 332 2 3 4 2 3 4 1 233 2 3 5 1 2 3 5 2 2 4 2 4 1 2 5 2 5 1 Fuel and calibration gas connections use 4 6 35 mm tube and self sealing quick connects Sample gas connections use 4 6 35 mm tube and fittings Fuel Required fuel is a 40 Hydrogen 60 Helium mixture The analyser can be adapted at the factory to use pure Hydrogen This requires changes to the fuel and sample flow rates Miniature regulated fuel bottle with one litre capacity An alternative fuel source can be used It must provide an input pressure from 25 psi to 35 psi 1 7 bar 170 kPa to 2 4 bar 240 kPa and a flow of 180 ml min 40 H2 60 He or 60 ml min H2 Air An internal pump and catalytic air purifier provides 600 ml min hydrocarbon free detector air and sufficient zero calibration gas from local ambient air Local air must have less than 500 ppm Methane equivalent hydrocarbon content to be usable An AIR INLET port on the rear panel allows bottled air to be used The inlet pressure should be raised by 0 5 psi 35 mbar 3 5 kPa above ambient for each 10 m length of piping DO NOT EXCEED 10 psi 690 mbar 69 kPa pressure measured at the inlet port Span Calibration Gas Miniature regulated calibration gas bottle with one litre capacity Calibration gas concentration is 500 ppm Methane in Air An alternative calibration gas source with a different concentration to suit the application can be used It m
26. 4 3 There are various different acknowledgement packets OK Acknowledgement If the received command was understood and processed by the slave the format of the acknowledgement is lt STX gt lt x gt lt CODE gt lt space gt lt error gt data lt ETX gt Where the data area contains the response to the command Offline Acknowledgement If the Analyser is offline i e not in remote mode the acknowledgement is lt STX gt lt x gt lt CODE gt lt space gt lt error gt lt space gt lt K gt lt 0 gt lt space gt lt 0 gt lt F gt lt ETX gt The command will be ignored Busy Acknowledgement If the Analyser is busy i e not ready to accept and process a new command the acknowledgement is lt STX gt lt x gt lt CODE gt lt space gt lt error gt lt space gt lt K gt lt 0 gt lt space gt lt B gt lt S gt lt ETX gt The command will be ignored 8 4 4 The Data Field The data field may be from 0 to 99 characters long Every data value will be preceded by a space lt CR gt and lt LF gt characters may also be used as separators 8 5 AK Codes 8 5 1 SRES Reset data NA results NA Used by Analyser host gas divider 8 5 2 STBY Standby Flame off pump off oven and catalyst at temperature data NA results NA Used by Analyser host gas divider 8 5 3 SPAU Pause data NA results NA Used by Analyser host gas divider SIGNAL GROUP LTD 3030PM MAN Page 47 of 64 Issue 1 01 3030PM OPERATION MANUAL 8 5
27. 4 SARE Auto range On data NA results NA Used by Analyser 8 5 5 SARA Auto range Off data NA results NA Used by Analyser 8 5 6 SEMB Set Range data Mx x 0 for auto range results NA x range number Used by Analyser 8 5 7 SMGA Set Sample gas data NA results NA Used by Analyser host 8 5 8 SNGA Set Zero gas data NA results NA Used by Analyser host 8 5 9 SEGA Set Span gas data NA results NA Used by Analyser host 8 5 10 SATK Calibrate equivalent to front panel SAMPLE CAL data NA results NA Used by Analyser host 8 5 11 SREM Enable Serial Remote Control data NA results NA Used by Analyser host gas divider 8 5 12 SMAN Disable Serial Remote Control data NA results NA Used by Analyser host gas divider 8 5 13 SMFR Set NON mode only possible with the non methane option data NA results NA Used by Analyser SIGNAL GROUP LTD 3030PM MAN Page 48 of 64 Issue 1 01 3030PM OPERATION MANUAL 8 5 14 SHCG Set TOT mode total hydrocarbon data NA results NA Used by Analyser 8 5 15 AKON Return Measured Value as shown on the front panel display data NA results ffff fffff Used by Analyser 8 5 16 AANG _ Return Zero point error Range Value PPM Error Error data NA results Mx xxxx xXXx XXXX XXX XX for each range Used by Analyser 8 5 17 AAEG Return Full scale error Range Value PPM Error Error data NA results Mx XXX
28. MODEL 3030PM PORTABLE HEATED VOC ANALYSER OPERATING MANUAL Signal Group Limited 12 Doman Road Camberley Surrey GU15 3DF England Tel 44 0 1276 682841 Fax 44 0 1276 691302 e mail instruments signatgroup com Part Number 3030PM MAN Issue 1 01 3030PM OPERATION MANUAL ADDENDUM TO 3030PM OPERATING MANUAL Carbon Trap Maintenance From 1994 analysers used in an environment with a high hydrocarbon ambient background may be fitted with an additional carbon trap before the air purifier The carbon granules must be changed after a period of one year to ensure efficiency This period may need to be reduced if a very high background is encountered You will need a refresh pack of carbon granules Part number CHEM 002 Disconnect the analyser form the mains supply and disconnect all external plumbing 2 Remove the eight analyser cover screws and lift the cover clear 3 Identify the in line fitting connecting a blue filter to the carbon trap and using one spanner on the fitting body and another on the nut disconnect the fitting from the carbon trap a Remove the screws securing the carbon trap to the rear panel and withdraw the trap 5 Remove the domed nuts from one end of the assembly Holding the assembly with the barrel vertical remove the end cap Discard the carbon granules Remove clean and replace the two filters 6 Add the contents of the refresh pack and re assernble in the reverse order ensuring that the fi
29. ROWN wire to one output Connect the BLUE wire to the other output Connect the GREEN amp YELLOW wire to the transformer earth The earth must be continuous back to the mains supply or a local earth must be provided Transformers with an earthed centre tap can be used Connect the GREEN amp YELLOW wire to the centre tap or earth point SIGNAL GROUP LTD 3030PM MAN Page 14 of 64 Issue 1 01 3030PM OPERATION MANUAL 3 4 3 4 1 3 4 2 3 4 3 3 4 3 1 3 4 3 2 3 4 4 3 4 4 1 3 4 4 2 3 4 5 3 4 5 1 Gas Connections The analyser is a very sensitive detector of hydrocarbons Itis very important not to connect contaminated tubing to the instrument Contaminated tubing KED z can be cleaned by heating in an oven at i GR X NJ 200 C for at least two hours while passing clean air through the tube 6 35 mm O D tube is required for all connections 0 060 1 5 mm wall PTFE tube is recommended Slide the nut and ferrule over the tube The tubing should be inserted into the tube fitting aperture and held firmly against the end stop The nut should be rotated clockwise until it is finger tight Tighten the nut a further 1 turns witha 9 16 14 3 mm A F spanner When connections are remade it is only necessary to tighten the nut slightly with the spanner after making it finger tight Figure 1 Pipe Fitting Assembly Fuel Place the fuel cylinder in the right hand section
30. X XXX XXXX XXX XX for each range Used by Analyser 8 5 18 ASTF Return Error Status Equipment error code s data NA results x xx list of all current error codes Used by Analyser 8 5 19 AEMB Return Selected Range Current analyser range data NA results Mx x to 8 Used by Analyser 8 5 20 AMBE Return Range Full Scale Range FSD data NA results MX xxxx xx xxxx xXX in ppm for each range Used by Analyser 8 5 21 AMBU Return Auto range Threshold Range Lower Upper data NA results Mx xxxx xx XXXX XX in ppm for each range Used by Analyser 8 5 22 AKAK Return Calibration gas concentration Range Cal Gas data NA results Mx Xxxx xxx Used by Analyser 8 5 23 ATEM Return Temperature oven data NA results xxxx xxxx in degrees kelvin Used by Analyser SIGNAL GROUP LTD 3030PM MAN Page 49 of 64 Issue 1 01 3030PM OPERATION MANUAL 8 5 24 AUKA Return Uncorrected values Range uncorrected analogue value data NA results Mx adc fixxxxx Used by Analyser 8 5 25 EKAK _ Set calibration gas concentration Range Concentration data Mx Span xxxx xx concentration in ppm results NA Used by Analyser 8 5 26 GKON Return Measured Values data NA results tttt tttt TOT for standard analyser or cccc cccc tttt tttt nnnn nnnn CH4 TOT NON if non methane option fitted Used by Analyser 8 5 27 GRAN Return Model Serial No and Gas Data data NA results Model x
31. calibration gas concentration from the bottle calibration certificate press SET SPAN and the UP or DOWN keys until the display shows the required value then complete the operation by a final press on SET This intuitive data selection and entry method is easy to learn and leads to fewer mistakes For most functions the display will resume showing the sample concentration if no key has been pressed for about 30s This section describes the function of each key and indicator It makes use of the square brackets to show where a key press is required As an example the key to select Sample measurement would be shown as SAMPLE It also makes use of the brace or curly brackets to indicate a warning number As an example a flame out warning would be shown by E1 Flashing indicators are cautionary signals to show functions which are not ready or that have encountered their limit conditions An operational description of key sequences required for immediate operation is given in section 4 and for full use is given in section 5 Basic Key Functios ON OFF This is the main power and is used to turn the analyser on and off SAMPLE Selects the sample gas port for measurement Sample will not be selected unless the oven is within 15 C of the oven set point and the flame is lit Until this condition exists selecting sample leaves the zero gas active and will set the SAMPLE indicator flashing As soon as the correct oven and
