1734 Operators Manual
Contents
1. E ie inc 7 Specifications Operational ie 8 Uni GyoenEspdli 17 18 7 WAN ra oo 3 Operators Manual November 2009 28 CONTHOLE Suda 1734 carbon controller Declaration of Conformity Application of Council Directives 2004 108 EC 2006 95 EC Standards to which conformity is declared EN50270 1999 Electromagnetic compatibility Electrical apparatus for the detection and measurement of combustible gases toxic gases or oxygen CFR47 FCC Part 15 Subpart B Class A Telecommunications Vibration and Shock 68 2 2 68 2 3 Manufacturer s Novatech Controls Ltd Manufacturer s address 309 Reserve Road Cheltenham VIC 3192 AUSTRALIA Type of equipment Carbon controller Model Number 1730 Series Transmitter 1231 Oxygen Probe 1232 Oxygen Probe 1234 Oxygen Sensor I hereby declare that the equipment specified herein conforms to the above directive s and standards s in 2007 Po Full Name Fraser Chapman Position R amp D Manager March 2009 tech Operators Manual 1734 carbon controller aa 292. gt CARBON CONTROLLER Function number 01 Probe 1 Offset Selected option Verification that the selected option has been saved Menu name Activity Indicator AorZ See chapter 4 1 5 2 0 To Change an Option in the Setup Menu 1 Select the SETUP mode by pressing the SETUP RUN key once The SETUP light will come and the display will have the format shown above The operations of the keys are now the operations written in white on the keypad The menu name is written at the bottom of the display 2 When SETUP mode has been selected the required function can be found by using FUNCTION UP and FUNCTION DOWN keys 3 The options available for that function can be seen by using the OPTION UP and OPTION DOWN keys 4 When the required option is on the display the ENTER key is used to save that option 5 Press the SETUP RUN key to return to the RUN mode The details of each function are given below NOTE An asterisk next to a listed option denotes default state after a COLD START March 2009 tech Operators Manual 1734 carbon controller ANITA 15 5 2 1 Probe 1 amp Probe 2 CARBON CONTROLLER 01 Probe 1 Offset 0 0 mV Saved Setup Menu CARBON CONTROLLER 02 Probe 2 Offset 0 0 mV Saved Setup Menu Each Novatech probe has an offset calibration value printed on a tag that is attached to the probe when it is dispatched The offset
3. 2 2 AAT 11 11 A 2 REYPAD 12 4 2 1 KEYPAD IN RUN MODE 12 AD 2 KEYPADIN SETUP E EAEE AEEA 13 4 2 3NFORMAVONSCREN alla ana Ln 13 5 SETUPMODE lisi iii 15 5 1 SETUP MODE FUNGTION SUMMARY rieti rain 15 SP O PETUR NODE DEL IE liane 15 5 2 0 TO CHANGE AN OPTION IN THE SETUP MENU vivi 15 5 2 FROBETS FROBEZGEGSEr aliante 16 52 OWE LINE ITEMS 16 AIP ING FACT e EEE 17 5259F ROCES ALARM landini 17 5 2 p CARBNCONPROLE 17 5 2 3 CARBON SET 18 5 2 6 HIGH CARBON ALARM amp ALARM DELAY ssccoccececcececcececcececsenceaenecaenecaesecesensesenseaenseaeuseaenecsesensenenassenenes 18 5 2 7 LOW CARBON ALARM amp ALARM DELAY sscccecsececcececcececcececsusseaesecaenecaenecsesunseseuseaunseaensedenecsesensesenacsenenes 19 5 2 8 CARBON DEVIATION ALARM amp ALARM DELAY ucccccccecccceccececcecccsececaessceesecesensesenseaeuseaenseenacsesansesenecseuenes 19 ALARMS 21 6 1 CHECKING AND ACCEPTING AN ALARM ccccceccececceccccececcececcecucuecucaucecenecuuaucuunecseaececucucacausueuenecsuneceuaesass 21 6 1 1 CURRENT ALARMS uu cccccccecccceccecsccecscceseceeseceesensesenseaenseaenseaenscaenacese
4. November 2009 CONTROLS m u 1734 carbon controller 5 2 4 Damping Factor r CARBON CONTROLLER 04 Damping Factor 5x Sampling Saved Setup Menu The carbon measurement can be damped if there are annoying fluctuations in the process gas Of course any damping will slow down the reaction time of the controller The larger the number selected here the steadier the measurement will be The damping factor is also used to damp the oxygen measurement and the damped oxygen value is also used in the calculation of all other parameters that are based on the oxygen value RANGE No Damping to 10 5x Samples is set after a COLD START 5 2 5 Process Alarms CARBON CONTROLLER 05 Process Alarms Disabled Saved Setup Menu This function allows the operator to Disable process alarms Setup functions 7 to 14 show the alarm trip points that have been set in the controller OPTIONS Enabled Disabled i 5 2 6 Carbon Controller CARBON CONTROLLER 06 Carbon Controller ON OFF Control Saved Setup Menu The 1734 is able to control the atmosphere to a specific carbon value The type of control selected here will depend on the gas control valve being used March 2009 itech Operators Manual 1734 carbon controller CONTROLS ss 17 Disabled No control OPTIONS ON OFF Control Proportional ON OFF Control Proportional Integral 4 20mA Floating Control 5 2 3 Carbon Set Point CARBON CO
5. tech CONTROLS PTY LTD Carbon Controller Model 1734 Operators Manual November 2009 TABLE OF CONTENTS TABLE OF CONTENTS ci a io er eta 1 1 USING THIS MANUAL 3 LA CALEO NS 1 2 CONNECTING THE CONTROLLER TO THE POWER SUPPLY ccsceccecececceccccecccceccccecuccecuecececaceueueeucacseceuaeceuaesass 4 1 3 MOUNTING POSITION OF THE CONTROLLER eseccccecececcccececccuccecececenenecacuuaenecstaeaeuenetseauaeuerstauacauaenensrenenens 4 1 4 WARNING SYMBOLS cccsceccecccecccceccccececcecsccecuccecsccecucucecuucecaucucsenecseauuecseausseuuecucecsunecsenecseaecseaesecausecaseass 4 2 INTRODUCTION ccceccececcecnccecnccsceceececeececesceeeceseneesenenseeeaeeseaeeseuseseaensenensesensnsenensesenenseusessnsenensenensesenensanensss 5 3 SPECIFICATION 7 3 1 HARDWARE SPECIFICATIONS cceccececcececcececcececcecucaececueuecuececueaucsenecseaesueaeuecsunecsunesecsunecsuaessuesacausecsunecetaesass 7 3 2 OPERATIONAL SPECIFICATIONS cccccecececcececececcccececuceuececscueuuuececeeueuenecscaeuuuenecseueaenenenetstauaunenstscauaenersraneenens 8 3 3 HEATER INTERLOCK RELAYS 9 DISPLAY AND
