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Teledyne 9060Z Oxygen Equipment User Manual

1. 53 14 54 14 1 TRANSMITTER MAINTENANCE 54 14 2 CLEANING 54 14 3 REPLACEMENT PARTS Vv PR PVC unu oen ukenen 54 Ng 55 APPENDIX 1 CONSTITUENT VALUES FOR VARIOUS 15 22 4 3113 57 APPENDIX 2 Rr EVER TEKPREDEK pA EUER Rap 58 APPENDIX 3 OXYGEN SCALE TO LOGARITHMIC 1 60 APPENDIX 4 C 61 4 gt TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual Copyright TELEDYNE ANALYTICAL INSTRUMENTS 2012 This manual describes the transmitter firmware version 1 24 September 2012 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 Teledyne Analytical Instruments The product described in this manual and products for us
2. 50 47 Alarms COMMON ici incedentes ead vident Paese ecu ces eed 47 Alarms PrOCES A ud n 49 Alarms process enabling 35 E 17 23 ENG osha 51 Calibration gas 27 Calibration 45 Calibration of the EE EL 27 0o o K i Te ANM RC c 52 Commissioning 2 37 Copmpmon Alar M S 23 Communications port 5 42 Eopnecting The BOMWBI E A 27 Connections electrical eee iter ierra 19 Damping TACEDE 35 Date 39 Display units OXY REN 30 Dust in the flue 28 Filter p r
3. 221mm Case Mounting Dimensions 4 2 INSTALLING A 9060H OXYGEN PROBE Weld a BSP or NPT socket to the flue in a suitable position for flue gas sensing For the correct size of socket refer to probe data in chapter 3 1 3 The closer to the source of combustion the smaller will be sensing lag time allowing better control The probe has a typical response time of less than four seconds so most of the delay time is normally the transit time of the gas from the point of combustion to the point of sensing 15 TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual Probes can be mounted at any angle However if the probe is to be mounted on a vertical duct wall it is better to angle the probe approx 15 down to avoid process condensation inside the cold end of the probe If there are any particulates in the flue gas a filter can be omitted by pointing the probe vertically downwards Otherwise the transmitter can be configured to automatically purge the filters or they can be replaced periodically Preferred mounting angle if there are particulates in the flue gas and no filter is used Furnace Flue Probe may be mounted horizontally but a small angle downwards will reduce condensation Oxygen Probe Mounting CAUTION It is important that there is no air in leakage upstream of the oxygen sensing point otherwise there will be a high oxygen reading If the probe is to be installed on a bend in the flue
4. 0010 5101005 5 5 010 10079 Probe EMF O 010 1 400mV _ 100to1 500mv 100 100 010 100mV Aux Temperature 0 to 1500 100 to 1600 100 C 100 0 to 1300 C No Output EF UNE 8 75 Only available in dual probe mode Only available in single probe mode The following are available on channel 2 Output Zero Span Step MinSpan Default Linear Oxygen 0109 110 100 2 1 1 0 010 Linear Oxygen Average 010 99 7110 100 1 1 0 to 10 Very L Low Oxygen 7010 19900ppm _ 100 t to 20000ppm 10ppm 100ppm Oto 2 _ Logaritimic Oxygen 1 09 COT tO OH Reducing Oxygen 1 3210 28 Oto 30 2 1 2decades 4 to 30 Oxygen EI 10 to 090 Oto 20 1 5 5 to 10 Combustion effiiency 080 _ 20 10 2080 0010096 Combusibles DA fixed 0510290 01 05 Oto2096 Max Dry CO 0010 510 100 5 5 u 0 to 100 Probe EMF _ 00 1400 amp 100 to 1500 100mv 100 u Oto 100mV Temperature to 1500C 100 to 1600 C 100 C 100 0 to 1300 No Output eS eae a 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 NOTE Regarding channel output configuration both 4 20mA channels are separately isolated and output variables and scaling are individually configured for each channel In
5. CAUTION 5 FIL 3 filter If the optional FIL 3 has been fitted to the 9060H probe in this installation please read the Important Notice regarding probe option FIL 3 on the previous page CAUTION 6 The heater is supplied from the mains power directly and the temperature is controlled at 720 C 1330 F The outside of the process end of the probe can get to temperatures that are dangerous to touch Wear insulating gloves when handling a probe that has been on CAUTION 7 7 TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual Please note that if this equipment is not installed and used in the manner described in this manual then the safety protection provided by the equipment may be impaired 2 INTRODUCTION 2 1 9060Z TRANSMITTER The Teledyne Analytical Instruments 9060Z oxygen transmitter is designed to measure the oxygen gas concentration in combustion applications such as power stations and industrial boilers The measurement is used to control the air fuel ration in the burner to maintain efficiency and safe operation conditions The transmitter is designed to be used in conjunction with a Teledyne Analytical Instruments probe model 9060H or 9060UL UH These two probes use a zirconia sensor that must operate at gt 650 C The 9060H probe has an integrated heater and the 906001 probe uses the process heat to heat the sensor There is a unique cable connection between the 9060Z transmitter and
6. For heated probes the preferred method of mounting for dust laden applications is facing vertically 25 gt TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual downwards with the filter removed Probes can also be mounted horizontally with no filter with some dusts An occasional automatic back purge is helpful in this case Normally heated probes are supplied with filters for applications with particulates in the flue gas The probe response time should be tested when the probe is first installed and then regularly until it remains constant for a significant period Filter purging should be set up on the time periods determined by these tests To test the probe response time use a stopwatch to obtain the time for a probe to achieve a 63 change from one reading to another If a probe filter blocks completely in a short period of time then there is no option but to use the probe without the filter A trial probe with filter can be installed to test whether a filter blockage is likely to occur 4 20 STRATIFICATION If the transmitter and probe have been fully tested and the oxygen readings in the flue gas are incorrect gas stratification may be occurring The phenomena cannot be anticipated for any particular installation Generally large flues have oxygen differences of approximately one percent across the flue Occasionally an oxygen error of several percent may occur in a flue of any size Moving the probe to a new location normally s
7. 29 Probe 2 Temperature Low The probe temperature is under 650 C 1200 F The oxygen 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 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 47 gt TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual level With heated probes this relay will be de energised while the probe is heating up from ambient making the contacts open circuit 30 Cal 1 in Progress 31 Cal 2 in Progress A calibration check is occurring either manual or automatic mode 32 Purge 1 in Progress 33 Purge 2 in Progress A probe purge is occurring either manual or automatic mode 9 3 ALARM RELAY OPTIONS The three process alarm relays relays 1 to 3 are user defined The relay action will depend on the selections made in the COMMISSIONING menu functions 45 to 48 The relay contacts are all designed to be Fail Safe That is they are e open when the transmitter power is off e closed when there is NOT an alarm condition open when alarm occurs The contact will close circuit again relay energised when the alarm condition is acknowledged Choose to have the relays react to a
8. TELEDYNE ANALYTICAL INSTRUMENTS Oxygen Transmitter Model 9060Z Technical Manual Model 90607 Manual TABLE OF CONTENTS TABLE OF CONTENTS 1 1 5 5 D 7 2 INTRODUCTION ec E 8 2 190602 TRANSMITTER 8 2 2 SERIES 9060H OXYGEN PROBES amp 5 5 85 gt 8 2 3 WARNING SYMBOLS Cava er Vo erbe nV cdd vua ibd OU Op Wa eV Ee adr Fu VUE FEE 9 3 DEVICE SPECIFICATIONS bk UE Du HO nes REPE 10 3 1 HARDWARE SPECIFICATION acoa n AFF AE env 10 3 1 1 5 20 VD RE vs paREEED 10 3 1 2 Standard U Eengtlis 10 3 1 3 Series 9060H Probes Specifications 1 11 3 1 4 Oxygen Probe Model Selection 211111 eee eene 12 3 2 OPERATIONAL SPECIFICATIONS ci krsss supr 14 4 INSTALLATION AND 15 4 1 MOUNTING THE TRANSM
9. 16 Transmitter 1 Span Combustibles 1 16 Transmitter 1 Span Dry CO2 1 16 Transmitter 1 Span Probe 1 EMF 16 Transmitter 1 Span Aux TC Temp 16 Transmitter 1 4 20mA Cal Mode 16 Transmitter 1 4mA Trim 16 Transmitter 1 20mA Trim 16 Tvpe unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer gt TELEDYNE ANALYTICAL INSTRUMENTS Transmitter 2 Configuration Process Alarms Configuration Fuel Characteristics Model 9060Z Manual Description Bits Transmitter 2 Output 16 Transmitter 2 Zero Linear Oxygen 1 16 Transmitter 2 Zero Linear Oxygen Avg 16 Transmitter 2 Zero Very Low O2 1 16 Transmitter 2 Zero Reducing O2 1 16 Transmitter 2 Zero Oxygen Deficiency 1 16 Transmitter 2 Zero Boiler Efficiency 16 Transmitter 2 Zero Combustibles 1 16 Transmitter 2 Zero Probe 1 EMF 16 Transmitter 2 Zero Aux TC Temp 16 Transmitter 2 Span Linear Oxygen 1 16 Transmitter 2 Span Linear Oxygen Avg 16 Transmitter 2 Span Very Low O2 1 16 Transmitter 2 Span Reducing O2 1 16 Transmitter 2 Span Oxygen Deficiency 116 Transmitter 2 Span Boiler Efficiency 16 Transmitter 2 Span Combust
10. IUE 32 6 3 1 Probe 32 6 3 2 Lower Line 32 6 3 3 Oxygen Display Dfifs 33 6 3 4 Damping Factor 2 33 6 3 5 Process 33 7 45 34 7 1 2 20 02 2 022 55 34 7 2 COMMISSIONING MODE 5 lt 36 7 2 1 Internal Date ORC 36 7 2 2 Service Date 36 7 2 3 NUMBER OF Probes dE And 36 7 2 4 BE NM mr t Pere 36 7 2 5 Probe 1 amp 2 Thermocouple 54 4 5 5 lt 36 7 2 6 Auxiliary Thermocouple Type eee eene nennen nnne nnn nnne nnn 36 7 2 7 Transmitter Output Channel 1 amp 2 36 7 2 8 Flue Pressure Units and Value 2 apa pE Erw Oda 38 7 2 9 Temperature Units 5 Uo Ye ee ak v a
11. The 9060Z has a timer and solenoid driving system that can be configured to admit a certified calibration gas into the probe or an air supply to purge the probe filters through the gas connection Both the calibration gas and the filter purge gas must be piped to the port on the probe labeled CAL There are two solenoids drivers in the 9060Z transmitter They can be used for any combinations of gas checking and probe filter purging The only limitation is that if the transmitter is in dual probe mode then solenoid 1 must be wired and plumbed to the probe 1 and solenoid 2 must be wired and plumbed to probe 2 The transmitter can also be configured to be ina MANUAL or AUTOMATIC purge and gas check mode Function Function Description Options 20 29 Solenoid 1 2 Operation Calibration Gas Purge V 21 30 Solenoid 1 2 Auto Manual Automatic Manual V V 22 31 Solenoid 1 2 Start Time 00 00 to 23 45 23 32 Solenoid 1 2 Period 1 hour 7 days 24 33 Solenoid 1 2 Duration 1 90 seconds 25 34 Solenoid 1 2 Post Freeze 5 300 seconds 26 35 Oxygen Content Cal Gas 1 2 0 1 20 9 27 36 Gas 1 2 Positive Error 0 1 to 3 0 V v 28 37 Max Cal Gas 1 2 Negative Error 0 196 to 3 096 Functions available if either Calibration Gas Purge and Manual are selected Functions available if Purge and Automatic are selected Functions available if Calibration Gas and Automati
12. he interlock is not required link terminals 10 amp 11 Optional wiring 4 20mA Outputs User selectable ranges Optional wiring Pressure sensor to detect a blocked filter during the automatic purge cycle Orange Sensor 1 Sensor 1 TC 1 TC 1 SENSOR 2 SENSOR 2 AUX TC 2 AUX TC 2 9 5VDC 10 BURNER INPUT 11 BURNER INPUT 1 2 3 4 5 6 7 8 12 OUTPUT 1 13 OUTPUT 1 14 OUTPUT 2 15 OUTPUT 2 16 FLOW SWITCH 17 FLOW SWITCH 18 RS232 Rx Optional wiring Digital communications Connect to 20 NETWORK a MODBUS network or computer 21 NETWORK See chapter 4 15 and 7 2 25 22 NETWORK COM V Optional wiring 43 Additional analogue input 24 used the 90602 25 BFT 44 HEATER 1 43 HEATER 1 Oxygen Probe 1 42 HEATER 2 41 HEATER 2 Oxygen Probe 2 40 CAL PRG1 Optional wiring 38 SOL COMM Gas solenoids MAINS VOLTAGE output Automatic system calibration checking or Essential wiring 37 MAINS A i Mains Power 36 MAINS N 100 240VAC 35 EARTH must be connected to PE earth stud 34 MAINS E 33 ALARM 3 32 ALARM 3 Optional wiring 31 ALARM2 Alarm relays User programmable NC contacts 30 ALARM 2 DO NOT USE MAINS VOLTAGE and LOW 29 ALARM 1 OLTAGE on ADJACENT TERMINALS 28 ALARM 1 27 COM ALARM 26 COM ALARM Connection Diagram for 9060Z Transmitter and one or two 9060UL UH Unheated Probes 19 gt TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual e The mains power must be e