32. calibration settings Connect a calibration bottle containing a known level of Propane in Air 200 ppm to 5000 ppm is recommended but any concentration between 4 ppm to 10 000 ppm can be used to the SPAN input port on the front panel Select the lowest range that will include the cylinder concentration 5 10 1 2 Press ZERO and adjust the ZERO control on the rear panel to display a concentration of zero 5 10 1 3 Press SPAN and adjust the SPAN control on the rear panel to display the cylinder concentration 5 10 1 4 Set the calibration value to the cylinder concentration by pressing SET CAL UP DOWNI SET or by using the fast set facility 5 10 1 5 Press SAMPLE CAL and allow a normal calibration to proceed Always use a propane calibration cylinder 5 10 1 6 Calibration can be returned to Carbon Number equivalence by repeating the above procedure using the original methane in air cylinder 5 10 2 The following conversion table gives the relationship between ppm and mg m3 at STP Standard Temperature and Pressure 101 3 kPa and 0 C and ISA International Standard Atmosphere 101 3 kPa and 15 C The figures in each row are the concentration in alternative units ppm Methane ppm Propane mg m STP mg m ISA Unit Conversion Table 5 10 3 If you are using a chart recorder or data logger with an input scaling facility it can be scaled to record in mg m3 SIGNAL GROUP LTD 3030PM MAN Page 27 of 64 Issue 1 01 30
33. characters except for the following lt STX gt Ascii STX Decimal 2 or Hex 02 lt ETX gt Ascii ETX Decimal 3 or Hex 03 lt CR gt Ascii carriage return Decimal 13 or Hex OD lt LF gt Ascii line feed Decimal 10 or Hex 0A 8 3 AK Command Packet 8 3 1 Commands and data packets are transmitted from the MASTER to a SLAVE 8 3 2 lt STX gt lt x gt lt CODE gt lt space gt lt K gt lt n gt lt space gt data J lt ETX gt Where K Ascii character K n A single digit 0 9 indicating channel number From the Signal Host to the Analysers n is always 0 8 4 AK Acknowledgement Packet 8 4 1 Acknowledgement messages are transmitted from a SLAVE to the MASTER as an acknowledgement to a command packet from the master 8 4 2 The general form of an acknowledgement is lt STX gt lt x gt lt CODE gt lt space gt lt error gt data field lt ETX gt Where space Ascii space character Error A one byte indication of the state of the equipment Ascii 0 No errors Ascii 1 9 cyclic count of errors increasing with each error and decreasing when each error is cleared Eg 1 can mean 1 or 10 or 19 errors CODE The code of the command that was sent if it was understood If received code was not understood CODE in the acknowledgement will contain four question marks i e Data field Dependent upon the command issued SIGNAL GROUP LTD 3030PM MAN Page 46 of 64 Issue 1 01 3030PM OPERATION MANUAL 8
34. commend 3 5 3 5 1 3 5 2 3 5 3 3 5 4 3 5 5 3 6 3 6 1 3 6 2 3 6 3 Chart Connections Identify the 15 way D plug and housing in the accessory kit It connects to the 15 way socket marked CHART on the front panel Chart connector pin allocation is given in Figure 2 A typical installation may use the TOTAL voltage output and the RANGE VOLTAGE output wired directly to an adjacent chart recorder or the TOTAL current output wired to a remote data logger Voltage and current outputs are available at the same time TW DBIS PLG View on rear of connector Figure 2 Chart Connections The RANGE voltage output can be used over long distances Any voltage drop down the line just offsets the trace slightly Range indication does not require great accuracy Analysers fitted with the Non Methane option will have additional CH4 and NON outputs available Remote Connections Identify the 37 way D plug and housing in the accessory kit It connects to the 37 way socket marked REMOTE on the front panel Remote connector pin allocation is given in Figure 3 Typical connections for switch logic and isolated logic are given in Figure 3 The grounded switch method of control is useful where the analyser must be placed in a different area from the control and where only manual control is required Computer or process controllers should use the direct or isolated method of operation Isolated connections
35. during calibration 6 16 15 REMOTE 6 16 15 1 This alarm glows when either serial or logic remote control is active and flashes if remote control has been selected but is not active 6 16 16 PUMP 6 16 16 1 This indicator glows when the internal sample air pump is switched on SIGNAL GROUP LTD 3030PM MAN Page 39 of 64 Issue 1 01 3030PM OPERATION MANUAL 6 16 17 IGN 6 16 17 1 This indicator glows when the detector flame is present and while the auto ignition state is being set It will flash when the ignition button is pressed and until a flame can be detected If no flame is detected within 1 min and provided that all auto ignition attempts have been made the indicator will turn off 6 16 18 TOT 6 16 18 1 This indicator glows when measuring Total Hydrocarbons or when setting the Propane Cut Percentage 6 16 19 NON 6 16 19 1 This indicator glows when measuring Non Methane Hydrocarbons 6 16 20 CH4 6 16 20 1 This indicator glows when measuring Methane or when setting the Methane Cut Percentage SIGNAL GROUP LTD 3030PM MAN Page 40 of 64 Issue 1 01 3030PM OPERATION MANUAL LOGIC REMOTE CONTROL Description A computer with a digital I O capability and running dedicated software or a series of switches and indicators can be used to control the most frequently required functions and display the analyser state The control is not as comprehensive as that provided by serial remote control Range gas path analyser
36. e DB25 SKT Data Bits 8 View on rear of connector Stop Bits Figure 5 RS232 Connections XON XOFF Enabled 3 9 RS232 Configuration 3 9 1 The RS232 port can be configured in other ways Baud rates can be set to 1200 2400 4800 9600 and 19200 parity to none odd or even data bits to 7 or 8 stop bits 1 or 2 XON XOFF on or off This requires access inside the analyser and is not a recommended user procedure If you require other settings contact our Service department SIGNAL GROUP LTD 3030PM MAN Page 19 of 64 Issue 1 01 3030PM OPERATION MANUAL 4 4 1 4 2 4 2 1 4 2 2 4 2 3 4 2 4 4 2 5 4 2 6 BASIC OPERATION Installation The pneumatic and electrical connectors are found on the front and rear panels If you do not have an analyser in front of you while reading this manual refer to the fold out diagrams on pages 53 54 and 55 Follow the instructions in section 3 to connect the mains power to the analyser and heated line controller Ensure that the mains voltage is suitable Connect the small fuel and calibration gas bottles by pushing the quick connect fittings onto their respective inlet ports on the front panel They are colour coded for easy identification The fuel connectors have a YELLOW band and the span gas connectors have a BLACK band Ensure that the fuel and calibration bottles have sufficient gas by checking the bottle pressures At least 200 psi 14 bar 1400 kPa is recommended
37. e cutter for 30 s and bypasses the cutter for the next 30 s giving concentrations for Total Hydrocarbons and Methane The Nom Methane content is calculated from the difference between them The cutting is not exact Some Methane will be catalysed and some of the other hydrocarbons will be left after the sample is passed through the cutter These cutter efficiency values are determined by an efficiency test and have been set during the factory calibration The microprocessor uses these values to apply correction factors to the concentrations before outputting to the display or chart These values can be changed from the front panel using the procedure in sections 6 12 and 6 13 Adjustment of the cutter temperature and determination of the efficiencies are best performed by our service department The CH4 TOT and NON keys control the sample path and hence the mode of operation The TOT mode bypasses the cutter and measures total hydrocarbon concentration The CH4 mode uses the cutter and measures the methane concentration The NON mode switches between the two modes and measures the non methane concentration by subtracting the previous two values The display shows the concentration of the selected mode The TOT and CH4 modes output on their respective channels when selected the other two channels are set to zero All three concentrations are continuously available on the CHART outputs when in NON mode High and low alarm levels can be set fo