6. Furnace or auxiliary thermocouple field selectable as type K J R S or N Purge pressure or flow switch Outputs Two linearised 4 20mA or 0 20mA DC isolated outputs max load 10000 The output function and the range are field selectable Common alarm relay Three other alarm relays with selectable functions Digital Interface RS 232 or RS 485 MODBUS for connection to a computer DCS PCL for diagnostics of the controller probe or combustion process Display Multi font graphical display Large font characters for the carbon on the top line Selectable lower line items for the secondary display functions ie Probe temperature carbon measurement on the second probe oxygen etc Alarm display mode that shows the time of the alarm the acceptance time and the time that the alarm was cleared of up to 4000 alarm events Power Universal mains supply voltage 100 to 240VAC Automatically detects the mains voltage and frequency and set the power control accordingly March 2009 tech Operators Manual 1734 carbon controller NALI 5 This page has been intentionally left blank Operators Manual November 2009 6 ica 1734 carbon controller 3 SPECIFICATIONS 3 1 Hardware Specifications Number of carbon probes Carbon range Oxygen range Oxygen accuracy Thermocouple types Temperature accuracy Analogue outputs Output load Alarm relays Alarm relay contacts 2 maximum up to 2 0
7. and have a dual pole isolation switch within easy access of the carbon controller The isolation switch must be marked as the isolation switch for this equipment It is recommended that a separate isolation switch be used for each controller so that a controller can be serviced individually The power supply cables must be supplied and installed according to local regulations The earth connection must comply with the local regulations must have a current carrying capability equal or greater than the supply fuse current rating The earth connection must be connected to the primary earth stud inside the controller on the right hand side All other bonded earth connections from the external wiring must be connected to the primary earth stud 1 3 Mounting Position of the Controller The controller should be mounted in a position where the ambient temperature will not exceed 55 C 130 F or be less than 25 C 10 F ambient temperature must not be exposed to radiation from appliances such as ovens or furnaces direct sunlight o rain snow or sleet The ventilation must be adequate to remove excess heat build up from the internal circuit of the controller 1 4 Warning Symbols Danger high voltage Risk of electrical shock Caution hot surface Caution risk of danger See additional information in the manual Operators Manual November 2009 4 IT CONTROLS min 1734 carbon controller 2 INTRODUCTION T
8. Carbon 2 Low The measured carbon level on the indicated probe has been below the trip level shown in setup function 10 for longer than the delay time shown in setup function 11 22 Carbon 1 High 23 Carbon 2 High The measured carbon level on the indicated probe has been above the trip level shown in setup function 08 for longer than the delay time shown in setup function 10 24 Carbon Deviation The difference between the carbon level measured on probe 1 and the carbon level measured on probe 2 is greater than the trip level shown in setup function 13 and the time delay shown in setup function 14 has expired 25 Probe 1 Temperature Low 26 Probe 2 Temperature Low The probe temperature is under 650 C 1200 F The carbon reading is therefore invalid If the probe heater has been on for more than 20 minutes and the temperature is less than 650 C 1200 F a Probe Heater Fail alarm will occur if a heated carbon probe is being used NOTE The Probe Temperature Low relay function is used with unheated probes to indicate oxygen reading is invalid the probe is below 650 C 1200 F in case the process temperature falls below this level With heated probes this relay will be de energised while the probe is heating up from ambient making the contacts open circuit 27 Purge 1 in Progress 28 Purge 2 in Progress A probe purge is occurring either manual or automatic mod
9. NOTE These menu functions are read only To change these settings see the Technical Manual CARBON CONTROLLER CARBON CONTROLLER 1 Low Carbon Alarm 1 1 Low Carbon Delay 0 35 20 seconds Locked Locked Setup Menu Setup Menu the controller has been selected to run a single probe it will show a low carbon alarm when the carbon measurement of probe 1 goes below the trip level for longer than the delay time If the controller has been selected to run dual probes it will show a low carbon alarm when the average of the two carbon measurements is below the trip level for longer than the delay time If either one of the probes has a failure alarm High sensor impedance thermocouple open circuit heater failure the alarm will then trip on the carbon measurement from the remaining working probe alone RANGE 0 01 to 2 00 2 5 is set after a COLD START RANGE 0 to 200 seconds 20 seconds is set after a COLD START 5 2 8 Carbon deviation Alarm amp Alarm Delay NOTE This menu function is read only To change this setting see the Technical Manual r CARBON CONTROLLER CARBON CONTROLLER 1 2 Carbon Dev n Alarm 1 3 Carbon Dev n Delay 2 00 30 seconds Locked Locked Setup Menu Setup Menu If the controller has been selected to run a single probe these two functions will be hidden If the controller has been selected to run dual probes it will show a carbon deviation alarm when the deviation of the two carbon m
10. can be avoided by regular in situ cleaning Passing a stream of air through the probe on the outside of the sensor and into the furnace causes combustion The free oxygen behind the flame front will burn away the soot However the flame will also heat up the probe The location of the flame front will be determined by the balance between the air pressure and the air flow against the furnace and the flow around the probe This will depend on the furnace and its operating regime The conditions of the furnace atmosphere near the probe is of great importance when establishing the correct flow rate of probe cleaning air For example if the furnace fan is switched off the furnace pressure will change and tis will alter the flow rate of the purge air The lower the probe mV during the more effective the cleaning action will be In most cases 3 5 litres per minute of air will be required lt is bad practice the let the flame front remain at the probe tip as it can cause dramatic over heating and probe damage The probe signal should show greater oxygen levels if the cleaning process is working and typical cleaning should take 3 6 minutes and should be carried out at the start of a cycle to ensure correct operation during the process Care should be taken to avoid the combustion interface coinciding with the probe tip a circumstance where the probe temperature may rise more that 120 C March 2009 tech Operators Manual 1734 carbon control