13. iroeci cessio eeu teo ere RYE VD cann 40 7 2 25 Communications Port Options 41 7 2 26 Alarm Log Clearing mee 41 8 CALIBRATION MODE mc 42 3 gt TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual 8 1 FUNCTION SUMMARY TABLE ss sssssieisiscsesnvcascvctascnssssstuansetcarnsaawsesonsasatiasnbeiaseteniantosiveian 42 8 2 CALIBRATION MODE FUNCTIONS 43 8 2 1 Reference Voltages 43 8 2 2 Output Channel 1 and 2 Calibration eee eene nennen 43 8 2 3 Ambient Temperature 1 2 43 8 2 4 Law Oxygen Callbratlol 43 8 2 5 Transmitter Output Scale e REPEPIEE PRERUE ME PUER 43 8 2 6 Transmitter Output Limiting nnne nannten 43 8 2 7 Mains Voltage Detection UR UE 43 8 2 8 Heater SSR Fault 44 8 2 9 SSR Fail Profectloli inoino OD Co Op cw Dd
14. it is best located on the outer circumference of the bend to avoid dead pockets of flue gas flow While the standard 9060 probe with a U length of 250 mm 10 will suit most low temperature flue applications it is occasionally necessary to have a longer probe with the sensing tip in the centre of the flue gas stream Although it is rare occasionally a probe may sense oxygen vastly differently from the average reading in the flue gas If it occurs then the probe should be moved or a longer probe installed This phenomenon is normally caused by stratification of the flue gas 16 gt TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual 4 3 INSTALLING THE AUXILIARY THERMOCOUPLE Weld a 1 2 inch BSP mounting socket to the flue within about 300 mm 12 and upstream of the oxygen probe The thermocouple should be of similar length to the oxygen probe to prevent flue temperature distribution errors The thermocouple should be connected to terminals 7 amp 8 These terminals will not be available for an auxiliary thermocouple if a second probe has been installed 4 4A SHIELD CONNECTIONS All external wiring to the 9060Z transmitter should be shielded Do not connect shields at the field end Simply clip off and insulate There are two M4 earth screw terminals available in the 9060Z transmitter An extra terminal strip may be required to connect all shields together This should be supplied by the installer 4 4B EARTH CONN
15. 2 can be shown in either or parts per million ppm See chapter 6 3 3 Oxygen Display Units for how to change the oxygen display The format of the oxygen display changes to maintain the best resolution for the measurement If Oxygen is selected the transmitter will display oxygen in the following format Range Display format 30 0 to 100 0 HH H 1 00 to 29 99 HH HH 0 100 to 0 999 HHHH lt 0 100 scientific notation 4 x 10 44 90 If Oxygen ppm is selected the transmitter will show the oxygen in ppm format between 10 and 9 999ppm Outside of this range the oxygen will be shown in format described above Display format for Oxygen ppm Range Display format 10 000ppm 196 format see Oxygen section above 1 000 to 9 999ppm ppm 100 0 to 999 9ppm ppm 10 00 to 99 99ppm HH ppm lt 10 scientific notation x 10 96 5 3 KEYPAD There are eight keys built into the decal on the outside of the door of the 9060Z transmitter The key functions are written 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 BLACK text SETUP RUN Enter SETUP mode Return to RUN mode DISPLAY FUNCTION UP Display Next Lower Line Item DISPLAY FUNCTION Display Prev Lower Line Item Previous Function DOWN 5 3 1 Keypad in RUN mode When the transmitter is turned on and has completed its start
16. 6 743 3 13 228 14 629 6 275 1 11 951 13 159 43 846 47 513 59 gt TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual 0 T 505 EMF Where is temperature 46 421 Thermocouple information from NIST ITS 90 data tables APPENDIX 3 6 OXYGEN SCALE TO LOGARITHMIC 60 TELEDYNE ANALYTICAL INSTRUMENTS Model 9060Z Manual APPENDIX 4 MODBUS The Teledyne Analytical Instruments 9060Z transmitter has the ability to work as a Modbus slave node on serial RS 232 or 3 wire RS 485 via RTU mode transmissions By accessing information stored in the input and holding registers it is possible to access runtime variables alarm conditions and modify the device configuration The implementation of the Modbus protocol is limited to the specific command set relevant to reading and writing register variables Attempting to send unrecognised commands will result in appropriate error responses MODBUS Functions Supported 0x03 Read Holding Registers 0x16 Mask Write Holding Register 0x04 Read Input Registers 0x17 Read Write Multiple Holding Registers 0x06 Write Single Holding Register Ox2B Encapsulated Interface read device 0x08 return query data for loopback testing information 0x10 Write Multiple Holding Registers 0x41 Special Instruction Function Serial Configuration The serial configuration for the slave device is accessed in the Commissioning menu of the transmitter De
17. ADC Calibration Fail alarm has occurred Turn the transmitter off and remove the main shield Turn the transmitter back on and measure the voltages on the Acom test points With the negative lead on the centre terminal the other 2 terminals should measure 12 0 3v If not replace the small DC DC converter PS4 An Output 1 2 Failure alarm has occurred Turn the transmitter off and remove the main shield Turn the transmitter back on and measure the voltages on the Dicom test points With the negative lead on the centre terminal the other 2 terminals should measure 12 0 3v If not replace the small DC DC converter PS4 A Heater 1 2 Failure alarm has occurred The software has found that the SSR4 has failed If only one probe is being used and you need to gets the transmitter back working quickly use the CALIBRATION menu function 18 Heater SSR Select to change the heater output terminals See chapter 8 2 8 Heater SSR fault correction A BBRAM Fail alarm has occurred Replace the BBRAM MEM1 on the 1732 1 main PCB 13 2 DETAILED FAULT ANALYSIS The 9060Z transmitter has a diagnostics mode built into the software This mode allows detailed analysis of the hardware of the transmitter but does require a level of competence in electronics The diagnostics mode is selectable by turning the Diagnostics DIP switch to ON and then turn on the power There is a separate Diagnostics Mode Manual available th
18. Analytical Instruments 9060H heated probes are always K type 9060UL UH unheated probes are available R type or S type Other thermocouple options are made available for special installations 7 2 6 Auxiliary Thermocouple Type When the transmitter is operating as a single probe mode the probe 2 thermocouple input terminals 7 amp 8 is used as an auxiliary thermocouple input In dual probe mode this option is unavailable Use of an auxiliary thermocouple allows for basic monitoring of temperature as well as enabling the calculation of combustion efficiency The thermocouple type can be set to K J R or S 7 2 7 Transmitter Output Channel 1 amp 2 90607 transmitter has two fully configurable 4 20mA analogue outputs The channels be configured independently to output one of several calculated values 36 gt TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual The following outputs ae available on channel 1 Output Zero Span Step MinSpan Default Linear Oxygen 0 to 99 1010 ___ 1 1 000 I Linear Oxygen Average 010 99 1 to 100 1 1 0 to 10 Very Low Oxygen Oto 19 900 100t020 000ppm 10 100 0026 Loganthmic Oyan rWed 0 Reducing Oxygen exp 210 28 00 30 2decades 11030 Oxygen Deficiency 10 to 0 _ 010 20 1 5 5 to 10 Combustion 008 105 5 Combustibles O fixed _0 5t02 1 0 1 05 0020 Max Dry CO
19. Kidd 44 9 ALARMS o 45 9 1 COMMON ALARMS c M 45 9 2 SELECTABLE PROCESS 5 22202 PUR ERKTRERAVEP ERR RPEN 47 9 3 ALARM RELAY OPTIONS etin Ye Cyl va Ord qa 48 10 INSTRUMENT CALIBRATION iiie eso oun tatu hic 49 10 1 CALIBRATION SUMMARY Ywv DE RN EVUS 49 10 1 1 Calibration of the e m 49 10 1 2 Calibration of the Outputs sssssseesssssssssssssossssescsessssesssoscossesssosossssseeesssseseseese 49 10 1 3 Probe Calibration ep era pu ch epu ku Vega 50 10 2 COLD c 50 10 2 1 Forcing Cold Start ru MEX 50 10 2 2 Resetting the Calibration 1 nennen 50 11 GAS CALIBRATION CHECK AND 1 1 11 11 111 51 IKE com Un ESEN urena 51 11 2 CALIBRATION 51 12 SOFTWARE UPGRADES 52 13 TROUBLESHOOTING snnccnmnnnsieionondintniinnbeeea aaa 53 13 1 FIRST APPROACH RE 53 13 2 DETAILED FAULT ANALYSIS
20. Link LK3 TERM in the bottom left hand corner of the PCB is used to connect the terminating resistor Link LK3 must be removed on all transmitters except the transmitter on the end of the network line If the 23 gt TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual network line from the transmitters is taken from the middle of the transmitter network string a terminating resistor should be enabled with LK3 at each end of the network line MODBUS protocol of the network is Baud Rate 19 200 Parity Even Stop Bits RS485 2 wire half duplex RTU binary mode For more details see Appendix 5 Analyser 1 22 Network 23 Network Network Master 24 Network Comm Network O Network 0 Network Comm Analyser 2 gt 22 Network 23 Network 5 24 Network Comm Analyser 31 O 22 Network 23 Network 24 Network Comm 4 14 ONNECTING POWER Before commissioning the probe sensor or transmitter read the CAUTION paragraphs at the front of this manual The green amp yellow EARTH wire MUST be connected to earth 4 15 COMMISSIONING RUN MODE When the transmitter is turned on it will go to RUN mode The SET UP RUN button will toggle between the two modes The upper line of the display will now read OXYGEN If the probe or sensor temperature is not above 650 C 1200 F a Probe Low Temperature message is flashed on the
21. Oxygen Alarm Delay Oto 200 7 7256060 4377 Tow Oxygen Alarm d ippm 100 7 7725 2477 Low Oxygen Alarm Delay 010200 7 0secods 45 _ High Oxygen Alarm NP Oippmto100 7 100 46 High Oxygen Alarm Delay 010200 seconds 7 60secods 1 47 Oxygen Deviation Alarm O ippmio100 20 48 Oxygen Deviation Alarm Delay 010 200 seconds 30 seconds 49 Alarm Relay 1 Function Seechaperg 7 7 50 AlamReay2Funcin See chapter T O 70 _ __ 51 Alarm Relay 3 Function See chapter9 52 Common Relay Function See chapter 9 53 AcceptRelay Hold Enabled Disabled 2 Enabled 202 54 Fuel Type Select See chapter 7 2 23 85 FuelHeat gramC 7 000030000 20990 56 7 ratio 0 00 to 10 00 uc ur B86 57 FuelO C atom ratio 0 00 to 10 00 900 A __ 58 Fuel N C atom ratio 0 00 to 10 00 0 10 59 _ FuelS Catomratio 000t1000 00 60 H2OMol Catomraio 0 00 to 10 00 Ic 61 ReferenceArPump Intemal Extmnal 62 ntemalPumpVolage 191090v 63 Reference Air RH 96 0 to 8096 5596 64 Serial Interface 9 232 RS 485 Disabled RS232 65 9600 57600 v 7192000 5 ee 66 _ Parity Even Odd No Parity Even Parity _ ___ 67 _MODBUS Address 15246 eve Disabled 0 68 Clear Alarm Log Clear Don t Clear Don t Clear 35
22. ratio of H20 molecules to C atoms in the fuel 50 55 0 08 13 3 08 b a 256 88 5 6 0 25 0 23 b a 101 98 1 18 17027 ED Mb a 209 9 3 86 0 01 0 0 176 4 2 69 0 0 0 0 166 1 2 34 0 0 0 0 172 59 3 97 s F 157 58 2 01 0 0 0 0 149 65 1 83 DIES 145 18 iab 145 54 0 01 142 25 0 0 0 136 52 1 25 0 01 0 110 91 2 26 1 07 0 O c 116 88 0 74 0 05 0 o 0 03 104 98 0 35 0 05 0 0 01 0 04 99 63 0 11 0 01 0 01 Oo 0 01 a The moisture level varies depending on the process details The calculated values assume M O b The sulfur level varies depending on the process details The calculated values assume 5 Variable Values calculated from the North American Combustion Handbook Tables 2 1a and 2 1b 57 gt TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual APPENDIX 2 PROBE EMF TABLES ZIRCONIA OXYGEN SENSOR OUTPUT mV PROBE TYPE 9060H SENSOR Probe EMF Probe EMF 720 C 1320 F 720 C 1320 F 80590009000 1593 18195 2ug 8 297 6 2698 a 9 us a95 04 888 K Type TC 29 965 mV 720 C 1320 F These tables are based on the Nernst equation O2 O T loge z 45 Where is temperature 46 421 58 gt TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual ZIRCONIA OXYGEN PROBE OUTPUT mV PROBE
23. shows the time of the alarm the acceptance time and the time that the alarm was cleared of up to 4000 alarm events 2 2 SERIES 9060H OXYGEN PROBES amp SENSORS 8 gt TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual Teledyne Analytical Instruments series 9060H oxygen probes and sensors employ state of the art zirconia sensors and advanced materials which provide the following benefits e Improved control due to fast response time to typically less than four seconds Cost efficient design provides improved reliability Longer life probes with greater resistance to corrosion from sulfur and zinc contaminants flue gas e Low cost allows maintenance by replacement e Reduced probe breakage due to greater resistance to thermal shock and mechanical damage during installation and start up Series 9060H probe or sensors are simple to install and maintain All models provide direct measurement of oxygen level On line automatic calibration check is available if required Probes or sensors may be used with Teledyne Analytical Instruments oxygen transmitters and some model transmitters from other manufacturers All Teledyne Analytical Instruments oxygen probe or sensors are designed and manufactured to exacting standards of performance and reliability Series 9060H probe or sensors are the result of extensive research and development by Teledyne Analytical Instruments industry and government agencies Teledyne Analytical Instruments pr