38. e cylinder supplied with the analyser open the valve one turn Itis not necessary to open the valve further If using an alternative supply it must be pressure regulated to 30 psig 2 1 bar 210 kPa Sample The sample gas is transported from the sample point via a heated line to the analyser This ensures that hydrocarbon sample is not lost by condensation Connect one end of the heated line to the sintered filter accessory kit and the other end to the rear panel port marked SAMPLE If the analyser or heated line are switched on this port and the heated line pipe ends WILL BE HOT Wear heat resistant gloves if necessary The filtered end of the line should be inserted into the sample point Exhaust The combustion gas leaving the detector the product of burning the sample in the hydrogen flame leaves the analyser at the rear panel port marked EXHAUST The exhaust flow rate is less than 1 l min of which about 8 ml min is sample gas It is normally safe to allow it to vent to atmosphere If local safety standards require this to be vented to a special area connect suitable piping to the port Short runs less than 2 m can use 1 4 6 35 mm piping Runs longer than this must be in larger piping to reduce back pressure on the detector It is also important that there are no pressure variations in the vent area This will cause measurement noise as the pressure variations affect gas flows The exhaust gas will contain water vapour If the
39. e non methane option includes an additional two pairs of outputs so that all three measurements can be recorded 2 21 2 Concentration Output 0 10 V represents selected range span 2 21 2 1 Over range capability 15 1 5 V to 11 5 V 2 21 2 2 Lowest load resistor 2 kU 2 21 2 3 Continuous short circuit allowed Recovery lt 15 min 2 21 3 Concentration Output 4 20 mA represents selected range span 2 21 3 1 Over range capability 15 1 6 mA to 22 4 mA 2 21 3 2 Highest loop resistance 600 including cable and any current sense resistance 2 21 4 Range Output 0 8 V represents selected range number 2 21 4 1 Ranges are numbered from 1 most sensitive to 8 least sensitive and the output changes by approximately 1 V for eachrange step Loss of mains power is indicated by an output of 0 V 2 21 4 2 Lowest load resistor 2 kU SIGNAL GROUP LTD 3030PM MAN Page 11 of 64 Issue 1 01 3030PM OPERATION MANUAL 2 21 4 3 Continuous short circuit allowed Recovery lt 15 min 2 22 2 22 1 2222 2 23 2 23 1 2 23 2 2 23 3 2 23 4 2 23 5 2 24 2 24 1 2 24 2 2 24 3 2 24 4 2 25 2 25 1 2 23 2 Fault Relay Contact ratings are 1 A at 50 Vdc Isolation gt 10 M at 50 Vdc Digital Inputs Digital control lines are provided for the remote control of Range Input Port Measurement Mode Sleep Standby and Calibration The inputs are arranged for contact closure to common return to represent
40. exhaust is allowed to cool condensation will form and may block the pipe Run all exhaust piping down from the analyser in a smooth and continuous drop The vent area must be able to remove the water as it exits the pipe Condensation may be corrosive Pipes and fittings should be corrosion resistant Stainless steel for fittings and PTFE for pipes are recommended Hot Bypass Unused sample gas and make up air leave the analyser at the rear panel port marked HOT BYPASS If the analyser is switched on this port WILL BE HOT Wear heat resistant loves if necessary If local safety standards require this to be vented to a special area connect suitable piping to the port Short runs less than 2 m can use 1 4 6 35 mm piping Runs longer than this must be in larger piping to reduce back pressure It is also important that there are no pressure variations in the vent area This will cause measurement noise as the pressure variations affect gas flows The bypass gas may contain water vapour If the bypass is allowed to cool condensation will form and may block the pipe Run all bypass piping down from the analyser in a smooth and continuous drop The vent area must be able to remove the water as it exits the pipe SIGNAL GROUP LTD 3030PM MAN Page 16 of 64 Issue 1 01 3030PM OPERATION MANUAL 3 4 8 4 Condensation may be corrosive Pipes and fittings should be corrosion resistant Stainless steel for fittings and PTFE for pipes are re
41. ff If the FID flame is extinguished during use and subsequent attempted automatic re ignition is unsuccessful the fuel solenoid will close and remain closed until the operator intervenes Methane Non methane Measurement Air pollution studies require the measurement of total hydrocarbons in order to correlate hydrocarbon emissions with ozone and nitrogen oxides Since methane is commonly produced by biological processes some applications require the ability to measure methane and non methane hydrocarbons separately This can be carried out with the Model 3030PM using the platinum cutter option There are two possible paths for the sample gas in an analyser fitted with the platinum cutter option One path bypasses the cutter while the other passes through it While the sample is being passed directly to the detector the total hydrocarbon content of the sample gas is being measured When the sample gas passes through the cutter the methane content only of the sample gas is being measured Automatically subtracting the methane content from the total hydrocarbon content gives the non methane content SIGNAL GROUP LTD 3030PM MAN Page 58 of 64 Issue 1 01 3030PM OPERATION MANUAL 11 ROUTINE MAINTENANCE 11 1 Filter Replacement CAUTION If the analyser has been switched on the filter housing will be too hot to touch The filter replacement tool provides a method for changing hot filter elements Dirty filters may contain corrosive co
42. for a short run Connect one end of the heated line the end with the electrical connector to the SAMPLE FILTER inlet Attach the heated line electrical connector to the output on the 540 controller The heated line should be laid out straight or in a gentle curve Do not coil the line This will cause local overheating and possibly damage the PTFE inner tubing Operation Switch on the analyser ON OFF key and the heated line controller At switch on the analyser display will show all segments lit for a period of three seconds This allows the display to be checked each time the power is applied The top left numerical display will then show the software number Pnnn for a period of two seconds and the software revision rnnn for a further two seconds You will need to quote these numbers if you require help with the operation or set up of the analyser Set the heated line controller to 180 C and leave both the analyser and line to warm up This will take about 20 min During this time the display will frequently show E1 This means that the flame is not lit and the analyser is not ready for use Open the valves on the fuel and calibration bottles one turn There is no need to open them further Opening further can damage the valves Select ZERO gas Press the PUMP button check that the PUMP light turns on and that the pressure gauge on the front panel registers between 5 5 psi to 7 5 psi 380 mbar 38 kPa to 520 mbar 52 kPa
43. for a minimum installation consists of an electrician s flat bladed screwdriver for the mains connections a sharp knife for cutting PTFE tubing and a 9 16 14 3mm A F spanner Full installation of remote control chart recorder and other features will require the use of a soldering iron plus solder wire cutters wire strippers small pliers and a working knowledge of the equipment to be connected Plumbing in stainless steel will require the use of pipe cutters and benders We or our local agent can offer an installation service if you do not have the necessary skills All functions provided by the front panel buttons can be mimicked by commands sent via the RS232 serial port A number of additional commands not present on the front panel are available via this port Connect the serial port to one of the ports on the host computer or to the serial port of any PC having either Signal or Custom software to affect control For those wishing to write their own software section 8 defines the communication protocol and lists the commands available together with their parameters and responses This is the preferred method of data logging where a PC based system is available The RS232 port may require customisation if the factory default settings are not satisfactory Connections to analogue data logging equipment or chart recorders are available on the CHART connector Voltage and isolated current outputs are available Consult section 2 for