11. current away from the output terminals terminals 12 amp 13 and 14 amp 15 and directing the current back into the controller input The controller will then calculate a zero and a span calibration factor for each of the output channels The output calibration will only happen if the channel is not set to manual output calibration See Technical Manual for more details 4 2 3 Information Screen The 1734 carbon controller has an information screen available to the user to allow more detailed information about the running of the controller to be easily read by the user The information available is Model and version of the current firmware The date time that the firmware was compiled The maximum temperature that the controller has measured inside the cabinet Current date and time The time of all the next timed events Impedance test 1 cal purge 2 ADC calibration data analogue input calibration DAC calibration data analogue output calibration Probe temperature record probe 1 and 2 oe el A The information screen is entered from the run mode by pressing and holding the ALARM ACCEPT key and then pressing the SETUP key The first data appears at the top of the screen and there is a scroll bar down the left hand side The data can be scrolled through by using the DISPLAY up and down keys The data cannot be changed The output and control functions continue as normal while the information screen 15 being displaye
12. is pressed again or one minute after the last key is pressed The front panel of the model 1734 carbon controller 4 1 Display The 1734 display is used to show the carbon percentage in a large font and the secondary functions a smaller font The default display is shown below with probe 1 carbon on the top line and the probe 1 temperature on the lower line Heartbeat Poweron gt CARBON CONTROLLER indicator Carbon measurement probe 1 0 98 N A Not Available will be Probe 1 TC 1020 3 C shown when probe 1 is below 550 C 1022 F Lower line B 14 20 36 secondary measurements Activity indicator see below for details In addition to displaying the current carbon and the various secondary values the display is also used to show the current and active alarm conditions and to configure the controller This is achieved by entering the SETUP mode see chapter 5 The backlight will turn off if the case temperature is over 35 C It will come on again as soon as a key is pressed and remain on for 60 seconds The Activity indicators show actions that are happening in the background B The burner input has been enabled terminals 10 amp 11 A The controller is doing an auto calibration This happens every minute or when the AUTO CAL keyis pressed in setup mode T Flashing The probe s is are below operating temperature 650 C 1200 F Z The controller is doing an impedance check of the pr
13. the SSR s are found to be faulty both heaters will be turned off immediately and the alarm will be raised The SSR must be replaced The SSR Leakage alarm will occur if one of the heater SSR s are partly shorted If probe 1 SSR has failed and only one probe is being used the 1734 Technical Manual describes how the SSR for probe 2 can be selected instead If 2 probes are being used but neither of the solenoid outputs are being used consult the Technical Manual 17 Probe 1 Filter Blocked 18 Probe 2 Filter Blocked Blocked probe filter This test is only performed when automatic purging of the probe is selected This alarm will not reset until the next purge cycle The cycle can be initiated manually or automatically 19 BBRAM Fail All of the setup options are held in the battery backed memory BBRAM This is the battery shaped device at the bottom centre of the 1730 1 PCB labeled MEM1 This alarm will occur when this device fails and will need to be replaced March 2009 tech Operators Manual 1734 carbon controller 23 6 4 Selectable Process Alarms There are three user configurable alarm relays Any or all of the following functions can be selected for each relay The description of how the trip levels and the delay times are set is in the 1734 Technical Manual NOTE The process alarms will only be activated if they are enabled in SETUP menu function 06 20 Carbon 1 Low 21
14. 1x 10 to 100 1 of actual measured oxygen value with a repeatability of 0 5 of the measured value J S amp N 2 C 0 20mA or 4 20mA field selectable Active outputs Do NOT loop power these outputs 1000 ohm max 4 2A 240VAC 2A 30VDC WARNING Do not use both mains voltage and low voltage connections to adjacent alarm contacts Mains voltage supply Overvoltage Power Fuses Environmental Rating Altitude Degree of Protection Case Size Weight 100 to 240VAC 6 10 50 60 Hz Category II IEC60364 4 443 5W for controller plus probe power 3A fast blow 250v 20x5mm heater fuses 2 of 1A slow blow 250v microfuse PCB mtg fuse 1 of Operating Temperature 25 C to 55 C Relative Humidity 5 to 95 non condensing 2000m maximum IP65 IP54 with internal reference air pump 260mm 10 2 wide 160mm 6 3 high 90mm 3 5 deep 3 Kg 6 6 lbs WARNING All signal level connections onto the controller must be treated as safety extra low voltage SELV as defined in the standard 61 140 Double insulation must be used when connecting these terminals to systems that might carry high voltage March 2009 1734 carbon controller Etech Operators Manual CONTROLS min 7 3 2 Operational Specifications The 1734 controller has two fully configurable 4 20mA analogue outputs The channels can be configured independently to output one of several calculated