24. single probe mode both channel 1 and 2 have identical options however when the analyzer is configured as dual probe then channel 1 will output process variables relative to probe 1 and channel 2 will output process variables relative to probe 2 37 gt TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual 7 2 8 Flue Pressure Units and Value The 9060Z transmitter is capable of fixed or variable input pressure compensation in the calculation of oxygen from 1 Atm to 3 Atm If the probe is running in a pressurized environment this value should be set to allow for accurate oxygen measurement If the flue pressure is constant select Fixed in this function and set the pressure units and value in the proceeding menus If the pressure varies select Variable and connect a pressure transducer to terminals 24 amp 25 See section 4 23 Set the range of the transducer using a zero and span value in the commissioning menus 7 2 9 Temperature Units The display on the transmitter can be changed to show temperature in either Celsius or Fahrenheit scales 7 2 10 Calibration Freezes Outputs During gas calibration checks it may be required that the analogue outputs remain frozen at their last reading When cal freezes is enabled both analogue outputs remain frozen until the entire calibration cycle has completed 7 2 11 Solenoid 1 amp 2 Operation The two solenoid outputs can be individually configured to perform gas calibration check o
25. thermocouple should be connected to terminals 7 amp 8 These terminals will not be available for an auxiliary thermocouple if a second probe has been installed 4 9 CONNECTING THE OUTPUT CHANNELS The two 4 to 20 mA DC output channels are capable of driving into a 1000Q load The output terminals are 12 amp 13 for channel 1 and 14 amp 15 for channel 2 4 10 CONNECTING THE ALARMS A common alarm which should be connected for all installations initiates on alarm functions described below Three additional alarm relays are available for selectable functions as listed in chapter 9 2 Each relay has normally open contacts The contacts will open in alarm condition Relays are connected as follows Common Alarm _ Terminal Numbers 26 amp 27 Probe 1 2 Heater Fail Probe 1 2 High Impedance Probe 1 2 TC Open Circuit el The watchdog timer is a special alarm There will not be an alarm message displayed but the transmitter will reset Alarms can be accepted by pressing the alarm button viewing the alarm messages Alarm relay 2 to 4 Select any one or all of the following for each relay Refer chapter 9 In addition any of the selections that are removed from the common alarm relay can be added to relays two to four High oxygen 1 2 Probe 1 2 temperature low Low oxygen 1 2 Calibration check 1 2 in progress Very low oxygen 1 2 Probe 1 2 purge in progress Oxygen deviation 4 11 CONNECTING THE A
26. 1 Nil 2 4 TypeR max 1400 C 2550 F Outer Sheath 1 1 Stainless Steel Grade 253MA max 1100 C 2010 F 3 High Purity Alumina max 1300 C 2370 F Horizontal max 1400 C 2550 F Vertical U Length 3 500mm 20 4 750mm 30 5 1000mm 40 8 1500mm 60 T Special length 140mm minimum Note 2 A standard oxygen probe for carburising furnaces has a 253 MA sheath 13 gt TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual 3 2 OPERATIONAL SPECIFICATIONS Range of outputs Function Linear oxygen 1 Very low oxygen 1 Linear oxygen 2 Very low oxygen 2 Average oxygen Logarithmic oxygen Reducing oxygen Oxygen deficiency Aux temperature Combustibles Carbon dioxide Probe 1 sensor EMF Probe 2 sensor EMF Minimum 1 0 to 0 001 1 0 to 0 001 to 1 0 1 to 20 0 to 1x10 30 10 to 0 0 to 100 C 0 to 0 5 0to 5 0 to 100mV 0 to 100mV Maximum 0 to 100 0 to 2 000 0 to 100 0 to 2 000 0 to 10056 Fixed range 0 to 100 10 to 20 0 to 1600 C 0 to 2 0 0 to 100 to 1500mvV Fixed zero to 1500mV Fixed zero Burner efficiency 0 to 20 0 0 to 100 0 No output Disables the output Adjustable zero Range of local indication 0 1 to 0 100 0 01 to 10 000ppm automatically defaults to range above 10 000ppm 1 Local display lower line secondary display items temperature
27. 40 1500 mm 60 2000 mm 80 Ordering Information 10 TELEDYNE ANALYTICAL INSTRUMENTS 90607 Probe insertion length from process end of mounting thread to probe sensing tip 3 1 3 SERIES 9060H PROBES SPECIFICATIONS MODEL Application Temperature Range Length Process Connection Electrical Connection Cable Heater Thermocouple Response Time Head Temperature Reference Gas Ref Air Connection Filter Calibration Check Gas Connection Weight 9060H Combustion flue 9060UL UH Combustion flue gases above 700 C 1290 F with no contaminants gases below 900 C 1650 F Refer to note 1 0 to 900 C Refer to note 2 32 to 1650 F 250 to 2000 mm 10 to 80 20 to 60 1 BSP or NPT BSP NPT Weatherproof plug in connector or optional screw terminals eg natural gas light oils 700 to 1400 C 1470 to 2550 F 500 to 1500 mm The plug connector can be supplied with the cable Order a specific length with the transmitter Yes No K integral R integral Typically lt 4 secs 25 to 100 C 15 to 210 F with weatherproof connector 25 to 150 C 15 to 300 F with screw terminals Ambient air 50 to 150 cc min 3 to 9 scim Pump can be supplied with Typically lt 1 sec transmitter 1 4 Integral air line in probe cable Barbed fitting to 3 16 ID PVC tube Removable sintered titanium alloy particulate filter 30 micron st
28. 485 Use RS 485 for MODBUS 61 Serial Baud Rate 9600 19200 38400 57600 RS 232 up to 19200 only 62 Serial Parity Even Odd or No Parity MODBUS Set the MODBUS address for this device between 1 and 246 Address is to disable the MODBUS 7 2 26 Alarm Log Clearing Every alarm that is instigated internally in the transmitter or as a process level is recorded in the alarm log with the activation time accepted time and the cleared time The last 4000 events will be recorded and then the oldest alarms will be dropped off as new ones occur If you would like to delete the log recording select CLEAR in SETUP step 64 by using the OPTION keys and press the ENTER key The message Alarm Log Cleared will be displayed 41 gt TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual 8 CALIBRATION MODE This chapter describes the functions available when the CALIBRATION mode is selected on the transmitter For specific information about calibrating the transmitter see chapter 10 Instrument Calibration The CALIBRATION mode is accessed by pressing and holding the SETUP key for approximately 4 seconds until the words Calibration Menu appears at the bottom of the display The transmitter will return to the RUN mode when the SETUP key is pressed again or 60 seconds after the last key press Changing options in the CALIBRATION mode is the same as the SETUP mode See chapter 6 2 Changing Options 8 1 FUNCTION SUMMARY TABLE When the tran
29. CALIBRATION menu function 5 8 and set the option to Calibrate 4mA Use the FUNCTION up key to go to function 6 9 Set this to 4 00mA and press the ENTER key Measure the actual output current with a digital multimeter Use the OPTION keys to set the option to the value read on the digital multimeter and press ENTER The output should go to 4 00mA The value in function 6 9 can be fine tuned if necessary Go back to function 5 8 and select Calibrate 20mA Go up to function 7 10 and set the option value to 20 00 Measure the actual output current with a digital multimeter 10 Use the OPTION keys to set the option to the value read on the digital multimeter and press ENTER 49 gt TELEDYNE ANALYTICAL INSTRUMENTS gt wm OND Model 90607 Manual 11 The output should go 20 00mA The value in function 7 10 can be fine tuned if necessary 12 Go back to function 5 8 and select Calibrate 4mA again and check that the output is still set to 4 00mA If it is not exactly 4 00mA the value in function 6 9 can be trimmed again 13 Go back to function 5 8 and select Manually Calibrated 10 1 3 PROBE CALIBRATION There is only one calibration factor for the calibration of the oxygen probe This is the sensor offset and it is written on a tag attached to every probe Use the FUNCTION keys to go to SETUP menu 1 2 and then use the OPTION keys to set the value to the value written on t
30. DYNE ANALYTICAL INSTRUMENTS Model 90607 Manual 6 SETUP MODE The SETUP mode is mode is accessed by pressing the SETUP key momentarily so the words Setup Mode appear at the bottom of the display The transmitter will return to the RUN mode when the SETUP key is pressed again or 60 seconds after the last key press 6 1 FUNCTION SUMMARY TABLE When the transmitter is in the SETUP mode the SETUP light will be on and the words Setup Menu will be shown at the bottom of the display The following table shows the SETUP functions Menu Functionname Range eaultvalue Probe 1 Offset 6 0 to 6 0mV 2 Probe20ffset 6 0 to 6 0mV 3 owe nlems SeeChapter632 8 Damping Factor 10 Samples 5 Samples _ 6 Process Alarms Enabled Disabled Disabled _ 6 2 CHANGING OPTIONS The purpose of having a menu driven SETUP mode is to allow for configuration of the transmitter using the graphical display and keypad Once an option is changed and entered using the ENTER key that value immediately becomes active It is also stored into the non volatile memory within the BBRAM and will be loaded again at device start up To reset the transmitter configuration defaults see chapter 10 2 Cold Start To change an option in the SETUP menu system 1 Select the SETUP mode by pressing the SETUP RUN key once The SETUP light will come on and the display will have the format shown below The operations of the keys ar
31. ECTION PE The PE protective earth input connection must be made to the earth stud on the right hand side of cabinet The PE input connection must be the first connection onto the earth stud and it must be secured by a separate nut and spring washer All other earth connections bonding connections can be made on either of the two earth studs in the base of the cabinet Right hand earth stud C gt C Other bonding earth wires Incoming a gt Assembly of the PE and bonding connections on the earth stud The transmitter MUST be securely earthed 4 5 ELECTRICAL CONNECTIONS All wiring should comply with local electrical codes The printed circuit boards are fully floating above earth The incoming safety earth PE must be connected to the primary earth stud in the right hand side of thebase cabinet The local fuse for the mains power supply the isolation switch and the supply wiring must all comply with the electrical safety codes and must only be installed by qualified technicians All earth and shield connections should be connected to the earth screws inside the case 17 TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual 1 Sensor 1 Brown o 2 Sensor1 Black o 3 1 Bue 4 1 5 SENSOR2 Essential wiring Brown 6 SENSOR2 Probe enable input Black 7 AUXTC2 Burner safety interlock or if Blue 8 AUXTC2 the interlock is not required 9 5VDC
32. EFERENCE VOLTAGES The calibration of the analogue inputs is based on the voltage of a temperature compensated voltage reference integrated circuit There are 4 voltages generated from the standard reference voltage They will vary by about 1 from one transmitter to another but can be trimmed by setting the actual voltages into CALIBRATION menu functions 1 to 4 These voltages should be measured and the reference voltage entries in the menu checked every year 8 2 2 OUTPUT CHANNEL 1 AND 2 CALIBRATION The output 4 20mA calibration can be set either AUTOMATICALLY default or MANUALLY If Auto Calibrated is selected the transmitter will go through an output calibration cycle when the power is turned on or when the AUTO CAL button is pressed in SETUP mode This will divert the outputs back to the input and automatically set the 4mA and 20mA calibration If Manually Calibrated is selected then the 4mA 20mA calibration must be set in the next two functions For the full explanation see chapter 10 1 2 8 2 3 AMBIENT TEMPERATURE CALIBRATION The ambient temperature measurement is used as the cold junction temperature for the thermocouple measurements Use an independent temperature sensor to measure the temperature inside the transmitter case near the screw terminal 1 Enter this temperature into the calibration function 11 by using the OPTION keys and then the ENTER key 8 2 4 LOW OXYGEN CALIBRATION The low oxygen calibration factors can be use
33. ING RUN 1 1 1 24 4 16 PROBE OR SENSOR CALIBRATION 5 5 aio 24 4 17 FILTER PURGING 25 4 18 CALIBRATION GAS CHECK 25 4 19 DUST IN THE FLUE GAS 25 4 20 STRATIFICATION 26 4 21 CONNECTING A PRESSURE 5 1111111 26 5 DISPLAY AND KEYPAD ss 27 5 1 GRAPHICAL DISPLAY M 27 5 2 OXYGEN DISPLAY 28 2 gt TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual 53 KEYPAD Sec 28 5 3 1 Keypad in RUN mode ad e cud vwd s raw duda 29 5 3 2 Keypad in SETUP COMMISSIONING CALIBRATION modes 29 6 SETUP ies ce tC 31 6 1 FUNCTION REUS DuDU FM A RD EP 31 6 2 CHANGING OPTIONS 31 6 3 SETUP MODE FEE re pPRRo FORE DEP SF PAM E