44. gure 6 Front Panel Layouts 62 Figure 7 Rear Panel Layouts 63 Figure 8 Typical Installations 64 TABLES Unit Conversion Table 27 Span Gas Range Limits 35 Range Control Logic 42 Gas Path Control Logic 42 Mode Control Logic 43 SIGNAL GROUP LTD 3030PM MAN Page 6 of 64 Issue 1 01 3030PM OPERATION MANUAL 1 2 1 2 1 1 2 2 INTRODUCTION Analyser The 3030PM is a heated portable hydrocarbon analyser designed to measure organic vapours in combustion stack gases and high dew point samples The high temperature sample system has been specially developed to minimise sample loss or degradation A flame ionisation detector with a cylindrical collector flame detector and igniter and housed in a temperature controlled oven produces an electrical signal proportional to the number of carbon atoms present in the sample This is amplified and digitised for maximum accuracy Automatic fuel enrichment ensures easy and reliable ignition while a built in catalyst transforms ambient air into hydrocarbon free air for use as Zero gas burner air and make up air for the sample system The full function embedded microprocessor provides both digital and analogue interfaces for data acquisition Additional features allow automatic ignition calibration and ranging An RS232 serial link using AK protocol allows communication with Signal s dedicated Host controller or with a PC running special software giving full remote control Remote control of major fu
45. irm selection The displayed range will always be selected and the display will revert to concentration if no key is pressed within two seconds A further press on the UP key after the highest range or a further press on the DOWN key after the lowest range sets the automatic range changing mode The display will show Auto On exiting the set routine the AUTO light will be on if Auto range has been selected The fast change sequence is not necessary for this parameter and is not available When in AUTO mode pressing RANGE will display the range in use as selected by the auto range function and will resume concentration display after a few seconds Pressing the UP key will select the lowest most sensitive range and exit from auto ranging Pressing the DOWN key will select the highest least sensitive range and exit from auto ranging Having exited the auto range mode use the UP and DOWN keys to choose a range SIGNAL GROUP LTD 3030PM MAN Page 34 of 64 Issue 1 01 3030PM OPERATION MANUAL 6 6 6 6 1 6 6 1 1 6 6 1 2 6 6 1 3 6 6 1 4 6 7 6 7 1 6 7 1 1 Set Span Gas Concentration SET SPAN SET The analyser should be set to a range suitable for the calibration gas concentration to be measured Acceptable values are from 80 of the next lower range to 15 above the current range Span Gas Range Limits On entry the display will show the current span gas concentration If the new concent
46. lame temperature and therefore the ionisation efficiency The ratio of air to fuel is set at 10 1 The gas flows are fixed at the factory and should not require adjustment If adjustment should be necessary it should only be carried out during service by an authorized service engineer The fuel mixture is automatically enriched during ignition SIGNAL GROUP LTD 3030PM MAN Page 56 of 64 Issue 1 01 3030PM OPERATION MANUAL 10 3 2 10 4 10 4 1 10 4 2 10 4 3 10 5 10 5 1 10 5 2 The Model 3030PM has a facility for the automatic ignition of the FID This facility can be enabled from the front panel When enabled an ignition procedure will be started whenever the flame is out provided that the oven is at temperature and the analyser is ready torun Should the flame fail to ignite the fuel valve is switched off This feature is necessary where unattended operation is required and the mains supply cannot be guaranteed Sample Bypass System The small sample flow rate about 8 ml min to the detector would give an impossibly long response time if it were not used with a bypass system The bypass system uses a high sample flow rate about 5 l min to give a rapid turnover of sample gas and therefore a rapid response time Most of the sample gas is dumped but a very small proportion of the gas is passed to the detector As the flame ionisation detector is mass sensitive that is its response is proportional to the total mass of h
47. le line is ineffective Analyser mode is shown by the state of two output lines MOO and MO1 They are encoded in binary using negative logic Analyser mode is controlled by the state of two digital input lines MIO and MI1 These are also coded in binary using negative logic A further input line MEN mode enable must be held low TRUE to enable mode control The codes are NOT the same for both output and control Both inputs held low is an invalid code and is interpreted as TOT The returned code is that for the TOT mode The codes are given in the following table Mode Control Logic Calibration Control and Indication Calibration is controlled by the ACAL auto cal and GPEN gas path enable input lines The progress through the calibration procedure is shown by the CIP calibration in progress READY and CFAIL calibration fail output lines A calibration can be started by taking the ACAL input Low for a minimum period of two seconds then returning it High The type of calibration will depend on the gas path selected Zero gas path causes a zero calibration span gas causes a span calibration and sample gas causes both zero and span calibration If no GPI lines are used both zero and span calibrations will be performed Taking the GPEN line Low disables the front panel CAL key in addition to the gas path selection keys Calibration is only possible from the ACAL input line A calibration can be stopped while in
48. lters are correctly placed and that the O rings are not damaged Repincement O rings are available under part number ORING 092 he 3130ADD1 Suppty with manual if the carbon trap is fitted SIGNAL GROUP LTD 3030PM MAN Page 2 of 64 Issue 1 01 3030PM OPERATION MANUAL DOCUMENT HISTORY 1993 2003 Signal Group Ltd All rights reserved No part of this manual may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Signal Group Ltd While we believe that the information and guidance given in this manual is correct all parties must rely upon their own skill and judgement when making use of it Signal Group Ltd will not assume any liability to anyone for any loss or damage caused by any error or omission in the manual whether such error or omission is the result of negligence or any other cause Any and all such liability is disclaimed SIGNAL GROUP LTD 3030PM MAN Page 3 of 64 Issue 1 01 3030PM OPERATION MANUAL CONTENTS 1 INTRODUCTION 7 1 1 Analyser 7 1 2 Keys Indicators and Warnings 7 1 3 Getting Started 8 2 SPECIFICATION 8 2 1 Safety 8 2 2 Power 8 2 3 Pneumatics 8 2 4 Ranges 9 2 5 Display 9 2 6 Detector 10 2 7 Oven Temperature 10 2 8 Catalyst Temperature 10 2 9 Catalyst Efficiency 10 2 10 Warm up Time 10
49. lue Note the methane percentage remaining Enter the propane percentage by pressing SET TOT SET and the methane percentage by pressing SET CH4 SET Refer to sections 6 12 and 6 13 for full instructions If the requirement for 15 or less of propane and 85 or more of methane residues cannot be achieved it is possible that the cutter has become poisoned Poisoning can often be reversed by setting the cutter control full clockwise pressing CH4 ZERO and leaving for twenty four hours If a satisfactory performance cannot be obtained a full service is required during which the cutter must be replaced SIGNAL GROUP LTD 3030PM MAN Page 60 of 64 Issue 1 01 3030PM OPERATION MANUAL 12 ROUTINE SERVICING 12 1 Schedule 12 1 1 Servicing should be carried out every 2700 hours of use and involves cleaning the detector and gas paths filter replacement electronic calibration linearity and drift tests We recommend that all servicing is carried out by our Service Department or approved distributors and agents 12 2 Service Manual 12 2 1 Full Maintenance Manuals are normal issued to distributors and service agents only but can be purchased by customers if they wish to carry out their own servicing All warranty will cease however if a customer carries out his own servicing during the warranty period unless special arrangements have been made in writing If you wish to carry out your own servicing contact Signal your local dist
50. mode auto cal and sleep can be set The readiness state range gas path mode high and low alarm states calibration progress and the analyser fault condition canbe monitored Logic remote control is enabled by pressing REMOTE on the front panel If the serial remote control is connected and the SREM command has been sent the logic commands will be ignored Sending the SMAN command will restore control to the logic inputs Logic inputs are coded for contact closure use Inputs left open circuit are regarded as OFF Only those functions required need be wired since the others will default to OFF This type of coding is often called negative logic because a Low level is TRUE and a High level is FALSE Voltages from 5 V TTL or CMOS logic can be used to code the inputs Due to the negative logic a Low voltage is TRUE and a High voltage is FALSE Refer to section 2 for input restrictions and to section 3 for wiring and typical interfacing methods Logic outputs are also coded in negative logic A TRUE state is a low voltage and a FALSEstate is a high voltage Refer to section 2 for input restrictions and to section 3 for wiring and typical interfacing methods The range gas path and mode selections are encoded to reduce the number of lines needed to control them SIGNAL GROUP LTD 3030PM MAN Page 41 of 64 Issue 1 01 3030PM OPERATION MANUAL 7 2 Range Control and Indication 7 2 1 Range is shown by the state of three o