15. NTROLLER 07 Carbon Set Point 1 20 Saved Setup Menu carbon controller type has been selected in the previous function a set point carbon value can be entered here The 1734 controller will operate the gas control valve to maintain the set point carbon in the process OPTIONS Carbon 0 01 to 2 00 1 20 is set after a COLD START 5 2 6 High Carbon Alarm amp Alarm Delay NOTE These menu functions are read only To change these settings see the Technical Manual r CARBON CONTROLLER r CARBON CONTROLLER 08 High Carbon Alarm O9 High Carbon Delay 1 50 20 seconds Locked Locked Setup Menu Setup Menu If the controller has been selected to run a single probe it will show a high carbon alarm when the carbon measurement of probe 1 goes above the trip level for longer than the delay time If the controller has been selected to run dual probes it will show a high carbon alarm when the average of the two carbon measurements is below the trip level for longer than the delay time If either one of the probes has a failure alarm High sensor impedance thermocouple open circuit heater failure the alarm will then trip on the carbon measurement from the remaining working probe alone RANGE 0 01 to 2 00 1 50 is set after a COLD START RANGE 0 to 200 seconds 20 seconds is set after a COLD START Operators Manual tech November 2009 18 1734 carbon controller 5 2 7 Low Carbon Alarm amp Alarm Delay
16. Oxygen Probe 2 Oxygen o Auxiliary TC Temperature Ambient Temperature Enabled as Default Service date Burner Run Time NOTE An asterisk on the end of the line identifies the item is enabled by default after a COLD START 3 3 Heater Interlock Relays When the solenoid outputs are to be used a link must be installed as shown O 10 BURNER INPUT O 11 Heater Supply Interlock Connection for Heated Probes If the solenoid outputs are to be used a link must be installed between terminals 10 amp 11 to enable March 2009 1734 carbon controller Carbon control using ON OFF control Carbon control using proportional ON OFF control Carbon control using an up down motor drive control Auto purge and auto cal checking eE tech CONTROLS rr im Operators Manual 9 This page has been intentionally left blank Operators Manual November 2009 10 ica 1734 carbon controller 4 DISPLAY AND KEYPAD The 1734 controller has a graphic display 8 keys that are accessed from the outside of the cabinet and 5 LED indicators to show the status of the controller All the keys have a dual function The black text on the key is the function while the controller is in the RUN mode and the white text on the key is the function in the SETUP mode The SETUP mode is accessed by pressing the SETUP key The controller will return to the RUN mode when the SETUP key
17. R update software in the EEROM lash Update Firmware Model 1734 Version 1 02 lash Press the ALARM UP key to Cancel the update and run the previous software version Press the DISPLAY UP key Cancel to Flash the update and run the new software version 10 Turn the power off 11 Remove the EEROM and save it in the original packaging 12 Replace the main shield and secure it with the three screws 13 Reconnect the reference air pump hose and plug if fitted 14 Turn the power back on without any keys pressed The version number of the software will be shown on the first screen NOTE The EEROM can be used to upgrade any number of controllers March 2009 Operators Manual 1734 carbon controller ii 27 9 INDEX GU PRO RO IA 21 AEREE RR RR IR I 21 Alarms UMMA NOI en 22 Alarms F rocess Ea 17 E ea rile 24 Alarms Warning Messier 24 25 Calibration urine ear 25 iii aria 17 Display RUMORI I 11 Display MONE criari bio rit 15 Healer MO dee e edera E E e a ER aeaa e Ee ENS e E a EES aA ERER E Eaa 9 OCK lire 9 o 13 Key Probe Impedance ie 13 OE RA 12 MOVE LIne Roo O OO RE ORA 16 FOO siete cree alieni 16 15 rd GC AN
18. anual 1734 carbon controller CONTROLS m n Copyright NOVATECH CONTROLS PTY LTD 2009 This manual describes the controller firmware version 1 00 November 2009 Neither the whole nor any part of the information contained in or the product described in this manual may be adapted or reproduced in any material form except with the prior written approval of Novatech Controls Pty Ltd Novatech The product described in this manual and products for use with it are subject to continuous developments and improvement All information of a technical nature and particulars of the product and its use including the information in this manual are given by Novatech in good faith However it is acknowledged that there may be errors or omissions in this manual A list of details of any amendments or revisions to this manual can be obtained upon request from Novatech Controls Technical Enquiries Novatech Controls welcome comments and suggestions relating to the product and this manual All correspondence should be addressed to Technical Enquiries Novatech Controls Pty Ltd 309 Reserve Road Tel 61 3 9585 2833 Cheltenham Fax 61 3 9585 2844 Victoria 3192 Email info novatech com au Australia Web site http www novatech com au Novatech Controls or their authorised dealers should carry out all maintenance and service on the product Novatech Controls can accept no liability whatsoever for any loss or damage caused by service or mainte
19. d The normal display is resumed by pressing the set up key March 2009 Operators Manual 1734 carbon controller a 13 This page has been intentionally left blank Operators Manual tech November 2009 14 IT CONTROLS m n 1734 carbon controller 5 SETUP MODE This chapter describes the functions available when the SETUP mode is selected on the controller The SETUP mode is accessed by pressing the SETUP key The controller will return to the RUN mode when the SETUP key is pressed again or 1 minute after the last key is pressed 5 1 Setup Mode Function Summary When the controller is in the SETUP mode the SETUP light will be on The following table shows the SETUP menu functions Menu Function name top line Range Default value 01 Probe 1 offset 6 0 to 6 0mV 0 0mV 02 Probe 2 offset 6 0 to 6 0mV 0 0mV 03 Lower line items See SETUP function 3 for details chapter 5 2 2 04 Damping factor No damping to 5 samples averaged 10 samples averaged 05 Process alarms Enabled Disabled Disabled 06 Carbon controller See chapter 5 2 6 07 Carbon amp set point 0 01 to 2 00 1 20 08 High carbon alarm 0 01 to 2 00 1 50 09 High carbon alarm delay 0 to 200 seconds 20 seconds 10 Low carbon alarm 0 01 to 2 00 0 35 11 Low carbon alarm delay 0 to 200 seconds 20 seconds 12 Carbon Deviation alarm 0 01 to 2 00 2 00 13 Carbon Deviation alarm delay 0 to 200 seconds 30 seconds 5 2 Setup Mode Details