34. ITTER 15 4 2 INSTALLING A 9060H OXYGEN nnne nnn tenen nnn sonne 15 4 3 INSTALLING THE AUXILIARY 17 2 SHIELD CONNECTIONS Fu VE Pu 17 4 EARTH CONNECTION ead ay Pao 17 4 5 ELECTRICAL CONNECTIONS Rx 17 4 6 HEATER INTERLOCK RELAYS rris ssa kde lvsvd d s Rave o zv YF Fb 20 4 7 CONNECTING AN OXYGEN PROBE 1 1 1 nennen 20 4 8 CONNECTING THE AUXILIARY THERMOCOUPLE OPTIONAL eere 22 4 9 CONNECTING THE OUTPUT CHANNELS 55 5 naar para orina anao E paa para 22 4 10 CONNECTING THE ALARMS iiia ei sso DE PUER RDE EE MURKM 22 4 11 CONNECTING THE AUTOMATIC PURGE AND CALIBRATION CHECK SYSTEM 22 4 12 CONNECTING REFERENCE 23 4 13 CONNECTING THE TRANSMITTER TO MODBUS 23 4 14 CONNECTING 562202224224 24 4 15 COMMISSION
35. Last Alarm Active Time Model 9060Z Manual Reg Description Heater 1 Fail Alarm Heater 2 Fail Alarm Probe 1 Hi Impedance Probe 2 Hi Impedance Probe 1 Thermocouple Open Ct Probe 2 Thermocouple Open Ct Auxilliary Thermocouple Open Ct Reference Air Pump Fail Reference Air Pump Overload Battery Backup RAM Failure Internal Alarm Log Memory Failure Internal ADC Fail Internal DAC Output 1 Fail Internal DAC Output 2 Fail Heater 1 SSR Relay Fail Heater 2 SSR Relay Fail Heater SSR Leaking Probe 1 Blocked Probe 2 Blocked Gas 1 Calibration Error Gas 2 Calibration Error Oxygen 1 Low Oxygen 2 Low Oxygen 1 Very Low Oxygen 2 Very Low Oxygen 1 High Heater 2 Fail Alarm Probe 1 Hi Impedance Probe 2 Hi Impedance Probe 1 Thermocouple Open Ct Probe 2 Thermocouple Open Ct Auxilliary Thermocouple Open Ct Reference Pump Fail Reference Air Pump Overload Battery Backup RAM Failure Internal Alarm Log Memory Failure Internal ADC Fail Internal DAC Output 1 Fail Internal DAC Output 2 Fail Heater 1 SSR Relay Fail Heater 2 SSR Relay Fail unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer TELEDYNE ANALYTICAL INSTRUMENTS 64 Last Alarm Active Time Last Alarm State Cleared Time Model 9060
36. RANTIES OR ASSURANCES AND EXCLUDES ALL LIABILITY INCLUDING LIABILITY FOR NEGLIGENCE IN RELATION TO THE PROBE AND THE FIL 3 DEVICE The user must ensure that it correctly follows all instructions in relation to the Probe and FIL 3 device correctly understands the specifications of the Probe and FIL 3 device and ensures that the Probe and FIL 3 device are regularly inspected and maintained FIL 3 equipped Probes should be inspected at least once a year for corrosion and more frequently if there is any reason to suspect that corrosion may have occurred 6 gt TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual 1 IMPORTANT NOTICES This manual is intended as a supplement to the 9060Z Operators Manual It is intended to be used by technical personal that are qualified to install commission service and calibrate electronic industrial control equipment Please read the safety information below before connecting power to the transmitter CAUTION 1 The probe heater is supplied with mains voltage This supply has electrical shock danger to maintenance personnel Always isolate the transmitter before working with the probe The EARTH wires green yellow from a heated probe must ALWAYS be connected to earth CAUTION 2 Combustion or atmosphere control systems can be dangerous Burners must be mechanically set up so that in the case of equipment failure the system cannot generate explosive atmospheres This danger is no
37. TYPE 9060UL UH TEMPERATURE C F 700 800 900 1000 1100 1200 1300 1110 1290 1470 1650 1830 2010 2190 2370 1 373 2 122 2 431 2 890 3 311 3 679 4 215 3 182 4 489 5 143 3 772 5 323 6 098 4 380 6 180 7 080 5 006 7 063 8 092 5 651 5 7 973 1 9 135 6 316 8 913 10 211 7 004 f 9 882 11 322 7 714 10 885 11 678 12471 8 450 11 923 12 792 13 660 9 212 12 999 13 946 14 892 10 004 14 115 15 143 16 171 10 826 15 276 16 388 17 500 11 682 i 16 483 17 684 18 884 12 574 17742 19034 20326 13 506 19 057 20 445 21833 14 481 20 433 21 921 23409 15 504 21 876 23 469 25063 16 579 23 394 25 097 26 801 17 712 24 993 26 813 28 633 18 911 26 684 28627 30 570 20 182 28477 30551 32625 21 535 30 386 32599 34812 22981 32 427 34 788 37150 24 534 6 34 619 37 140 39 661 26 212 I 36 987 39 680 42374 28 036 L 39560 42442 45 323 30 035 42 380 45466 48 552 32 243 1 45496 48810 52123 34 712 48 980 52547 56 115 37 512 52 930 56 785 60 640 40 743 I 57 490 61677 65 864 44 565 62 883 67463 72 042 49 243 69484 74544 79 604 55 274 1 77 994 83 674 89354 63 774 89 988 96541 103 094 78 305 86 351 102 445 110 491 118 538 126 584 97 514 107 534 127 575 137 595 147 616 157 636 29 129 L E 48 838 39 132 f 69 553
38. UTOMATIC PURGE AND CALIBRATION CHECK SYSTEM CAUTION The purge and calibration solenoid valves are supplied with mains voltage This supply has electrical shock danger to maintenance personnel Always isolate the transmitter before working with the purge and calibration solenoid valves 22 gt TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual The on line auto purge and calibration check system is optional For details on its operation see chapters 4 24 4 25 and chapter 11 To automatically sense a blocked probe filter a flow switch should be installed in the purge line to the probe CAL port It should be adjusted so that it energizes just below the purge flow with new or clean filters installed The flow switch contacts should be connected to terminals 16 amp 17 FLOW SW If the filter is still blocked or partly blocked after an auto purge cycle the flow switch will not energize and will therefore cause a 1 2 Filter Blocked alarm After installation the purge cal system should be tested thoroughly for leaks Any leaks can cause significant errors if the flue is at negative pressure If the flue is at positive pressure an outward leak can cause corrosion in the purge cal system piping and fittings If probe filter purging is required but a 1 2 Filter Blocked alarm is not required do not install the flow switch but link terminals 16 amp 17 40 Cal Purge1 Sol Aut
39. Up to 1760 C 3200 F temperature Up to 1760 C 3200 F EMF 30 to 1350mV EMF 30 to 1350mV sensor impedance 0 to 300k sensor impedance 0 to 300k 0 1 to 0 100 0 1 to 0 100 Up to 1760 C 3200 F 20 to 70 C 5 to 125 F 5 to 95 0 to 2 0 0 to 2 0 10 0 to 20 0 14 i TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual The oxygen deficiency output can be used in the same way as a combustibles analyzer to signal the extent of reducing conditions of combustion processes 4 INSTALLATION AND COMMISSIONING 4 1 MOUNTING THE TRANSMITTER Surface mount the transmitter case on to a flat surface or bracket using the four mounting brackets provided The transmitter should never be mounted so that it is directly expose to the sun or rain Always leave at least 10cm of clearance around the four sides of the case Make sure the temperature of the case is below 55 C and that the radiated heat from furnaces and boilers is kept to a minimum There should be adequate ventilation to maintain ambient temperature Install the cables through cable glands There are 4 holes cut in the base of the transmitter case 2x 17mm amp 2x 21mm Use a sharp knife to cut away the covering film for only the glands that are needed NOTE ALWAYS LEAVE THE UNUSED GLAND HOLES SEALED Ensure that the electrical connection complies with the local electrical requirements see chapter 4 6 Electrical Connections 110mm gt
40. Z Manual Description Heater SSR Leaking Probe 1 Blocked Probe 2 Blocked Gas 1 Calibration Error Gas 2 Calibration Error Oxygen 1 Low Oxygen 2 Low Oxygen 1 Very Low Oxygen 2 Very Low Oxygen 1 High Oxy 2 High Heater 2 Fail Alarm Probe 1 Hi Impedance Probe 2 Hi Impedance Probe 1 Thermocouple Open Ct Probe 2 Thermocouple Open Ct Auxiliary Thermocouple Open Ct Reference Air Pump Fail Reference Air Pump Overload Battery Backup RAM Failure Internal Alarm Log Memory Failure Internal ADC Fail Intemal DAC Output 1 Fail Intemal DAC Output 2 Fail Heater 1 SSR Relay Fail Heater 2 SSR Relay Fail Heater SSR Leaking Probe 1 Blocked Probe 2 Blockd Gas 1 Calibration Error Gas 2 Calibration Error Oxygen 1 Low Oxygen 2 Low Oxygen 1 Very Low Oxygen 2 Very Low Oxygen 1 High 2 High Bits unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned inte
41. able for firmware v1 16 and newer Probe 1 Runtime Data Reg Description Oxygen EMF mV Temperature degC Thermocouple Open Ct Flag Temperature Low Flag Impedance kOhms Combustibles Maximum Theoretical CO Bits S 17 Oxygen 32 floating point 2 19 EMF mV 32 floating point z 21 Temperature degC 32 floating point z 23 Thermocouple Open Ct Flag 16 boolean 5 24 Temperature Low Flag 16 boolean a 25 Impedance kOhms 32 floating point E 27 Oxygen Deficency 32 floating point 2 29 Combustibles 32 floating point m 31 Maximum Theoretical CO 32 floating point 33 Heater 2 Output 16 unsigned integer Analyser Runtime Data Auxillary TC Temperature degC Auxiliary TC Open Ct Flag 4 20mA Outputs Frozen Ambient Temperature Maximum Ambient Temperature Average Oxygen Reference Air Oxygen Boiler Efficiency Bumer Runtime Minutes Bumer On Time Minutes Current Date amp Time Next Purge Cal 1 Time Next Purge Cal 2 Time Next Probe Relay 1 Status Relay 2 Status Relay 3 Status Common Relay Status Mains Power Mains Frequency DAC Output 1 mA DAC Output 2 mA floating point boolean boolean signed integer signed integer floating point floating point floating point unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer TELEDYNE ANALYTICAL INSTRUMENTS 63 Current Alarm Status
42. andard optional 15 micron available Refer to note 2 1 8 NPT female 1 8 NPT female 2 kg 4 4 Ib plus 165 g 5 8 oz 100 mm 4 length 1 kg 2 2 Ib plus 100 g 3 5 oz 100 mm 4 length Notes 1 Care must be taken to avoid contact with explosive or inflammable gases with 9060H heated probes when hot Teledyne Analytical Instruments transmitters have built in safety protection 2 Process gas temperature must be below 800 if the filters are fitted Please contact factory for corrosives other than sulfur or zinc We can provide test materials to try in your atmosphere 11 gt TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual 3 1 4 OXYGEN PROBE MODEL SELECTION GUIDE Heated probes temperature range 0 900 C 1650 F 9060H de Mounting Thread 1 12 BSP Fixed 2 17 NPT Fixed Internal Thermocouple 1 T ype K max 900 C 1650 F Outer Sheath 1 Stainless Steel Grade 316 max 850 C 1560 F 2 Inconel 1 U Length 2 250mm 10 3 500mm 20 4 750mm 30 5 1000mm 40 6 1500mm 60 T 2000mm 80 Note 1 The Inconel option has all inconel wetted parts except for the ceramic sensor and viton o rings 12 gt TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual Unheated probes for clean gases temperature range 700 1400 C 1290 2550 F 9060UL UH X X X X Mounting Thread 1 2 BSP Fixed 2 NPT Fixed Internal Thermocouple
43. at describes its use Ask Teledyne Analytical Instruments for more details 53 gt TELEDYNE ANALYTICAL INSTRUMENTS Model 9060Z Manual 14 MAINTENANCE 14 1 TRANSMITTER MAINTENANCE The 9060Z transmitter has several hardware checking systems that confirm the correct operation of the transmitter and raise an alarm if there is a fault detected Because of this system the transmitter only requires periodic maintenance Teledyne Analytical Instruments recommends an annual check of the transmitter The annual check should include the following items 1 Measure and record the reference voltages and check that the correct voltages are set in the calibration menu 2 Check that the reference air flow from the port on the bottom of the transmitter case is between 100 and 300cc m 3 Check for contamination and potential blockage of the reference air filter that is mounted on the bottom of the transmitter case 4 If an external burner interlock has been connected terminals 10 amp 11 check that if one of the wires is disconnected the probe heater is disabled 9060H probes only 5 Check the integrity of the cable Particularly check the main power supply cable and the probe cable for any damage 6 Check the integrity of the earth connections in the transmitter 14 2 CLEANING The 90607 transmitter is made in an IP65 IP54 rated diecast case It is painted with a tough ripple finish power coating to maintain a clean look However
44. by 0 196 oxygen If in any doubt about the correct offset value set it to 0 0mV The function Probe 2 Offset will only appear if the transmitter has been configured for 2 probes see chapter 7 2 3 Number of Probes 6 3 2 Lower Line Items This function allows the operator to change the items that are available to be displayed on the lower line of the transmitter 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 32 gt TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual OPTIONS Enabled as Default Temperature probe 1 Temperature probe 2 Sensor EMF probe 1 gt _Sensor EMF probe 2 n Sensor impedance probe 1 Sensor impedance probe 2 Oxygen probe 2 k Oxygen Average probe 1 and probe 2 Auxiliary thermocouple temperature s Ambient temperature Ambient relative humidity _Oxygen deficiency probe 1 _Oxygen deficiency probe 2 annon annon annon ol od af of j gt TETEN 14 Combustibles probe 1 15 Combustibles probe 2 16 Maximum theoretical dry CO probe 1 ST theoretical ry CO probe 7 7 070 7 mom o