51. mpounds Use gloves 11 1 1 Disconnect the sample gas line The filter is immediately underneath the pipe fitting The pipe fitting and filter cap are removed as a single item using a special tool 11 1 2 Identify the filter extraction tool in the accessory kit It has a T bar at one end 11 1 3 Using the filter extraction tool release the filter cap by rotating turn anti clockwise Reverse the tool and screw it onto the pipe fitting Withdraw the housing taking care not to touch any hot surfaces 11 1 4 The filter element will be found protruding from the cap It will quickly cool and may be removed by hand Dirty filters may contain corrosive compounds Use gloves 11 1 5 Fit a new filter element Filter elements are available from Signal in packs of ten under the part number FILT 010 If you purchased a 1 year spares kit with the analyser a pack of filters was included 11 1 6 Re assemble the filter cap to the analyser using the reverse procedure and reconnect the sample line 11 2 Calibration 11 2 1 Regularly perform a span and zero calibration Allow the instrument to warm up fully before the calibration is checked If the analyser is in continuous use consider using the automatic calibration facility 11 2 2 The frequency of calibration checks depends on the degree of accuracy expected from the instrument the conditions under which it is being used and its mode of operation Calibration every four days 96 hours is rec
52. nalyser 8 5 45 GSCT Set the Auto cal time data ATnnn nnn in 6min 0 1h units results NA Used by Analyser SIGNAL GROUP LTD 3030PM MAN Page 52 of 64 Issue 1 01 3030PM OPERATION MANUAL 8 5 46 GRCT Return the Auto cal time data NA results ATnm nnn in 6min 0 1h units Used by Analyser 8 5 47 GRTS Return the Temperature oven set point data NA results T xxx xxx in degrees kelvin Used by Analyser 8 5 48 GRWG Return Which Gas CH4 TOT NON data NA results Gx x Gas number 0 CH4 1 TOT 2 NON Used by Analyser 8 5 49 GRMW Return Which Gas path SAMPLE ZERO SPAN data MA results me x x path 0 SAMPLE 1 ZERO 2 SPAN Used by Analyser 8 5 50 GRSS Return System State data NA results Gx me a Mb Conc b AvC c CS d ZS e SS f LA g HA h ZA i SA j TA k NF 1 x which gas number 0 1 2 see GRWG a which gas route 0 1 2 see GRMW b the instantaneous reading in ppm c The average reading in ppm d The calibration status see GRCL e The zero calibration status see GRCL f The span calibration status see GRCL g The low alarm status see GRAL h The high alarm status see GRAL i The zero alarm status see GRAL j The span alarm status see GRAL k The temperature alarm status see GRAL The number of faults Used by Analyser 8 5 51 GMET Set CH4 mode only possible with the non methane option data NA results NA Used by Analyser SIGNAL GROUP LTD 3030PM MAN
53. nctions is also possible using parallel logic or switches to set the state of digital control lines Remote indication of analyser status is also provided An optional cutter allows simultaneous total methane and methane free hydrocarbon measurement Miniature bottles of fuel and span gas are held below the analyser in a combined bottle rack and analyser stand Full size bottles can be used for continuous monitoring This manual does not apply to the Model 3030P analyser The 3030PM analyser contains many enhancements over the 3030P and the differences are sufficient to cause confusion if the wrong manual is used Check the model number at the bottom right of the front panel Keys Indicators and Warnings This manual makes use of the square brackets to show where a key press is required As an example the key to select Sample measurement would be shown as SAMPLE It also makes use of the brace or curly brackets to indicate a warning number As an example a flame out warning would be shown by E1 Flashing indicators are cautionary signals to show functions which are not ready or that have encountered their limit conditions If you do not have an analyser in front of you while reading this manual refer to the fold out diagrams on pages 53 54 and 55 for the basic controls and connections SIGNAL GROUP LTD 3030PM MAN Page 7 of 64 Issue 1 01 3030PM OPERATION MANUAL 1 3 1 3 1 1 3 2 2 2 2 2 1 2 211 222 2
54. nd that the calibration certificate value agrees with the SET CAL value 4 2 12 Refer to section 5 for full instructions on calibration chart recorder outputs alarms auto ignition and all the other features SIGNAL GROUP LTD 3030PM MAN Page 21 of 64 Issue 1 01 3030PM OPERATION MANUAL 4 3 Decommissioning 4 3 1 Remove the sample probe from the sample point and allow it to sample clean air until the reading drops to near zero This ensures that no organic hydrocarbons are present in the sample paths which may otherwise condense as the analyser 4 3 2 Switch the heated line controller off Allow cool air to purge through the line for about thirty minutes to reduce the line temperature Do not tightly coil the heated line until it is cool about 60 C to 70 C Coiling when hot may cause the PTFE inner tubing to kink causing restricted flow next time it is used If the line must be disconnected before it is cool take care to avoid skin contact with the fittings wear heat resistant gloves if necessary and only lightly coil it for transportation 4 3 3 Disconnect the heated line from the controller and analyser The SAMPLE FILTER fittings will still be hot Avoid skin contact 4 3 4 Turn the pump off and close both the fuel and span cylinder valves Switch the analyser off SIGNAL GROUP LTD 3030PM MAN Page 22 of 64 Issue 1 01 3030PM OPERATION MANUAL 5 5 1 5 2 5 2 1 5 3 5 3 1 32 54 5 4 1 5 4 2
55. oed The ZERO and CAL indicators will flash if any range failed the zero calibration and the values from the previous calibration are used 6 4 Set Parameter Key Sequences 6 4 1 Parameter values such as alarms and calibration gas concentration are adjusted using the SET key The general sequence is SET param lt UP DOWN gt SET Press SET then the parameter key you wish to adjust e g HI AL or LO AL thenthe UP or DOWN keys until the display shows the required value and finally the SET key to confirm the operation 6 4 2 The above sequence is satisfactory if a minor adjustment to a value is to be made Where large changes are necessary a faster method for changing the value is available The general form for this faster entry method is SET param param lt UP DOWN gt param lt UP DOWN gt param lt UP DOWN gt SET Press SET then the parameter key you wish to adjust then the parameter key again This sets the most significant digit flashing Press UP or DOWN to adjust this digit Press the parameter key again The next less significant digit will flash Press UP or DOWN to adjust this digit A change from digit 9 to digit 0 will increment the next more significant digit A change from digit 0 to digit 9 will decrement the next more significant digit Press the parameter key again and repeat the sequence until all digits have been set Press SET to confirm the value This value will be
56. ogic output on the front panel REMOTE connector will go low if the concentration is above the high alarm limit LO AL will flash and a logic output on the front panel REMOTE connector will go low if the concentration is below the low alarm limit The analyser is shipped with the alarms disabled The alarm limits must be set before the alarms will function Alarm levels are set by pressing SET HI AL or LO AL and the UP and DOWN keys to adjust the value A display of means that the alarm is disabled Confirm the value witha final press on SET Refer to sections 6 4 6 10 and 6 11 for full instructions on setting the alarm values Non Methane Option An analyser can be fitted with an option to allow the measurement of methane and non methane hydrocarbons An additional catalyst cutter is run at a particular temperature that selectively catalyses all hydrocarbons except methane It effectively cuts the non methane hydrocarbons from the sample path The catalyst is a high surface area platinum coating on a ceramic substrate The platinum can be poisoned by heavy metals such as lead and silicone compounds The non methane option should not be used in applications where the sample gas may contain these contaminants SIGNAL GROUP LTD 3030PM MAN Page 25 of 64 Issue 1 01 3030PM OPERATION MANUAL 5 8 3 5 9 5 9 1 5 9 2 5 9 3 5 9 4 The microprocessor controls the sample path so that the sample goes through th