20. door The light will be off if there are no alarms current The light will flash if there is a current alarm that has not been accepted The light will be on steady if there are current alarm s that have been accepted The light will flash faster as more alarms occur 6 1 Checking and Accepting an Alarm When a new alarm occurs either a process alarm or an alarm that will appear in the common alarm list the ALARM light will flash The more new alarms there are the faster the light will flash To check the cause of the alarm 1 Press the ALARM up key This will put the controller into the current alarm mode The SETUP light will flash 2 The alarm screen will appear displaying the cause of the alarm on the top line Cause of the alarm CARBON CONTROLLER Time Time Activated Probe 1 TC Open Ct Time Accepted Time Activated Time Cleared 13 Apr 2006 13 05 28 7 l ime of the Status Active event Alarm status Active Accepted Self cleared 3 Press the ALARM ACCEPT key to accept the alarm 4 Press the OPTION up key to see the next active alarm or the OPTION down to see the previous active alarm 5 When all the new alarms have been ACCEPTED the ALARM light will stop flashing 6 Accept each alarm and then press the SETUP RUN key to return to the run mode March 2009 tech Operators Manual 1734 carbon controller Sa eR Re 21 6 1 1 Current Alarms To view the alarms that are still current pre
21. e 29 Carbon 1 Invalid Low 30 Carbon 2 Invalid Low 31 Carbon 1 Invalid High 32 Carbon 2 Invalid High The carbon within the process may not be valid due to the probe EMF resulting in a carbon potential that is above below the maximum carbon potential for the temperature of the process 6 5 Warning Messages 27 Probe 1 Temperature Low 28 Probe 2 Temperature Low The probe temperature is under 650 C 1200 F The carbon reading is therefore invalid If a heated probe is being used the probe heater has been on for more than 20 minutes and the temperature is still less than 650 C 1200 F a Probe 1 2 Heater Fail alarm will occur There will be a flashing T symbol on the bottom left hand corner of the display until the temperature of the probe s is over 650 C 1200 F NOTE The Probe 1 2 Temperature Low function is also used with unheated probes to show that the probe temperature is below 650 C 1200 F when the process temperature falls below this level 31 Purge 1 in Progress 32 Purge 2 in Progress A probe purge is occurring either manual or automatic mode Operators Manual November 2009 24 1734 carbon controller 7 PROBE PURGE The Novatech oxygen sensor that is used in the Novatech carbon probe is extremely predictable stable and reliable For this reason the calibration of a Novatech carbon system does not require the use o
22. easurements 15 above the trip level for longer than the delay time If either one of the probes has a failure alarm High sensor impedance thermocouple open circuit heater failure the alarm will not operate RANGE 0 01 to 2 00 2 00 is set after a COLD START RANGE 0 to 200 seconds 30 seconds is set after a COLD START March 2009 Operators Manual 1734 carbon controller 19 This page has been intentionally left blank Operators Manual November 2009 20 RITA ZIE 1734 carbon controller 6 ALARMS The 1734 controller has 4 alarm relays and a built in alarm annunciator and an alarm log When an alarm occurs and the ALARM up key is pressed the controller goes into the alarm display mode In this mode some of the keys take on a special function Key text RUN mode ALARM mode SETUP RUN Return to RUN mode DISPLAY FUNCTION up Next alarm time DISPLAY FUNCTION down Previous alarm time ALARM OPTION up Enter ALARM display mode Next Alarm ALARM OPTION down Enter ALARM log mode Previous Alarm ALARM ACCEPT ENTER Accept alarm When the alarm mode has been entered the SETUP light flashes once a second relays have fail safe alarm contacts That is When the controller is off the contacts are open circuit When the controller is on but there are no alarms the contacts are closed When there is a current alarm event the contacts are open circuit All alarms drive the alarm light on the front
23. eys are used to scroll the lower line up and down through the variety of measurements that are available on the lower line display The list can be changed to suit the operator by using SETUP function 3 ALARM UP Key there is either a new alarm or an active alarm the ALARM UP key can be pressed to examine the alarm status The alarm light will be flashing if there is a new alarm or steady if there is an existing alarm see chapter 6 Alarms ALARM DOWN Key When the controller is in the run mode or the alarm mode the ALARM UP key has been pressed the ALARM DOWN key and the ALARM UP key allow the operator to examine the alarm log The date time of last 4000 alarms can be scrolled through Each alarm record consists of the alarm name and the date time that the alarm was initiated accepted and cleared see chapter 6 Alarms ALARM ACCEPT Key The ALARM ACCEPT key is used to accept a new alarm see chapter 6 Alarms GAS 1 PURGE 1 and GAS 2 PURGE 2 Keys These two keys are used to turn on the purge solenoids When the controller is in the manual purge mode Commissioning function 21 amp 26 the solenoid will be activated for as long as the key is pressed When the controller is in the auto purge mode the automatic purge cycle is started The cycle can be stopped by pressing any key See chapter 7 Probe Purge Operators Manual November 2009 12 1734 carbon controller 4 2 2 Keypad in Setup Mode When t