45. c are selected 11 1 PURGE For processes that have particulate present in the gas stream probe filters are necessary and should be back purged with sufficient frequency to avoid blocked filters Select Purge in function 20 29 and Automatic in function 30 and then set the times in function 22 31 to 25 34 The outputs can be frozen during purging if selected in COMMISSIONING menu function 19 A flow switch can be wired to terminals 16 and 17 If the flow is not sufficient at the end of the purge cycle to close the contacts of the flow switch a Probe 1 2 Filter Blocked alarm is generated If a flow switch is not being used a short circuit should be placed across terminals 16 and 17 to suppress the Probe 1 2 Filter Blocked alarm 11 2 CALIBRATION GAS If it is required to automatically check the oxygen probe and transmitter on line select Calibration Gas in function 20 29 and Automatic in function 30 and then set the times in function 22 31 to 25 34 and the gas levels in function 26 35 to 28 37 If the transmitter measurement does not fall within the limits set in function 26 35 to 28 37 a 51 2 Calibration Error alarm will be generated If the transmitter has Automatic selected in function 21 30 and one of the GAS PURGE keys is pressed in RUN mode the automatic cycle will be started and the alarms will be checked The cycle can be stopped at any time by pressing t
46. d 2 Auto Man Solenoid 2 Start Time Solenoid 2 Period Solenoid 2 Purge Cal Duration Solenoid 2 Post P C Freeze Solenoid 2 Calibration Gas Content Solenoid 2 Calibration Gas Positive Error 16 Solenoid 2 Calibration Gas Negative 16 Solenoid 2 Configuration Solenoid 1 Configuration 0x41 Special Instruction Function This command allows you to interact with the transmitter allowing access to functionality that would otherwise only be accessible via the keypad The request length will vary from one command to the next depending on what arguments are required Requests are formed the same as other modbus requests date expressed as seconds since 1 Jan 2004 67 gt TELEDYNE ANALYTICAL INSTRUMENTS
47. d confirmed this message will be shown Upgrade Firmware Model 90607 New Version 1 Upgrade Cancel 11 Press the DISPLAY up key to Upgrade the firmware 12 Press the ALARM up key to cancel the upgrade and continue the start up of the current firmware 13 When the transmitter has upgraded the firmware it will start up the normal initialization The version of the firmware is shown on the startup screen Upgrading Firmware Analyser will reset itself in approx 15 seconds Do not turn off the power NOTE While the firmware is being upgraded it is essential that the power is not turned off otherwise the programme will be corrupted and will not be recoverable 14 Turn the transmitter power off 15 Unplug the EEROM by pressing out the wings of the blue upgrade socket Keep the EEROM in a safe place It can be used to upgrade any number of transmitters as required 16 Replace the main shield and secure it with the three screws 17 Reconnect the reference air pump hose and plug if fitted 18 Turn the power back on NOTE The transmitter may do an automatic COLD START after the upgrade The words Cold Start will be shown on the display in step 14 if the cold start has been performed The calibration will NOT be changed but the configuration have been changed 52 gt TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual 13 TROUBLESHOOTING The Teledyne Analytical Instruments oxygen transmi
48. d to fine tune the oxygen calculation at low oxygen readings It will not affect the measurement at 20 9 They are included to allow oxygen probes made by other manufacturers to be used on a Teledyne Analytical Instruments transmitter The default is 100 but can be set to between 80 and 120 8 2 5 TRANSMITTER OUTPUT SCALE The transmitter outputs can be configured to either 4 20mA or 0 20 The two scaled outputs are capable of outputting 0 24mA and will transmit over scale unless the over scale limit option is selected 8 2 6 TRANSMITTER OUTPUT LIMITING If the oxygen reading is invalid the output can be made to set to 4mA 20mA An invalid reading is when the probe temperature is below 650 C 1200 F or the probe thermocouple has been detected as open circuit The default is to set the output to 20mA but the function can also be disabled 8 2 7 MAINS VOLTAGE DETECTION The default setting for the 9060Z transmitter is that it will automatically detect the mains voltage and frequency in order to correctly drive the probe heaters If there is any uncertainty in this detection system the voltage can be forced to 220 240 or 100 127 and the frequency can be set to 50 or 60Hz 43 gt TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual 8 2 8 HEATER SSR FAULT CORRECTION In the event of one of the heater solid state relays SSR failing in single probe mode the heater drive output can be swapped to the HEATER 2 output S
49. e Fixed OlmchesWG 0 19 Flue Input Zero 1 to 3 Atm 0 Inches WG 20 Input Span e lOO Inches WG 21 Temperature Units Celsius 1 Fahrenheit Celsius 22 Cal Freezes Outputs Enabled Disabled _ Enabled 0 23 Solenoid 1 Operation Calibration G Gas Purge _ Calibration Gas 24 Solenoid 1 Auto Manual Automatic Manual Mana OO O OOOO 25 Solenoid 1 Start Time 00 00 to 23 45 00 00 midnight 34 gt TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual 26 Solenoid 1 Period 1 minute 7 days 1 hour 27 1 Duration 7 1 90seconds 77 30secnds 0 00 28 Solenoid 1 Post Freeze _ 5 300seconds 6Oseconds 29 OxgentonenCalGas 01 2096 7 1 808 30 MaxCalGas 1 Positive Error 0 1 t to 3 096 uuu uu DSA 31 Max Cal Gas 1 Negative Error 0 1 to 3 0 0 2 32 Solenoid 2 Operation CaibraionGas Puge _ CalbraionGas 33 _ Solenoid2 Auto Manual Automatic Manual _ 34 7 Solenoid2 Start Time 00 00 23 45 222222 00 00 midnight 02 35 Solenoid 2 Period 1 minute 7 days _ 1 hour 36 Solenod2Duraion 1 90 seconds S0seonds 37 Solenoid 2 Post Freeze 57300 seconds 7 eoseconds _ 38 02 Content CalibrationGas2 0 1 1020 9 80 39 n Max Cal Gas 2 Positive Error 0 1 to to 3 0 DEVE 05 _ 2 40 Cal Gas 2 Negative Error 0 1 to 3 0 0 2 41 Oxygen Alam 0 1 0 100 7 90500 5000 ppm 4277 Very Low
50. e 1 Jumper terminal 4 to 8 if efficiency or fiue temperature display is required Use copper wire Connection of Probe Cable for Unheated Probes Models 9060UL UH Connecter mounted on the M orobe head viewed rom the E U ev cutside of the head 2 lube from reference suoply o 2 internal pump to Air on prove Probe head conrector P N C Oran 2 1 5 SENS Zirconia sensor gt Brown 2 8 SENS Tremmocoupe i m 4 Fd 48 TC at 30 TC Note 1 White 25 43 41 Heater White 22 TC m Ru eee i G 4 vi G een Yeliow Earth screw Green and yc ov wires musi be connected to the EARTH screw in the transmitter Note 1 Numbers in the brackets are the connector numbers ft e orobe is to connected as probe 2 Connection of Probe Cable for Heated Probes Model 9060H 21 gt TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual 4 8 CONNECTING THE AUXILIARY THERMOCOUPLE OPTIONAL For 9060H heated probes the auxiliary thermocouple must be a separate TC with the junction isolated from earth mounted near to and upstream of the oxygen probe It can be either a J Ror S type thermocouple It is optional If the auxiliary temperature or combustion efficiency is not to be displayed or transmitted then an auxiliary thermocouple is not necessary The
51. e ALARM ACCEPT key is used to accept a new alarm see chapter 9 Alarms GAS 1 PURGE 1 and GAS 2 PURGE 2 keys These two keys are used to turn on the gas purge solenoids When the transmitter is in the manual cal purge mode Commissioning functions 21 and 30 the solenoid will be activated for as long as the key is pressed When the transmitter is in the auto cal purge mode the automatic cal purge cycle is started The cycle can be stopped by pressing the same key again 5 3 2 Keypad in SETUP COMMISSIONING CALIBRATION modes NOTE In order to enter either COMMISSIONING or CALIBRATION modes the corresponding DIP switch on the 1732 1 PCB must be turned on From RUN mode if the SETUP RUN key is pressed once the transmitter will go into the SETUP mode From RUN mode if the SETUP RUN key is pressed and held for 2 seconds the transmitter will go into the COMMISSIONING mode From RUN mode if the SETUP RUN key is pressed and held for 4 seconds the transmitter will go into the CALIBRATION mode The following key functions are then available in all of the above modes SETUP RUN key Pressing the SETUP RUN key while in any of the set up modes will return the transmitter to the RUN mode 29 gt TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual FUNCTION up and FUNCTION down keys These two keys allow for the selection of the setup function A function summary table is found at the start of the rel
52. e now the operations written in WHITE on the keypad The menu name is written at the bottom of the display 2 When the SETUP mode has been selected the required function can be found by using the FUNCTION UP and FUNCTION DOWN keys The options available for that function can be seen by using the OPTION UP amp OPTION DOWN keys 3 When the required option is on the display press the ENTER key to save that value When finished press the SETUP RUN key to return to the RUN mode 31 gt TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual 6 3 SETUP MODE FUNCTIONS Poweron SE OXYGEN TRANSMITTER de Function indicator name O1 Probe 1 offset Function number Verification that the selected option has 0 0 mV been saved Shows Setup Menu has been accessed Selected option Setup Menu 6 3 1 Probe 1 Offset Each Teledyne Analytical Instruments probe has an offset calibration value printed on a tag that is attached to the probe when it is dispatched To achieve accurate measurement the offset value must be entered with the same polarity as it is printed on this label The offset value should be within t1 0mV NOTE An offset of 1 0mV will change the oxygen reading by approximately 196 oxygen when the probe is in ambient air However as the process oxygen measurement drops this offset will have a reduced affect At a process gas oxygen concentration of 296 the 1 0mV offset error will only change the reading
53. e 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 Teledyne Analytical Instruments 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 Teledyne Analytical Instruments Teledyne Analytical Instruments welcome comments and suggestions relating to the product and this manual All correspondence should be addressed to gt Teledyne Analytical Instruments 16830 Chestnut Street City of Industry CA 91748 Phone 626 934 1500 or 888 789 8168 Fax 626 934 1651 Email ask_tai teledyne com www teledyne ai com Teledyne Analytical Instruments or their authorised dealers should carry out all maintenance and service on the product Teledyne Analytical Instruments can accept no liability whatsoever for any loss or damage caused by service or maintenance by unauthorised personnel This manual is intended only to assist the reader in the use of the product and therefore Teledyne Analytical Instruments 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 5 gt TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual Impo
54. elect Heater 1 lt gt Heater 2 If you are running in dual probe mode but not using the calibration gas or purge solenoid outputs the solenoid outputs be swapped to the 2 heater outputs Select Heaters lt gt CalPurge The default setting is Normal 8 2 9 SSR FAIL PROTECTION The transmitter continuously monitors the high voltage outputs on the solid state relays that power the probe and purge cal solenoids If it detects that any solenoids are not switching off correctly then it mechanically isolates all high voltage outputs in order to protect the instrument This feature can be switched off by setting the SSR fail protection to disabled 44 gt TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual 9 ALARMS The 9060Z has 4 alarm relays and a built in alarm annunciator If an alarm occurs the ALARM light will flash To find out what the alarm is press the ALARM up key When the ALARM up key has been pressed the transmitter goes into the alarm display mode In this mode some of the keys take on a special function SETUP RUN Return to RUN mode DISPLAY FUNCTION up Next alarm DISPLAY FUNCTION down Last alarm ALARM OPTION up Enter ALARM display mode Alarm activated time ALARM OPTION down Enter ALARM log mode Alarm acknowledged time ALARM ACCEPT ENTER Acknowledge alarm GAS 2 PURGE 2 AUTO CAL This key is not used in the ALARM mode The common alarm relay is used to monitor faults