57. ommended for normal operation under good conditions if the analyser is left running for 24 hours per day Once per day is recommended if the analyser is switched off overnight or if barometric pressure compensation is desired SIGNAL GROUP LTD 3030PM MAN Page 59 of 64 Issue 1 01 3030PM OPERATION MANUAL 11 3 11 3 1 11 3 2 11 3 3 11 3 4 11 3 5 11 3 6 Cutter Efficiency At intervals of about three months or more frequently if required check the efficiency of the methane cutter An additional calibration bottle of 1000 ppm Propane in air is required Allow the analyser to warm up and stabilise and enter the methane span gas concentration from the cylinder certificate Make a separate note of the value Perform a normal full calibration using the 500 ppm Methane in air cylinder by pressing SAMPLE CAL Select automatic range changing Connect 1000 ppm Propane in air to the SPAN port press TOT SPAN wait for the reading to stabilise and note the concentration reading The concentration will be in the order of 3000 ppm if you have previously calibrated in methane equivalent concentration Press CH4 and adjust the CUTTER control on the rear panel until the concentration is 15 of the originalreading Note this value Note the propane percentage remaining Connect the 500 ppm Methane span gas to the SPAN port and wait for the reading to stabilise Check that the concentration is greater than 85 of the certificate va
58. other function adjustments does not require but will accept the SET prefix A final press on the SET key accepts the new data and returns to the previous measurement mode The change can be abandoned by pressing SAMPLE prior to the final SET The change will be abandoned if no key is pressed for thirty seconds 6 3 Calibration Key Sequences 6 3 1 SAMPLE CAL 6 3 1 1 Performs a full Zero and Span Calibration and uses the results to replace previous span and zero calibration details The span gas concentration value from the bottle calibration certificate must have been previously entered A further press on CAL before the calibration is complete cancels the operation without updating calibration details The first press on SAMPLE is not necessary if already measuring sample gas 6 3 1 2 The CAL indicator will flash if either or both zero or span calibration failed If the zero calibration failed the span calibration will not be attempted but a span fail condition is recorded as though the calibration itself failed To determine which calibrations failed press ZERO and SPAN in turn 6 3 1 2 1 The ZERO and CAL indicators will be flashing if the zero calibration failed The span calibration was not attempted 6 3 1 2 2 The SPAN and CAL indicators will be flashing if the span calibration failed or if the zero failed and span calibration was not attempted 6 3 1 3 A valid zero and span calibration must have occurred befo
59. r each mode Only the alarm levels applicable to the selected mode will be active Fault Relay A fault relay is de energised when an error condition exists that prevents the analyser operating correctly Its contacts are available on the front panel REMOTE connector Refer to section3 for installation instructions The most common error condition occurs when there is no power to the analyser This could be due to a local power failure mains lead not connected mains power not switched on fuse in mains plug faulty or analyser fuse faulty The next most common error condition occurs when the flame is not lit This condition causes the relay to turn off and an E1 code to be flashed on the front panel display Loss of flame can occur if the pump is not running there is insufficient air supply or if there is a problem in controlling the oven temperature The microprocessor constantly monitors many operational parameters and will display an En code if an error condition exists Any En code will cause the fault relay to turn off A list of error codes in given in section 9 SIGNAL GROUP LTD 3030PM MAN Page 26 of 64 Issue 1 01 3030PM OPERATION MANUAL 5 10 Converting To Other Units 5 10 1 The analyser is calibrated at the factory in Carbon Number equivalence using Methane in Air The analyser can be calibrated in Propane equivalence 5 10 1 1 Press SET SAMPLE lt UP and DOWN together gt SET to restore the factory default
60. ration is to be on a different range press RANGE lt UP DOWN gt until the required range is selected Wait for the display to revert to the setting mode If the concentration is within the limits for that range the same concentration value will be displayed If it is outside the limits the display will show the minimum for that range Set the value to that on the calibration gas bottle certificate If an UP or DOWN key is pressed that takes the value outside the limits for that range the next higher or lower range will be selected Continue setting the value for that range Set Automatic Calibration Period SET CAL SET The display shows the calibration period in hours and is adjustable in 0 1 h 6 min intervals A period of 0 disables automatic calibration SIGNAL GROUP LTD 3030PM MAN Page 35 of 64 Issue 1 01 3030PM OPERATION MANUAL 6 8 Set Oven Temperature 6 8 1 lt TEMP TEMP gt for oven temperature then SET TEMP SET 6 8 1 1 The nominal set point for oven temperature has been optimised for best performance It should only be changed if instructed to do so by an authorised Signal representative or if you are experienced in the effects of temperature on the analyser performance 6 8 1 2 The upper right hand display will show C OV to indicate oven temperature in C units Adjust the temperature to suit your application The oven temperature range limits are given in section 2 6 9 Set Catalyst Tempera
61. re the calibration details are updated and the CAL indicator stops flashing Both span and zero calibration details will remain at their previous levels if either span or zero calibration fails 6 3 2 SPAN CAL 6 3 2 1 Performs a Span Calibration only and uses the results to replace previous span calibration details The span gas concentration value from the bottle calibration certificate must have been previously entered Pressing CAL again before the calibration is complete cancels the operation without updating the span calibration details The first press on SPAN is not necessary if already measuring span gas SIGNAL GROUP LTD 3030PM MAN Page 32 of 64 Issue 1 01 3030PM OPERATION MANUAL 6 3 2 2 The SPAN and CAL indicators will flash if the calibration failed The value from the previous calibration is used 6 3 3 ZERO CAL 6 3 3 1 Performs a Zero Calibration only and uses the results to replace previous zero calibration details The analyser assumes that ALL hydrocarbons have been removed from the ambient air by the catalytic convertor It may be necessary to connect the air inlet port to hydrocarbor free bottled air if the hydrocarbon concentration in the ambient air is too high Pressing CAL again before the calibration is complete cancels the operation without updating the span calibration details The first press on ZERO is not necessary if already measuring zero gas 6 3 3 2 Each analyser range is individually zer
62. return to the sample path A calibration may fail if the wrong calibration gas value is entered or if the internal amplifier or analogue to digital convertor response to the calibration gas is outside their working ranges The calibration constants will not have been updated so that recordings can continue with the original constants This condition is shown by a flashing CAL indicator and will remain until satisfactory calibrations are achieved or until the factory default calibration values are restored To determine which calibration failed press ZERO or SPAN and the ZERO or SPAN indicator will flash If the calibration gas value is correct and the bottle contents have been confirmed on another analyser a calibration failure is an indication that a routine service should be performed by our service department Refer to section 6 15 for instructions on restoring the factory default values Logic outputs and inputs available on the front panel REMOTE connector allow the analyser to report and control calibration Refer to section 7 for full details on using this facility As part of the calibration procedure the internal digital converter is independently calibrated During this time about 3 5 s the concentration display will show and the chart recorder output will be at full scale This is additional confirmation for the start of the calibration process Concentration Alarms Two alarms are available HI AL will flash and a l
63. ributor or agent to discuss the implications and ask for Part Number 3030PM SERV SIGNAL GROUP LTD 3030PM MAN Page 61 of 64 Issue 1 01 3030PM OPERATION MANUAL Figure 6 Front Pane Layout SIGNAL GROUP LTD 3030PM MAN Page 62 of 64 Issue 1 01 3030PM OPERATION MANUAL SPAN sas CUTTER O m o 2 O O ZE n Ow ls mma eat MODEL Standards House Doman Road CamberleySurrey Made in England O WARNING USE ONLY go O CORRECT FUSE O O SEE MANUAL O Figure 7 Rear Panel Layout SIGNAL GROUP LTD 3030PM MAN Page 63 of 64 Issue 1 01 3030PM OPERATION MANUAL I FILTER K SAMPLE lt SPAN CYLINDER FUEL CYLINDER SAFE AREA gt WASTE GAS LARGE BORE PIPE IF gt 2m Figure 8 Typical Installation SIGNAL GROUP LTD 3030PM MAN Page 64 of 64