24. f calibration gases However it may be necessary to periodically purge a build up of carbon from around the sensor tip The 1734 controller has a timer and solenoid driving system that can be configured to admit an air supply to purge the probe through the gas connection on the probe The purge gas must be piped to the port on the probe labelled CAL PURGE There are two solenoid drivers in the 1734 carbon controller They can be used to independently purge a single probe if the 1734 controller has only one probe connected If the controller has two probes connected one solenoid can be connected to two probes with a T piece tube connector or the solenoids can be connected independently to each probe Single Probe Configuration Cal Purge 1 Solenoid 1 should be connected to the purge gas and the gas connection on the probe Cal Purge 2 No connection Dual Probe Configuration Cal Purge 1 Solenoid 1 should be connected to the purge gas and the gas connection on the first probe Or a T piece can be used on the purge line to purge 2 probes at a time Cal Purge 2 Solenoid 2 should be connected to the purge gas and the gas connection on the second probe The controller can also be configured to be in a MANUAL or AUTOMATIC purge mode The information on configuring the controller is contained in the 1734 Technical Manual 7 1 Notes on purging the probe Most probe failures are caused by probe sooting which
25. he Novatech 1734 Carbon Controller provides in situ measurement for one or two carbon probes in furnace and gas generators with temperatures up to 1400 C The controller provides local indication of carbon percentage and oxygen plus numerous other related measurements Within the same process either one or two probes can be controlled providing average and or individual probe readings The controller provides two isolated 4 20mA outputs 4 normally closed configurable relay outputs and digital communications via MODBUS Alarms are displayed at the controller and the relay contacts can be configured to activate remote alarm devices Using unheated Novatech zirconia carbon probes the analyser also provides automatic probe filter purging The model 1734 carbon controller is based on the well Known model 1634 controller It includes a number of hardware and software improvements such as a graphic display larger characters faster microprocessor simplified set menu alarm logging faster probe heater control and more accuracy in the calculation of carbon The 1734 Carbon Controller has a variety of user selectable functions The device is configured locally using a menu driven interface and the local keypad amp display For a description of the configuration process refer to Chapter Error Reference source not found Features include Inputs Two Novatech zirconia carbon oxygen probes Carbon range up to 2 0 Oxygen range from 10 to 100
26. he SETUP RUN key is pressed once the controller will go into the SETUP mode For information about the additional user selectable options see the 1734 Technical Manual The following key functions are then available in the SETUP mode SETUP RUN key Pressing this key once will put the controller into the SETUP mode The function of all the keys will then change to the functions that they have in the SETUP mode Pressing the SETUP RUN key again will return the controller to the RUN mode or it will return automatically one minute after the last key press FUNCTION UP FUNCTION DOWN Keys These two keys allow the selection of the required setup function from the list shown at the start of chapter 5 1 Setup Mode Function Summary OPTION UP OPTION DOWN keys These two keys allow for the selection of the options that are available in the selected function See the details of these in chapter 5 2 Setup Mode Details ENTER key The ENTER key saves the selected option If the ENTER key is not pressed when a new option is chosen the previous option will be retained SENSOR IMPEDANCE key When this key is pressed the controller will measure the impedance of the sensor in the probe s This will only happen if the burner is enabled terminals 10 and 11 and the probe temperature is over 700 C 1290 F AUTO CALIBRATE key When this key is pressed the controller will calibrate the analog output channels This is done by directing the output
27. he packaging NOTE The EEROM is static sensitive Avoid static discharges through the pins of the EEROM by earthing yourself before picking up the EEROM 6 Plug the EEROM into the 32 pin socket in the lower left hand corner of the main PCB NOTE Be very careful not to bend any of the pins of the EEROM If the EEROM does not have all the pins correctly plugged into the socket during upgrade the controller program may be destroyed and it will have to be returned to Novatech for service Note also the direction of the EEROM Pin 1 is identified by a small dot on the EEROM The writing on the EEROM label must be up the same as controller _ fale alt ici DE 2 gt 9 AE F bon 167 0 231 BFT 24 See BFT 25 rr Mati DE FIRMWARE UPDATE SOCKET NT Pin 1 of the EEROM RI SFB eee F amp F amp 2 5 A O START bCONNG LOC SS ni socal Loc ae Eee bDIAG Fi 7 While the power is still turned OFF press and hold the DISPLAY DOWN and the ALARM LOG DOWN keys The following message should be shown on the display 8 If the message Invalid EEROM Unable to Upgrade is displayed turn the power off again and check the pins of the EEROM and that it was in the correct direction 9 display looks like the following image press the DISPLAY UP key to load the upgrade software Description of the CARBON CONTROLLE
28. ler NALI 25 7 2 Actions that Occur when Gas Solenoid Keys are Pressed The 1734 carbon controller has a built in timer to operate the solenoid outputs The menu functions allow setting of the purge start time the purge period the purge duration and the output freeze time timer has not been enabled in the commissioning menu pressing the GAS1 2 PURGE1 2 key will turn on the solenoid for as long as the key 15 pressed If the timer has been enabled in the commissioning menu pressing the GAS1 2 PURGE1 2 key will turn on the solenoid for as long as the programmed duration has been set for Refer to the person responsible for the commissioning to find out how the controller has been configured Operators Manual November 2009 26 1734 carbon controller 8 UPDATING THE SOFTWARE The programme for 1734 carbon controller is run from memory that is inside the main microprocessor The programme is inserted at the time of manufacture If the software needs to be updated to a later version the factory can supply an EEROM electrically erasable read only memory containing the update The following procedure should be used Turn the power off to the controller Remove the hose from the reference air pump if fitted Unplug the reference air pump DC power lead if fitted Remove the shield from the main PCB in the back of the cabinet by undoing the 2 M4 screws Carefully remove the update EEROM from t