55. evant SETUP COMMISSIONING or CALIBRATION mode chapter OPTION up and OPTION down keys These two keys allow for changing the option for the selected function A list range of options for each function is found in the function summary table at the start of the relevant SETUP COMMISSIONING or CALIBRATION mode chapter ENTER key The ENTER key sets the currently displayed option and stores the value in non volatile memory to be retrieved on device start up If the ENTER key is not pressed when a new option is chosen the previous option will be retained Probe impedance key When this key is pressed the transmitter will measure the impedance of oxygen sensor s attached to the transmitter If the burner is not enabled terminals 10 amp 11 or the probe temperature is below 700 C 1292 F impedance checking will not be performed A 7 will be seen in the bottom left hand corner of the display as the test is performed Auto calibrate key When this key is pressed the transmitter will calibrate the analogue output channels that are set to auto calibration see chapter 10 This is performed by directing the output current away from the output terminals terminals 12 amp 13 and 14 amp 15 back to an analogue input to the transmitter in order to calculate a zero and span calibration factor for each of the output channels During this process normal output to the analogue channels will be interrupted sending the outputs to zero mA 30 TELE
56. fault settings are highlighted in bold Baud Rate 9600 19200 38400 57600 Parity Even Odd None Stop Bits 1 Interface RS 485 RS 232 All holding register addresses contain a single 16 bit value however some variables span multiple holding registers to yield a single 32 bit variable When reading register values be aware that the byte order of data within registers may differ from that of the target system Modbus Protocol The modbus over serial line protocol defines a messaging system for master slave communications Only one master device may be connected to any network with one or several slave nodes In unicast mode the master initiates communication with a specific slave node by sending a request message The slave processes the request and returns a reply message containing the requested information or a confirmation that the request was fulfilled Modbus requests are transmitted as a formed request frame with a CRC for data integrity checking The frame for each request and reply type will vary somewhat but will always have the basic structure described below up to 255 bytes Internal Representation of Dates amp Alarm Status The transmitter stores all dates as an unsigned 32bit count of seconds elapsed since 1 Jan 2004 61 TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual Alarm status is stored as an integer value 1 self cleared 3 acknowledged 62 90602 Transmitter Modbus Input Register T
57. ger unsigned integer unsigned integer TELEDYNE ANALYTICAL INSTRUMENTS 65 Model 90607 Manual 9060Z Transmitter Modbus Holding Register Table for firmware v1 16 and newer Analyser Calibration amp Configuration Transmitter 1 Configuration Reg Description Bits 50mV Reference Voltage 200mV Reference Voltage 1200mV Reference Voltage 2500mV Reference Voltage Single Dual Probe Service Date Probe 1 Type Probe 1 TC Type Probe 1 Offset Probe 2 Type Probe 2 TC Type Probe 2 Offset Aux TC Type Flue Pressure Units Flue Pressure Value Temperature Units Oxygen Display Units Lower Line Items Reference Air Pump Reference Air Pump Voltage Reference Air RH Oxygen Damping Factor Ambient Temperature Offset Transmitter 4 20 0 20mA Select Transmitter Output Limiting for Low Ten 16 Manual Mains Voltage Select Transmitter 1 Output Transmitter 1 Zero Linear Oxygen 1 Transmitter 1 Zero Linear Oxygen Avg 16 Transmitter 1 Zero Very Low O2 1 16 Transmitter 1 Zero Reducing O2 16 Transmitter 1 Zero Oxygen Deficiency 1 16 Transmitter 1 Zero Boiler Efficiency 16 Transmitter 1 Zero Dry CO2 16 Transmitter 1 Zero Probe 1 EMF 16 Transmitter 1 Zero Aux TC Temp 16 Transmitter 1 Span Linear Oxygen 1 16 Transmitter 1 Span Linear Oxygen Avg 16 Transmitter 1 Span Very Low O2 1 16 Transmitter 1 Span Reducing O2 1 16 Transmitter 1 Span Oxygen Deficiency 116 Transmitter 1 Span Boiler Efficiency
58. ging n 27 Fuel N 42 53 Graphical display rm 29 Heater interlock Tela a cicer tus FD EI Coq PAS ERIS deas 21 Installing 9060H Oxygen Probe 15 a cM 35 Mains Valtaga detecllop 46 MODBUS 25 Mo nting th TransmitteT ud qutbus deua 15 Number of probes 39 OQu tpu ts A 20MA Tm 37 39 40 Pressure Trans o mE 28 Probe 22 55 gt TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual Probe EEE RE TEENETE EEEE EEE 34 PUI ge ir e 53 Purge and calibration connections ere 24 COMMOTION sas 25 Reference air OP CONS TETTE TT 42 Reference VOM AICS TTE OO 46 RUN 27 crudus ea
59. gt TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual 7 2 COMMISSIONING MODE FUNCTIONS 7 2 1 Internal Date Time The date and time are used in the transmitter to run time based operations such as impedance readings and gas calibration checks The correct date and time should be entered by pressing and holding the OPTION UP amp DOWN keys The date and time will change faster the longer the OPTION key is held 7 2 2 Service Date The service date can be used to keep a record of when a probe was changed The RUNTIME timer which keeps a track of the hours and minutes that the transmitter and probe has been operating is reset when the service date is changed The service date and the runtime timer can be displayed as lower line items in RUN mode 7 2 3 Number of Probes The 9060Z transmitter can operate in single or dual probe mode By selecting single probe all dual probe options and alarms will be disabled and second probe options hidden from the user If you are using the transmitter as a single probe device you should set the number of probes to single probe to disable all probe 2 alarms and display items 7 2 4 Probe 1 amp 2 Type The probe type function allows a selection between a heated probe and an unheated probe types Heater control and alarms will be disabled if unheated probe type is selected 7 2 5 Probe 1 amp 2 Thermocouple Type The thermocouple type can be set to K J R or S The thermocouple in the Teledyne
60. he same key during the cycle 51 gt TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual 12 SOFTWARE UPGRADES The software for the 9060Z series transmitters is contained in memory inside the microprocessor integrated circuit IC The transmitter therefore does not require an external memory IC for the software Provision has been made to enable the software to be upgraded in the field without the use of a computer If an upgrade is to be made to the software it will be supplied in a 32 pin EEROM IC type 29 010 do the upgrade use the following steps 1 Turn the power off to the transmitter at the power switch 2 Remove the hose from the reference air pump if fitted 3 Unplug the reference air DC power lead if fitted 4 Undo the two M4 screws at the top and bottom of the main shield 5 Remove the earth screw from the main shield on the right hand side of the cabinet 6 Lift out the main shield around the cable glands 7 Fold out the two wings of the blue socket labeled FIRMWARE UPGRADE SOCKET Plug the 29F010B into the socket Carefully note the direction of the IC Pin 1 is identified on the PCB and pin 1 on the IC has a small round indentation next to the pin 8 Hold down the DISPLAY down and the ALARM LOG keys and then turn on the power 9 Release the keys when the message Verifying the EEROM will be shown The transmitter is confirming that the new firmware is valid 10 After the EEROM has been read an
61. he tag If in doubt the best option is to set the offset to 0 0mV because this will only produce an error of around 0 196 oxygen in a combustion application for a 1mV error in the offset value For information on checking the probe and transmitter system with a certified gas see chapter 11 10 2 COLD START The intention of the cold start function of the transmitter is to return all of the configuration set up back to the default values There are 3 parts to the cold start 1 Ifa software upgrade is installed and the changes require a change to the menu functions then the transmitter will automatically do a cold start The transmitter will also do a cold start when the power is turned on and the configuration calibration factors are found to be corrupted It will only reset either the configuration values or the calibration values if either of them is found to be corrupted 2 Acold start can be forced if the operator wants to reset the transmitter back to the default set up See chapter 10 2 1 Forcing a Cold Start 3 Resetting the calibration factors back to the default values See chapter 10 2 2 Resetting the Calibration Factors 10 2 1 FORCING A COLD START The cold start can be initiated by following these steps 1 Turn the transmitter power off 2 Use a fine point or screw driver to turn the COLD START switch on The switch is at the bottom of the 1732 1 PCB accessible through the window in the shield 3 Turn the transmitter back o
62. ibles 1 16 Transmitter 2 Span Dry CO2 1 16 Transmitter 2 Span Probe 1 EMF 16 Transmitter 2 Span Aux TC Temp 16 Transmitter 2 4 20mA Cal Mode Transmitter 2 4mA Trim Transmitter 2 20mA Trim Alarm m Relay 1 Options Alarm Relay 2 Options Alarm Relay 3 Options Common Relay Opti Fuel Heat of combustion per gram atom 16 Fuel Hydrogen Carbon atom ratio 16 Fuel Oxygen Carbon atom ratio 16 Fuel Nitrogen Carbon atom ratio 16 Fuel Sulphur Carbon atom ratio 16 Fuel H2O molecues Carbon atom ratio 16 unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer unsigned integer D 66 gt TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual Reg Description Bits Solenoid 1 Operation Cal Purge unsigned integer Solenoid 1 Auto Man unsigned integer Solenoid 1 Start Time unsigned integer Solenoid 1 Period unsigned integer Solenoid 1 Purge Cal Duration unsigned integer Solenoid 1 Post P C Freeze unsigned integer Solenoid 1 Calibration Gas Content unsigned integer Solenoid 1 Calibration Gas Positive Error 16 unsigned integer Solenoid 1 Calibration Gas Negative 16 unsigned integer Solenoid 2 Operation Cal Purge Solenoi
63. if it is necessary to clean the case use either a warm soapy water solution or an isopropyl alcohol A build up of dust on or around the transmitter should be removed before the cabinet door is opened If there is a buildup of dust inside the cabinet check the door o ring seal for damage and replace it if necessary Take care when wiping the display window to avoid scratching the surface If the filters of the probe if fitted become blocked use an ultrasonic cleaner with a few drops of household detergent If the filters cannot be cleaned this way replace the sintered filters The filter in the base of the analyzer may become blocked if the analyzer is operating in a dusty environment It is available as a field replacement item 14 3 REPLACEMENT PARTS The following list identifies field replaceable parts 1732 1 Main PCB 1732 2 Display PCB MP 24E Reference air pump Fuse M205 3 15 250V fuse pack of 5 Instruction manual EEROM 9060 firmware FIL 230 Titanium sintered filter 30um FIL 215 Titanium sintered filter 15um Filter analyzer bulkhead 54 gt TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual 15 INDEX 9060H Oxygen PION GS e csaxddoualdsoidexedeaececesaaulantansdaianuadleauddndausaceravedonsudeenguedtensuvecagitecensduraneiacaadlindaanond 9 Alarm RR 23 Alarmlog clearing 43 Alari relay
64. ir regulator Then the setting on the rotameter flow regulator will be the same as that for the airflow The flow required is 1 to 5 SLPM 2 to 10 SCFH for a 9060 probe and up to 20 SLPM 40 SCFH for an unheated probe Air is not the best gas for calibration checking on a zirconia sensor The output of a zirconia sensor with air on both sides of the sensor is zero millivolts It is better to choose a gas value which provides a reasonable output from the sensor and which is near to the process oxygen level A cylinder with 2 oxygen in nitrogen is a commonly used calibration gas The maximum pressure on the calibration check gas cylinder regulators is 100 kPa 15 psi Note If Dual probe was selected in commissioning menu 4 Cal Gas 2 must be connected to probe 2 4 19 DUST IN THE FLUE GAS For unheated probes with no filter entrained solids or dust in the flue gas does not present a problem unless the dust when settled is not porous Allow the dust in the process to build up on the probe It will form a porous layer slowing the response time To avoid mechanical abrasion of the electrode material in installations with unheated oxygen probes pack SAFFIL or equivalent alumina based ceramic fiber in the sensing holes to protect the electrode Do not use silica based ceramic fibers such as KAOWOOU which can attack the electrode at high temperatures Once the dust has built up the response time of the probe will be slower