64. s a command packet to an analyser slave the analyser processes the data and responds with an acknowledgement packet The analyser cannot transmit any data to the host other than as an acknowledgement packet The analyser is placed in remote control by using the REMOTE button on the front panel AND by sending the serial SREM command Remote control via the serial port has a higher priority than logic control and will over ride any logic control inputs Control can be restored to the logic inputs by sending the serial SMAN command Pressing the front panel REMOTE command a second time restores control to the front panel The full sequence of pressing REMOTE and sending the serial SREM command is necessary to restore serial control When the analyser is in local mode it will respond correctly to any interrogation command A set command will return the off line acknowledgement When the analyser is in remote control it will respond correctly to both interrogation and set commands General Packet Format The general form of every packet is as follows lt STX gt lt x gt lt CODE gt data field lt ETX gt Where lt STX gt Ascii STX lt ETX gt Ascii ETX lt CODE gt 4 Ascii Character Command code x is a don t care byte that is read from DIP switches in the equipment SIGNAL GROUP LTD 3030PM MAN Page 45 of 64 Issue 1 01 3030PM OPERATION MANUAL 8 2 2 All characters transmitted are standard ASCII printable
65. s reset to zero if enable is toggled off and on or if manual ignition is attempted 6 15 Restore Factory Defaults 6 15 1 SET param lt UP and DOWN gt SET 6 15 1 1 Each parameter value can be restored to its original factory setting using this key sequence After the UP and DOWN keys have been pressed the display will show the default setting This can be changed using the UP or DOWN keys as required Confirm the value with a final press on SET 6 15 1 2 Using SAMPLE as the parameter re initialises the zero and span calibration values to no offset and unity span This should be done during a routine service where the analyser electronics are calibrated After the UP and DOWN keys have been pressed the concentration display will show norL in recognition of the key presses and will show donE when the final SET is pressed SIGNAL GROUP LTD 3030PM MAN Page 37 of 64 Issue 1 01 3030PM OPERATION MANUAL 6 16 Indicators 6 16 1 General Numeric Display 6 16 1 1 This is located in the top area of the window and is used for all displays requiring a numeric value and units The units are abbreviated to PPM parts per million 10 6 PERC and C C degrees Celcius 6 16 1 2 It also shows any warning codes applicable by interrupting the concentration display after ten seconds and displays each code for a period of two seconds and then reverts to concentration 6 16 1 3 The concentration value will flash if it
66. should be used if the analyser is in an electrically noisy environment with the analyser some distance from the controlling logic and where the controlling logic is connected to the local earth SIGNAL GROUP LTD 3030PM MAN REMOTE LOOK pop b o Ip p p p p fp DB37 PLG View on rear of connector Figure 3 Remote Connections Page 17 of 64 Issue 1 01 3030PM OPERATION MANUAL 3 6 4 Some typical installation arrangements are shown in Figure 4 ANALYSER INTERF ACE CONTROL FROM ANALYSER TO INDICATOR OPTO ISOLATOR ALTERNATIVE CONTACT CLOSURE CAUSES INPUT TO BE LOGICAL TRUE Figure 4 Remote Examples 3 6 5 Relay contacts are available for warning of a fault condition within the analyser The FRCOM common contact will be connected to the FRNC normally closed contact when there is no power to the analyser and when there is a fault or error condition The FRCOM common contact will be connected to the FRNO normally open contact when power is present and there is no fault or error condition detected SIGNAL GROUP LTD 3030PM MAN Page 18 of 64 Issue 1 01 3030PM OPERATION MANUAL 3 7 RS232 Socket Connections 3 7 1 Identify the 25 way D socket in the accessory kit It connects to the 25 way plug marked RS232 on the front panel 3 7 2 RS232 Pin Allocation is given in Figure 4 3 8 RS232 Defaults 3 8 1 The RS232 port uses the following factory set defaults Baud Rate 9600 Parity Non
67. ter via a serial link and AK protocol or from external logic inputs This key must be pressed for more than three seconds to change the current control mode The REMOTE indicator will be off if remote control is disabled flashing if remote control is enabled but not activated or on continuously if either serial or logic control is activated 6 2 16 2 When serial link control is enabled all front panel controls that change the analyser operation are disabled It is still possible to view the analyser state ie pressing RANGE shows the current range but it cannot be changed 6 2 16 3 When external logic control is active a remote enable for a function group will inhibit front panel control for that group As an example if remote range control is enabled the range cannot be set from the front panel It is still possible to view the analyser state SIGNAL GROUP LTD 3030PM MAN Page 31 of 64 Issue 1 01 3030PM OPERATION MANUAL 6 2 16 4 An attempt to change an analyser state or parameter when under remote control will cause an E30 code to be displayed 6 2 17 PUMP 6 2 17 1 Control the operation of the internal pump The pump must be on for ignition to be possible unless bottled air at pressure is connected to the AIR inlet port on the rear panel 6 2 18 SET 6 2 18 1 Allows function values to be changed Used as a prefix with RANGE SPAN CAL TEMP HI AL or LO AL keys The RANGE key used more frequently than
68. the TRUE condition This is sometimes referred to as Negative Logic All voltage levels are with respect to the common return line Absolute maximum input 5 0 Vdc Absolute minimum input 0 0 Vdc Logic 1 TRUE level lt 1 2 Vdc Logic 0 FALSE level gt 3 7 Vdc Digital Outputs Digital output lines are provided for the remote indication of the analyser status Range Input Port Measurement Mode Calibration in Progress Calibration Failed High Alarm and Low Alarm are available Voltages must not be applied to these outputs Continuous short circuit to common return is allowed Logic 1 TRUE level lt I Vdc at 5 mA sink to common return Logic 0 FALSE level from a nominal 5 Vdc via 1 k resistor Serial Interface RS232C serial interface using AK protocol provides full remote control and reporting facilities Factory set to 9600 baud no parity 8 data bits 1 stop bit XON XOFF enabled SIGNAL GROUP LTD 3030PM MAN Page 12 of 64 Issue 1 01 3030PM OPERATION MANUAL THE ANALYSER AND HEATED LINE CONTROLLER MUST NOT BE USED WITHOUT A SAFETY EARTH CONNECTION Heated line sample inlet exhaust and bypass connections WILL BE HOT While the analyser or heated line controller are ON and for some time afterwards TAKE PRECAUTIONS AGAINST BURNS BY USING GLOVES INSTALLATION Introduction Installation requires the use of a tool set compatible with electrical and pneumatic skills A suitable set of tools
69. tputs will show the calibration range and any offset due to span drift To cancel a calibration sequence before it finishes and updates the internal calibration constants press CAL The CAL light will turn off In order to perform a calibration the analyser must be informed of the span gas concentration as indicated on the calibration certificate When the analyser leaves the factory a default value of 500 ppm is set for the calibration value Press SET CAL and the display will show the current value used for calibration If this is not the same as that on the bottle certificate press UP or DOWN to adjust it Confirm the value with a final press on SET Refer to sections 6 4 and 6 6 for full instructions on setting the calibration gas value It is possible to perform a zero calibration only Press ZERO CAL to perform a zero calibration only The ZERO and CAL lights will glow When the zero calibration has finished the CAL light will turn off but the gas path will remain on ZERO Press SAMPLE to return to the sample path SIGNAL GROUP LTD 3030PM MAN Page 24 of 64 Issue 1 01 3030PM OPERATION MANUAL 5 6 4 5 6 5 5 6 6 5 6 7 5 7 5 7 1 5 7 2 5 8 It is possible to perform a span calibration only Press SPAN CAL to perform a span calibration only The SPAN and CAL lights will glow When the span calibration has finished the CAL light will turn off but the gas path will remain on SPAN Press SAMPLE to
70. ture 6 9 1 lt TEMP TEMP gt for catalyst temperature then SET TEMP SET 6 9 1 1 The nominal set point for catalyst temperature has been optimised for best performance It should only be changed if instructed to do so by an authorised Signal representative or if you are experienced in the effects of temperature on the catalyst performance 6 9 1 2 The upper right hand display will show C CA to indicate catalyst temperature in C units Adjust the temperature to suit your application The catalyst temperature range limits are given in section 2 6 10 Set High Alarm 6 10 1 SET HI AL SET 6 10 1 1 The high alarm trip point can be set anywhere in the measurement range of the analyser A concentration higher than this value will set the High Alarm state The highest point is 15 above the highest range 11500 ppm A further press on the UP key when the U highest point is set will turn the high alarm off and the display will show 6 10 1 2 The Non Methane option allows a high alarm trip point for each mode TOT NON and CH4 Use mode SET HI AL SET as required 6 10 1 3 A fast way to turn the high alarm off is to reset to the factory default Press SET HI AL lt UP amp DOWN together gt SET 6 11 Set Low Alarm 6 11 1 SET LO AL SET 6 11 1 1 The low alarm trip point can be set anywhere in the measurement range of the analyser A concentration lower than this value will set the Low Alarm