29. nance by unauthorised personnel This manual is intended only to assist the reader in the use of the product and therefore Novatech Controls shall not be liable for any loss or damage whatsoever arising from the use of any information or particulars in or any error or omission in this manual or any incorrect use of the product Operators Manual November 2009 2 1734 carbon controller 1 USING THIS MANUAL This manual is intended to be used by the operator It is not intended to describe how the 1734 carbon controller should be connected configured or serviced If more detailed information is required than is shown in this manual the 1734 Technical Manual should be used This is supplied with each controller and is also available on the Novatech web site at www novatech com au 15 assumed in this manual that the controller has been installed by competent personal and that the wiring to the main power supply the carbon probe and all the associated signal devices complies with the local safety codes and regulations 1 1 Cautions Please read the safety information below before connecting power to the controller CAUTION March 2009 tech Operators Manual 1734 carbon controller CONTROLS ev us 3 1 2 Connecting the Controller to Power Supply The mains power must be either 100 110VAC or 220 240VAC with a mains frequency of 50 or 60Hz The supply circuit must be fused to at least 10
30. obe s March 2009 Netech Operators Manual 1734 carbon controller CONTROL ija 11 4 2 There are 8 keys built into the decal on the outside of the door of the 1734 carbon controller The key function is printed in BLACK and WHITE to identify the function of the key in either RUN mode or SETUP mode Key text RUN mode WHITE text SETUP mode BLUE BLACK text SETUP RUN Enter SETUP mode Return to RUN mode DISPLAY FUNCTION A Display scroll up Function scroll up DISPLAY FUNCTION V Display scroll down Function scroll down ALARM OPTION A Alarm scroll up Option scroll up ALARM OPTION V Alarm scroll down Option scroll down ALARM ACCEPT ENTER Alarm accept Enter GAS 1 PURGE 1 SENS IMP Gas 1 Purge 1 manual activate Probe impedance GAS 2 PURGE 2 AUTO CAL Gas 2 Purge 2 manual activate Auto calibrate 4 2 1 Keypad in RUN Mode When the controller is turned on and has gone through the start up procedure it will go to the RUN mode In this mode the top line of the display will show the carbon measurement from probe 1 The other key functions are SETUP RUN Key Pressing this key once will put the controller into the SETUP mode The function of all the keys will then change to the functions that they have in the SETUP mode Pressing the SETUP RUN key again will return the controller to the RUN mode or it will return automatically one minute after the last key press DISPLAY UP DISPLAY DOWN Keys The display k
31. s not needed select NO T C for Aux TC Type or place a short circuit between terminals 7 amp 8 8 Reference Air Pump Fail The reference air pump in the controller is either disconnected is drawing lt 20 9 Reference Air Pump Overload The reference air pump in the controller has drawn gt 300mA The power will be turned off to the pump to avoid damage to the pump driving circuit The 1734 controller will attempt to restart the pump every minute To force a restart disconnect the pump and reconnect it 10 ADC Calibration Fail The analog to digital converter has been found to fall outside the normal calibration specifications In this case the probe heater will automatically be turned off 11 Alarm Log Fail The alarm history is kept in an EEROM This alarm will be raised if this memory device fails 12 Output 1 Failure 13 Output 2 Failure The digital to analog and voltage isolator circuit has been found to fall outside the normal calibration specifications This check is only performed when the AUTO CAL button is pressed Refer to chapter 4 2 2 14 Heater 1 SSR Failure 15 Heater 2 SSR Failure 16 Heater SSR Leakage The 1734 controller has the ability to monitor the operation of the heater current in a heated probe Asa result the controller will give an alarm within 1 second of a heater power control switch Solid State Relay failure If either of
32. ss the ALARM up key from the RUN mode and then use the ALARM up and down keys to view all alarms Use the DISPLAY up and down keys to view the Time Activated Time Accepted and the Time Cleared of each alarm 6 1 2 Alarm Log The alarm log keeps a record of the alarm events after the cause of the alarm has been cleared It will hold a record of up to 1000 alarm events and will be retained even with the controller power off To view all the alarms that have occurred in the alarm log press the ALARM down key from the RUN mode The display will look like this Cause of the alarm CARBON CONTROLLER Time title Probe 2 TC Open Ct Time Activated Time Accepted Time Cleared Time Activated 08 Mar 2009 03 45 29 Alarm Log 0002 0057 Time of the event Number of the alarm being viewed Total number of alarms in the log Use the OPTION up and down to scroll through the alarm events that have been saved in the alarm log The alarm event will be transferred to the alarm log when the alarm has been cleared The alarms are stored in the alarm log in chronological order However it may be seen that the current alarm number will skip some numbers These numbers have been reserved for alarm events that are still current When the alarm cause has been removed these alarm events will be transferred to the alarm log 6 2 Alarm Relays The common alarm relay is used to monitor faults within the controller and the probe The list of even