65. ither 100 110VAC or 220 240VAC with a mains frequency of 50 or 60Hz e The supply circuit must be fused to at least 10Amps and have a dual pole isolation switch within easy access of the oxygen transmitter 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 transmitter so that a transmitter can be serviced individually The power supply cables must be supplied and installed according to local regulations e The earth connection must comply with the local regulations must have a current carrying capability e equal or greater than the supply fuse current rating e The earth connection must be connected to the primary earth stud inside the transmitter on the right hand side e All other bonded earth connections from the external wiring must be connected to the primary earth stud All operations relating the electrical wiring and installation must be carried out by qualified persons in accordance with the safety regulations and the wiring rules NOTE The power switch in the transmitter can be used to turn off the transmitter There must be an approved isolation device installed to provide complete isolation of the mains power to the transmitter The mains wiring terminal must not be used as an disconnect device 4 6 HEATER INTERLOCK RELAYS CAUTION Explosion protection for heated probes is achieved by switching the power to the probe heater off whene
66. link terminals 10 amp 11 O 10 BURNER INPUT O 11 BURNER INPUT Optional wiring 4 20mA Outputs User selectable ranges 12 OUTPUT 1 13 OUTPUT 1 14 OUTPUT 2 b Optional wiring 150UTPUT2 ressure sensor to detect a plocked filter during the 16 FLOW SWITCH automatic purge cycle 17 FLOW SWITCH O 18 RS232Rx Optional wiring O 19 RS232Tx Digital communications Connect to O 20 NETWORK a MODBUS network or computer 21NETWORK chapter4 15 and 7 2 25 O 22 NETWORK COM Optional wiring 23 Additional analogue input 24 BFT Not used the 90607 O 25 BFT White 44 HEATER1 White 43 HEATER1 Oxygen Sensor 1 Oxygen 2 White 42 HEATER2 White 41 HEATER2 O 40 CAL PRG1 O 39 CAL PRG2 Optional wiring Gas solenoids MAINS VOLTAGE output Automatic system calibration checking or Essential wiring Mains Power 100 240VAC EARTH must be connected to PE earth stud Optional wiring Alarm relays User programmable NC contacts DO NOT USE MAINS VOLTAGE and LO OLTAGE on ADJACENT TERMINALS 38 SOL COMM o 37 MAINS A 36 MAINS N 35 34 MAINS E 33 ALARM3 32 ALARM3 31 ALARM2 30 ALARM2 29 ALARM 1 28 ALARM 1 27 COM ALARM 26 COM ALARM Connection Diagram for 9060Z Transmitter and one or two 9060H Heated Sensors 18 gt TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual Essential wiring Probe enable input Burner safety interlock or if
67. ll not up to 650 C 1200 F or the probe temperature falls below 650 C 3 Probe 1 High Impedance 45 gt TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual 4 Probe 2 High Impedance Oxygen probe or electrode failure The sensor has a high impedance measurement Replace the probe This alarm is inhibited when the probes are less than 650 C 1200 F 5 Probe 1 TC Open Circuit 6 Probe 2 TC Open Circuit Probe thermocouple is open circuit The heater in heated probes will switch off 7 Aux TC Open Circuit The AUX thermocouple is open circuit If the thermocouple is not needed select Disabled in COMMISSIONING menu function 9 Aux TC Type or place a short circuit between terminals 7 amp 8 8 Ref Air Pump Fail The reference air pump in the transmitter has been either unplugged or has gone open circuit lt 20mA Replace the reference air pump 9 Ref Air Pump Overload The reference air pump in the transmitter has stalled and is drawing in excess of 300mA The transmitter will attempt to restart the pump every minute for 1 second Replace the reference air pump 10 ADC Calibration Fail The analogue 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 Out
68. losed circuit Closed circuit The default setting is Enabled after a cold start 7 2 23 Selecting the Correct Fuel The 9060Z transmitter can calculate several measurements that are based on the oxygen reading and the temperature of the process gas These calculations also require some details about the chemical makeup of the fuel The additional calculations are Oxygen deficiency The volume of oxygen required to bring the combustion back to stoichiometry Combustibles This theoretical scale is equivalent to a combustibles analyzer maximum dry efficiency mode Select the required fuel in function 50 by using the OPTION keys and then press the ENTER key The table of values in the next 6 functions will be updated for that fuel 7 2 24 Reference Air Pump Options Normally the reference air is supplied from the transmitter using the internal pump The default option is 5 00v Reference Air Pump External or Internal 058 Internal Pump Voltage Pump voltage setting between 2 5 and 5 00 in 0 25v steps Reference Air RH96 If external is selected set the RH level 596 if instrument air is used 40 gt TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual 7 2 25 Communications Port Options The 9060Z transmitter has a serial communications port available at terminals 18 to 22 The default protocol is for RS 232 running at 19 200 baud rate with 8 bits Even parity and 1 stop bit 60 Serial Interface RS 232 or RS
69. lower line The probe or sensor temperature can be checked on the lower line of the display 4 16 PROBE OR SENSOR CALIBRATION The zirconia sensor provides an absolute measurement of oxygen partial pressure There are no calibration adjustments apart from Probe 1 Offset for the probe The zirconia sensor EMF is either correct or it needs to be replaced To check that the probe is functioning correctly first check that the 24 gt TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual high impedance alarm Probe 1 2 High Impedance is not active The actual impedance can be displayed on the lower line It should be less than 9 KQ at 720 C 1320 F Once it has been established that the impedance is normal the offset may be set using the millivolt value marked on the oxygen probe See chapter 6 3 1 Probe Offset The probe offset can be tested on site A small flow of air must be admitted to both the REF and CAL ports when testing the probe offset If the probe is in the process the air must fully purge the probe sensor without interference from the process gas sample Teledyne Analytical Instruments probes can easily achieve this with or without a probe filter and a gas flow of only 1 to 5 SLPM 2 to 10 SCFH for a 9060H probe and up to 20 SLPM 40 SCFH for an unheated probe When a stable oxygen reading has been achieved read the Probe EMF Enter this value into the set up menu 1 for the probe 1 set up 2 f
70. mo 18 Combustion efficiency requires Single probe and Aux Type to be set 19 Flue Pressure 20 Burner run time 21 Service date 22 Analog Output 1 4 20mA 23 Analog Output 2 4 20mA NOTE An asterisk on the end of the line identifies the item is enabled by default after a COLD START 6 3 3 Oxygen Display Units The top line of the display that shows the oxygen measurement can be displayed in either 96 or ppm see chapter 5 2 Oxygen Display Units 6 3 4 Damping Factor The oxygen measurement can be damped by averaging successive readings from the probe This will smooth out fluctuations in the process gas level and will slow down the reaction time of the transmitter The larger the number selected here the more successive readings are averaged and the smoother the measurement will be The damped oxygen value is also used in the calculation of all other parameters that are based on the oxygen value 6 3 5 Process Alarms This function allows the operator to enable and disable process alarms The process alarm menu functions will also be hidden if the process alarms are disabled See also chapter 7 2 19 Process Alarms 33 gt TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual 7 COMMISSIONING MODE This chapter describes the functions available when the COMMISSIONING mode is entered on the transmitter The COMMISSIONING mode is accessed by pressing and holding the SETUP key for approximately 2 seco
71. n 4 You will be prompted to select Reset or Cancel to the prompt Reset Calibration Data Press the DISPLAY up key to reset the calibration factors and the configuration data or the ALARM up key to only reset the configuration of the transmitter 5 Turn off the cold start switch when prompted by Turn off C Start Switch If the calibration factors have been reset follow the instructions in chapter 10 1 to recalibrate the transmitter If only the configuration has been reset it is also important to check items that will affect the transmitter outputs number of probes the serial communications the solenoid configuration and other items 10 2 2 RESETTING THE CALIBRATION FACTORS If it is required to reset the calibration factors follow the instructions in the previous section and select Reset when prompted to Reset Calibration Data 50 gt TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual 11 GAS CALIBRATION CHECK AND PURGE The oxygen sensor that is used in the Teledyne Analytical Instruments oxygen probe is extremely predictable stable and reliable For this reason the calibration of a Teledyne Analytical Instruments oxygen system does not require the use of calibration gases However all Teledyne Analytical Instruments oxygen probes have a built in gas connection that does allow the accuracy of the probe to be checked in situ This chapter describes the operation of this gas checking system
72. nds until the words Commissioning Menu appears at the bottom of the display The transmitter will return to the RUN mode when the SETUP key is pressed again or 60 seconds after the last key press Changing options in the COMMISSIONING mode is the same as the SETUP mode See chapter 6 2 Changing Options 7 1 FUNCTION SUMMARY TABLE When the transmitter is in the COMMISSIONING mode the SETUP light will be on and the words Commissioning Menu will be shown the bottom of the display The following table shows the COMMISSIONING menu functions Menus Function name Range Default value a RE ap AN ae H GARY neice 03 Service Date 04 _ NumberofProbes Singe DualPrbe Single Probe _ ___ 05 Probe 1 Type 9060H 9060H Heated 06 Probe 2Type 7 _ 9060H Heated __ _ __ 07 Probe 1 TC Type J Ror S Types KType 08 Probe2TC Type 5 Klpe 09 AuxlayTCType _ KJ R or S Types Disabled Disabled _ _ ____ 10 Transmitter Output Channel 1 _Linear oxygen _ 11 Transmitter Zero Channel 1 12 E Transmitter Span Channel 1 Seechapter7 27 Transmitter 1 13 Transmitter Output Channel 1 Output Channel _Linear oxygen _ 14 Transmitter Zero Channel 2 15 Transmitter Span 2 e 16 Flue Pressure Units Inches WG mm WG kPa PSI Inches V WG BEES 47 Flow Pressure Input Fixed Variable Fixed 18 Valu
73. ny or all of the following alarms or warnings Probe 1 Temperature Low Probe 2 Temperature Low Progress Progress Purge on probe 1 in Progress Purge on probe 2 in Progress In addition to the above process alarms that can activate the process alarm relays any of the common alarm relay events that have been taken off the common alarm list in COMMISSIONING menu function 49 will appear on the process alarm relay lists in function 46 to 48 48 TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual 10 INSTRUMENT CALIBRATION 10 1 CALIBRATION SUMMARY The 9060Z oxygen transmitter has a self calibration and diagnostic system built into the hardware and software Once the reference voltages have been set into memory the self calibration system maintains the calibration of the transmitter An automatic update of the zero and span is done every minute The 4 20mA outputs can be automatically calibrated with the press of the AUTO CAL key or manually fine tuned One entry for each probe offset is required to optimise the calibration of the oxygen measurement although an automatic system calibration check can be programmed into the transmitter using certified gasses 10 1 1 CALIBRATION OF THE INPUTS The calibration of the analogue inputs is based on the voltage of a temperature compensated voltage reference integrated circuit There are 4 voltages generated from the standard reference voltage They will vary by about 1 from one
74. olves this problem The effects of stratification can be reduced by using two probes and averaging the two oxygen readings This can be achieved within a Teledyne Analytical Instruments 9060Z transmitter controlling two probes 4 21 CONNECTING A PRESSURE TRANSDUCER If the process gas pressure varies more than 4 WG and therefore requires automatic compensation connect a pressure transducer as shown below Place a link across LK2 near to the input terminals 24 amp 25 If the link is not populated you can achieve the same thing connecting a 1200 resistor across the two terminals A pressure change of 4 WG will cause a change in the calculated oxygen reading of approximately 1 24 120ohm Resistor 25 There calibration adjustments for the zero or span of the pressure transducer input Set the transducer scale range in the commissioning menu See Section 7 2 8 The pressure can be displayed on the lower line by enabling the corresponding option See Section 6 3 2 26 gt TELEDYNE ANALYTICAL INSTRUMENTS 5 DISPLAY AND KEYPAD Operator interaction with the oxygen transmitter is done through a graphical display and 8 keys on the front of the case The five LED indicators are used to show the status of the transmitter and to alert the operator of any errors Each of the keys has a dual function The BLACK text printed on the key is the function while the transmitter is in the RUN mode The WHITE text prin