71. under the analyser Connect the hose to the front panel quick connect fitting marked FUEL The front panel and hose connectors for the fuel line are colour coded with a YELLOW band If using the miniature cylinder supplied with the analyser open the valve one turn It is not necessary to open the valve further If using an alternative supply it must be pressure regulated to 30 psig 2 1 bar 210 kPa Air Unless an external air supply is connected the analyser will use local ambient air removing hydrocarbons by a catalytic process If the local air has high hydrocarbon content the catalyst will not be able to remove all traces and an elevated zero will result Refer to section 2 3 3 for ambient air limits An external air supply can be connected to the AIR INLET port Do not connect an industrial shop air supply as this normally has a high oil content and may result in serious contamination of the instrument Only connect to a known oil free air supply Span Calibration Gas Place the span calibration cylinder in the left hand section under the analyser Connect the hose to the front panel quick connect fitting marked SPAN The front panel and hose connectors for the span line are colour coded with a BLACK band SIGNAL GROUP LTD 3030PM MAN Page 15 of 64 Issue 1 01 3030PM OPERATION MANUAL 3 4 5 2 3 4 6 3 4 6 1 3 4 7 3 4 7 1 3 4 7 2 3 4 7 3 3 4 7 4 3 4 8 3 4 8 1 3 4 8 2 3 4 8 3 If using the miniatur
72. ust provide an input pressure from 25 psi to 35 psi 1 7 bar 170 kPa to 2 4 bar 240 kPa and a flow of 1 5 l min Sample Inlet via 14 6 35 mm tube fitting 0 4 micron 0 4 um internal filter Element replacement from the rear Ranges Eight ranges 0 4 ppm 0 10 ppm 0 40 ppm 0 100 ppm 0 400 ppm 0 1000 ppm 0 4000 ppm and 0 10000 ppm with manual and auto range selection Auto range status indicated on the front panel Display Large four digit LED display for concentration and eight character alphanumeric for units and gas Horizontal bar graph shows fraction of chart recorder range SIGNAL GROUP LTD 3030PM MAN Page 9 of 64 Issue 1 01 3030PM OPERATION MANUAL 2 6 2 6 1 2 7 2 7 1 2 8 2 8 1 2 9 2 9 1 2 10 2 10 1 2 11 2 11 1 2 12 2 12 1 2 13 2 13 1 2 14 2 14 1 2 15 2 15 1 2 16 2 16 1 Detector Flame Ionisation Detector with cylindrical collector complete with flame out detector and igniter mounted on heated sample manifold block Automatic or push button ignition with fuel enrichment Oven Temperature Nominally 190 C Adjustable between 130 C and 210 C Stability 4 C Warning given if outside set point 15 C Measurement resolution 1 C Catalyst Temperature Nominally 600 C Adjustable between 0 C and 640 C Stability 10 C Warning given if outside set point 60 C Measurement resolution 4 C Catalyst Efficiency Greater than 98 remo
73. utput lines ROO ROI and RO2 They are encoded in binary using negative logic Range is controlled by the state of three digital input lines RIO RI and RI2 These are also coded in binary using negative logic A further input REN remote enable must be held low TRUE to enable range control The codes are the same for both output and control and are given in the following table 6 0 1000 ppm 7 0 4000 ppm 8 0 10000 ppm Range Control Logic 7 3 Gas Path Control and Indication 7 3 Gas pathis shown by the state of two output lines GPOO and GPO1 They are encoded in binary using negative logic Gas path is controlled by the state of two digital input lines GPIO and GPI1 These are also coded in binary using negative logic A further input line GPEN gas path enable must be held low TRUE to enable gas path control The codes are the same for both output and control and are given in the following table Gas Path Control Logic SIGNAL GROUP LTD 3030PM MAN Page 42 of 64 Issue 1 01 3030PM OPERATION MANUAL 7 4 7 4 1 1 4 2 7 4 3 7 5 7 5 1 7 5 2 7 5 3 7 5 4 7 5 5 7 5 6 Analyser Mode Control and Indication The mode control is only operational if the Non methane option is fitted It allows the selectionof total methane and non methane modes of operation The default mode for the output lines of a standard analyser is total only one mode possible Codes on the input lines are ignored The enab
74. val of Methane 500 ppm maximum concentration Warm up Time 30 min Repeatability Better than fil of range full scale Response Less than 2 s to reach 95 of value Bypass Flow Sensitivity Less than 4 of reading when the flow varies from 1 l min to 3 l min Zero Drift Less than 1 of range or 1 ppm in eight hours whichever is the greater Ambient Temperature Effect An ambient temperature change from 10 C to 30 C has an effect on the reading of less than 1 of range full scale Detector Noise Less than 0 1 ppm Methane equivalent measured over a period of 1 min SIGNAL GROUP LTD 3030PM MAN Page 10 of 64 Issue 1 01 3030PM OPERATION MANUAL 2 17 Linearity 2 17 1 Better than 0 5 of range full scale 2 18 Carbon Number Correlation 2 18 1 Less than 5 difference in carbon number correlation between Toluene Hexane Propylene and Propane when using Hydrogen Helium fuel 2 19 Oxygen Synergism 2 19 1 500 ppm Methane in Air changed to 500 ppm Methane in Nitrogen has less than 0 5 effect when using Hydrogen Helium fuel 2 20 Methane Cutter optional 2 20 1 85 efficiency in Propane Methane separation 2 20 2 When set to NON mode the dwell time is a nominal 30 s in each path 2 20 3 The cutter can be poisoned by heavy metals such as lead and some silicone compounds Do not use this option where these contaminants are present 2 21 Analogue Outputs 2 21 1 Simultaneous voltage and isolated current outputs Th
75. y on the display and chart outputs before accuracy is lost If too low a range is used with a high hydrocarbon concentration the internal digital converter saturates The concentration display will show when this happens Range Controls The concentration represented by a full scale on the chart recorder can be set using the RANGE UP and DOWN keys Press RANGE The display will show the concentration that will cause full scale output on the chart outputs While the RANGE indicator is glowing press UP or DOWNI to select the required range When setting the range a further press on the UP or DOWN key when at the highest or lowest range respectively will set automatic range changing This is shown as Auto on the display Logic outputs and inputs available on the front panel REMOTE connector allow the analyser to report and control the range Automatic ranging is not possible using these inputs Refer to section 7 for full details on using this facility SIGNAL GROUP LTD 3030PM MAN Page 23 of 64 Issue 1 01 3030PM OPERATION MANUAL 5 5 5 5 1 5 5 2 5 5 3 5 5 4 5 6 5 6 1 5 6 2 5 6 3 Sample There are three gas paths used for measurement SAMPLE ZERO and SPAN SAMPLE is used for sample concentration analysis It is the only path that is fully heated to prevent loss of sample by condensation Press the SAMPLE key to set this path The SAMPLE indicator will glow If the oven is not at
76. ydrocarbon entering the detector per unit time any changes in pressure in the sample system brought about by changes in sample flow rate will have a directly proportional effect on detector response The analyser uses air from the sample air pump to compensate for variations in sample flow to maintain a constant pressure in the sample system and a constant flow to the detector The bypass air is added to the sample flow after the sample take off point to the detector and therefore does not dilute the sample The constant pressure maintained in the sample system by the back pressure regulator produces a constant flow through the orifice at the vent outlet composed of a mixture of sample and bypass air Excess bypass air exits the analyser via the bypass vent and the back pressure regulator This system ensures that no sample gas comes into contact with the back pressure regulator Problems associated with contamination of the regulator by the sample gas and exposing the regulator to high temperatures are therefore avoided Heated Sample Manifold The analyser incorporates a heated sample system and detector which maintains a sample temperature of up to 200 C The upper temperature is adjustable over a fixed range by the user For applications where hydrocarbons with high boiling points are required to be measured high temperature heated lines are necessary to maintain high temperatures within the entire sample system The analyser is supplied with

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