33. ts that will cause the common alarm relay to be activated is shown in chapter 6 3 Common Alarms The relay contacts will be open circuit if there is a current alarm condition The other three alarm relays are user defined and are used to monitor the process The function of the process alarm relays is user selectable See chapter 6 4 Selectable Process Alarms and the Technical Manual for further information 6 3 Common Alarms The events that drive the common alarm relay are 1 Probe 1 Heater Fail 2 Probe 2 Heater Fail If a heated probe has been selected in the first 20 minutes of power being applied to the heater after being switched on this alarm will not occur but a T display will be shown on the bottom of the display If an ADC alarm occurs the heaters will automatically be turned off If the probe has not reached 650 C 1200 F in 20 minutes the Probe 1 2 Heater Fail alarm will be raised 3 Probe 1 High Impedance 4 Probe 2 High Impedance Carbon probe or electrode failure high impedance This alarm is inhibited when the probe temperature is under 650 C 1200 F Operators Manual November 2009 22 1734 carbon controller 5 Probe 1 Open Circuit 6 Probe 2 TC Open Circuit Probe thermocouple is open circuit The heater in heated probes will switch off 7 Auxiliary TC Open Circuit Stack thermocouple is open circuit If the thermocouple i
34. ure _ 0t01500 0 100t01600 1008 100 0to1300 No Output Only available in dual probe mode Only available in single probe mode The zero and span of the selected output are set in the following two menus functions 11 amp 12 and 14 amp 15 Range of local indication The measurement of carbon is shown as the main and largest value on the display It is shown with 2 decimal places as The measured oxygen content displayed on the Lower line is shown in either or in scientific notation The format of the oxygen display changes to maintain the best resolution for the measurement Range Display format 30 0 to 100 0 HHH 1 00 to 29 99 HHHH 0 100 to 0 999 HHHH lt 0 100 scientific notation x 107 Operators Manual Abtech November 2009 8 CONTHOLE Suda 1734 carbon controller Local display secondary functions This function allows the operator to change the items that are available to be displayed on the lower line of the controller in RUN mode If the word Enabled appears on the display for a selected lower line option the measurement will be available to be shown on the display in the RUN mode by scrolling through the list using the DISPLAY UP and DISPLAY DOWN keys A lower line measurement can be Enabled or disabled by pressing the ENTER key o 10 11 12 13 oo 1i8 19 OPTIONS Average Carbon __ TEMF mV Probe 1
35. usesaseusesansedenseaenscaenscsuacsesensssenssaens 22 22 6 2 ALARM RELAYS 22 6 3 COMMON ALARMS cccceccececcececcececcececcccucuecucececuucucueaecseaucueueuecsunecsunenecsuaecsuausseeuecsunecauaecsuaesauaececaeaessenass 22 6 4 SELECTABLE PROCESS ALARMG ccccsecececccececccccececucuuncuecscucauaenecscuaesecscauausenscseauauaenenstseauaenerstauaunenenseass 24 6 5 WARNING MESSAGES naran n annakaan arana LAARA PACALA RLECALA RAAPA CALARE AEARE DACARA REAREA anaana 24 7 PROBE lt lt 25 7 1 NOTES ON PURGING THE PROBE ccsceccececcecececcececceccceccececueuecseuecacacuucuuecsenecuunecsuaeaessuuseeesseaunecsuneceuaesass 25 7 2 ACTIONS THAT OCCUR WHEN THE GAS SOLENOID KEYS ARE PRESSED eccececcececcececcececeececaccececueceuaecass 26 8 UPDATING THE 27 SUINDER 28 2009 tech Operators M
36. value must be entered into this setup function to achieve the most accurate measurements The value is usually between 1 0 to 1 0mV RANGE 6 0 to 6 0mV 0 0mV is set after a COLD START NOTE An error of 1mV in the probe offset will change the carbon reading by about 0 01 carbon The function 02 Probe 2 Offset will only appear if the controller has been configured for 2 probes 5 2 2 Lower Line Items amp CARBON CONTROLLER 03 Lower Line Items Probe 1 EMF Enabled Setup Menu This function allows the operator to change the items that are available to be displayed on the lower line of the controller when it is in the RUN mode If the word Enabled appears on the display for a selected lower line measurement option the measurement will be available to be shown on the display in the RUN mode by scrolling through the list using the DISPLAY up and DISPLAY down keys A lower line selection can be Enabled or disabled by pressing the ENTER key OPTIONS Probe 2 Carbon Average Carbon th Temperature Probe 1 Temperature Probe 2 Sensor EMF Probe 1 Sensor EMF Probe 2 Sensor Impedance Probe 1 Sensor Impedance Probe 2 Oxygen Probe 1 i Oxygen Probe 2 i Ambient Temperature i Ambient RH Controller Set Point Burner Run Time Service Date Auxiliary TC Temperature NOTE An asterisk identifies the item is enabled by default after a COLD START Operators Manual 16
37. values The following outputs are available on channel 1 Output Zero Span Step Min Span Default Probe 1 Carbon 0600 01 t01 5 01 01 0t01 5 Average Carbon 0 0 1 to 1 5 0 1 019 00 0101596 Probe 1 EMF 0 to 1400MV 100 to 1500mV 100mV 100mV 0 to 100MV Probe 1 TC Temperature 1500 C 100 to 1600 C 100 1005 Oto 1300 Probe 1 Oxygen 2009996 n 1 to 100 01 1 Oto 25 Reducing Oxygentexp 2t0 28 0 to 30 1 2 decades 1030 Aux Temperature Oto 1500 00 100 to 1600 100 100 0 to 1300 _ No Output 5 J Only available in dual probe mode Only available in single probe mode The following outputs are available on channel 2 Output Zero Span Step Min Span Default Probe 1Carbon 0 0 1t01 5 0 1 0 1 0t015 Probe 2 Carbon 0 0 1t01 5 0 1 0 1 0t015 Average Carbon 0 0 1 to 1 5 01 01 0t015 Probe 1 EMF Oto1400mV 10010 15007 100mV 100mV Oto100mV Probe 2 EMF Oto 1400 100to1500mV 100 100MV Oto 100mV__ Probe 1 Temperature 150092 1001016006 100 100 0013006 i Probe 1 TC Temperature 1500 100to1600 100 100 0to13000 __ Probe 1 Oxygen 1Oto99 110100 0 1 1 010 25 Probe 1 Oxygen 01099 1 to 100 01 1 0025696 Reducing Oxygen 1 exp 210 28 30 1 2 11030 02 Reducing Oxygen 2 exp 2t0 28 1Oto 30 4 2decades 1t030 Aux TC Temperat
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