75. omatic Purge amp Mains Voltage gt 38 Sol Common Calibration check 110 240 ZU Solenoids System Wiring 39 Cal Purge2 Sol Schematic 38 Sol Common Check Gas Flowmeter Reguiator 5 Itres min 10 scm To Oxygen Probe port 4 Automatic Purge amp 140 20 Calibration check System Piping Schematic Clean amp Dry Purge J Supply 140 kPa max 20 51 4 12 CONNECTING REFERENCE AIR For oxygen probes a 1 4 tube connector on the transmitter should be connected via a nylon copper or stainless steel tube to the REF connector on the probe If two probes are being used a T fitting must be supplied to provide reference air supply to both probes 4 13 CONNECTING THE TRANSMITTER TO A MODBUS NETWORK The transmitter can be networked to other transmitters and to a network master The network uses the transmitter s RS485 port Up to 31 transmitters can be connected to the network and can be interrogated by the Network Master NOTE Hardware Protocol Selection The communications port of the 9060Z can be configured to communicate on either RS232 or RS485 If the transmitter is to be used on a MODBUS network the 9060Z transmitter must be set to RS485 For further details see chapter 7 2 25 Communication Port Options NOTE Terminating Resistor There is a terminating 100 ohm resistor fitted to the 1732 1 PCB
76. or the second probe if it is installed 4 17 FILTER PURGING Purging probe filters is controlled from the GAS PURGE buttons on the transmitter when in RUN mode If Automatic has been selected in either Sol 1 Auto Man or Sol 2 Auto Man in Commissioning Menus 21 or 30 pressing the GAS PURGE button will start the automatic cycle Pressing the button again will cancel the auto purge cycle If Automatic was not enabled the solenoid will only stay open for as long as the button is pressed Gradually adjust the purge air supply regulator increasing the pressure until sufficient flow is obtained to clear the filter This is best checked with a dirty filter after a period of operation by withdrawing the probe from service and watching any build up on the filter being blown off at the set pressure Normally 30 kPa 5 psi is adequate but the air pressure may be set as high as 100 kPa 15 psi 4 18 CALIBRATION GAS CHECK If the installation has a filter purge facility set this up first Refer to the previous paragraph Press the GAS PURGE 1 GAS PURGE 2 button while in SET UP mode to obtain a reasonable flow through the calibration check gas flow meter If air is being used as a calibration check gas use the air from the regulator for filter purge Then when setting up a gas for calibration checking set the pressure from the calibration gas cylinder so that it is the same as the pressure set on the a
77. ovides application and after sales support for oxygen probes sensors and transmitters worldwide Model 9060H Heated Oxygen Probe Model 9060UL UH Unheated Oxygen Probe 2 3 Warning Symbols A Danger high voltage Risk of electrical shock A Caution hot surface 9 TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual A Caution risk of danger See additional information in the manual 3 1 HARDWARE SPECIFICATIONS 2 maximum 0 1 to 0 100 1 of actual measured oxygen value with a repeatability of 0 5 of the measured value J S 0 20 or 4 20mA field selectable Active outputs Do NOT loop power these outputs 1000 ohm max 2A 240VAC 2 100 to 240VAC 6 1096 50 60 Hz Category Il IEC60364 4 443 5W for controller plus probe power 530W max 25 duty cycle each probe on 240VAC 110W max 100 duty cycle each probe on 110VAC 2 5A max 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 54 with internal reference air pump 260mm 10 2 wide 160mm 6 3 high 90mm 3 5 deep 3 Kg 6 6 lbs 3 1 2 STANDARD U LENGTHS 9060H 9060UL UH 250 mm 10 500 mm 20 350 mm 14 750 mm 30 500 mm 20 1000 mm 40 750 mm 30 1500 mm 60 1000 mm
78. put 1 Failure 13 Output 2 Failure The digital to analogue 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 See chapter 10 1 2 14 Heater 1 SSR Failure 15 Heater 2 SSR Failure One of the heater power control devices SSR has been found to have failed See chapter 8 2 8 Heater SSR fault correction 16 Heater SSR Leakage One of the heater power control devices SSR has been found to have failed but the transmitter cannot determine which one s has failed 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 See chapter 11 This alarm will not reset until the next purge cycle The cycle can be initiated manually or automatically 46 gt TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual 19 Gas 1 Calibration Error 20 Gas 2 Calibration Error At the end of an automatic gas calibration check cycle the oxygen reading was outside the values set in the COMMISSIONING menu 26 to 28 35 to 37 This alarm will not reset until the next calibration check cycle The cycle can be initiated manually or automatically 21 BBRAM Fail All of the setup options are held in the battery backed memory This is the battery shaped device at the bottom cent
79. r probe purge Some of the menus between functions 22 to 28 31 to 37 will not appear depending on what has been selected in function 20 and 21 29 and 30 7 2 12 Solenoid 1 amp 2 Automatic Manual When set to automatic the solenoid will perform a pre programmed gas calibration or purge cycle When set to manual the solenoid is controlled directly from the corresponding key on the front of the case When set to automatic the calibration check or the purge cycle can be started by pressing the corresponding key on the front of the case It can be stopped by pressing the same key again 7 2 13 Solenoid 1 amp 2 Start Time For automatic gas calibration checking or purge events a start time is specified to allow precise control over the timing of such events Starting at this specified time the next gas calibration or purge event will occur in successive intervals from this time 7 2 14 Solenoid 1 amp 2 Period This option specifies the period between automatic gas calibration or purge events For periods less than 24 hours the period is divisible into 24 hours forcing scheduling of events to occur at the same time each day between 1 minute and 7 days The No Timed Operation option accessible by scrolling the option below 1 minute allows for pre configured solenoid cycles to be triggered manually via the keypad but without the automatic scheduling 7 2 15 Solenoid 1 amp 2 Duration Duration of time that an automatic gas calibra
80. re of the 1732 1 PCB labeled MEM1 This alarm will occur when this device fails and will need to be replaced 9 2 SELECTABLE PROCESS ALARMS The alarm relays 1 2 and 3 are generally used to transmit a gas related alarm event Any or all of the following functions can be selected for each relay The trip levels and the delay times are set is in the COMMISSIONING menu NOTE The process alarms will only be activated if they are enabled in the SETUP function 6 See chapter 6 3 5 21 Oxygen 1 Very Low 22 Oxygen 2 Very Low The measured oxygen level on the indicated probe has been below the trip level shown in COMMISSIONING menu function 38 for longer than the delay time shown in function 39 23 Oxygen 1 Low 24 Oxygen 2 Low The measured oxygen level on the indicated probe has been below the trip level shown in COMMISSIONING menu function 40 for longer than the delay time shown in function 41 25 Oxygen 1 High 26 Oxygen 2 High The measured oxygen level on the indicated probe has been above the trip level shown in COMMISSIONING menu function 42 for longer than the delay time shown in function 43 27 Oxygen Deviation The difference between the oxygen level measured on probe 1 and the oxygen level measured on probe 2 is greater than the trip level shown in COMMISSIONING menu function 44 for longer than the delay time shown in function 45 28 Probe 1 Temperature Low
81. rmally avoided with flue gas trim systems by adjustment so that in the case of failure the appliance will not generate CO in excess of 400 ppm in the flue The CO level in the flue should be measured with a separate CO instrument normally an infrared or fuel cell type CAUTION 3 The oxygen probe is heated to over 700 C 1300 F and is a source of ignition Since raw fuel leaks can occur during burner shutdown the transmitter has an interlocking relay that removes power from the probe heater when the main fuel shut off valve power is off If this configuration does not suit or if it is possible for raw fuel to come into contact with a hot oxygen probe then the Model 9060Z transmitter with a heated probe will not be safe in your application An unheated probe can be utilized in such applications however the oxygen readings are valid only above 650 C 1200 F CAUTION 4 The reducing oxygen signal from the transmitter and the associated alarm relay can be used as an explosive warning or trip This measurement assumes complete combustion If incomplete combustion is possible then this signal will read less reducing and should not be used as an alarm or trip A true excess combustibles analyzer normally incorporating a catalyst or thermal conductivity bridge would be more appropriate where incomplete combustion is possible Also read the probe electrical shock caution in the probe heater interlock caution in chapter 4 7
82. rtant Notice Regarding 9060 Probe Option FIL 3 WARNING The only identifiable standard for flame arresters for general use is British Standard BS EN 12874 2001 British Standard BS EN 12874 2001 refers to an operating environment up to 150 Degrees Centigrade The FIL 3 device optionally fitted to 9060 Heated Zirconia Probes the Probes or Probe operate in an environment considerably greater than 150 Degrees Centigrade Therefore we know of no Australian British European or USA standard applicable to flame arresters or their testing above 150 degrees Centigrade Consequently the FIL 3 device cannot be certified as a safety device The probe is only on probes during the start up processes of a combustion appliance The Teledyne Analytical Instruments Burner Interlock Relay facility which is a standard part of the Teledyne Analytical Instruments transmitter is designed to be wired to the main safety shut off fuel valves in a way that can shutdown the probe heater when the fuel valves are closed The risk of ignition of flammable gas mixture at the hot end of the Probe can only be minimized by correct use maintenance and operation of the FIL 3 device The user of the FIL 3 device is responsible for verification and maintenance and correct use and operation of the FIL 3 device THE USER AGREES THAT IT USES THE PROBE AND THE FIL 3 DEVICE AT ITS SOLE RISK TELEDYNE ANALYTICAL INSTRUMENTS TO THE FULL EXTENT PERMITTED BY LAW GIVES NO WAR
83. smitter is in the CALIBRATION mode the SETUP light will be on and the words Commissioning Menu will be at the bottom of the display The following table shows the CALIBRATION menu functions lcu NE GLEN Ec value 2 Reference Voltage 2 200mV_ 180001021000mV 18224mV Reference Voltage 3 1200mV 115001012500mV 12218mV 4 Reference Voltage 4 2500mV 240001025500mV 2M4892mV Output Channel 1 Calibration Auto Calibrated Manual Calibrated Set Auto 4mA Set 20mA Calibrated 6 Output Channel 1 4mA Trim 3 00 to 5 00mA 4 00mA Output Channel 1 20mA Trim 19 00 to 21 00mA 20 00mA Output Channel 2 Calibration Auto Calibrated Manual Calibrated Set Auto 4mA Set 20mA Calibrated 9 OwpuhamelAmATim 300t50m 41 Ambient Temperature Sensor Offset A00 Cto100C 00 32 lowOwgentall 800 to120 0 1100006 Transmitter Output Select 4 20 0 20 4 20mA over 4 20mA scale limit 0 20mA over scale limit Transmitter Output Limiting Disabled Hold OmA Hold 4mA Hold OmA Hold 20mA 16 Mains Voltage Detection Override Automatic 220 240 10 120 Mains Frequency Detection Override Automatic 50Hz 60Hz Heater SSR Selection Normal Heater1 lt gt Heater2 Heaters lt gt Cal Purge SSR Fail Protection Enabled Disabled Enabled 42 gt TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual 8 2 CALIBRATION MODE FUNCTIONS 8 2 1 R
84. ted on the key is the function in one of the three configuring menus SETUP COMMISSIONING and CALIBRATION The menu driven modes are accessed by pressing and in some cases holding down the SETUP key see chapters 6 7 and 8 for details of these modes The transmitter will return to the RUN mode when the SETUP key is pressed again or if 60 seconds has elapsed since the last key was pressed 5 1 Graphical Display In RUN mode the 9060Z shows the first oxygen probe measurement in large characters at the top of the display and a user selectable lower line in smaller characters below Other items on the display include the activity heartbeat indicator in the top right corner a row of single letter action indicators in the bottom left corner and the current time in the bottom right corner Heartbeat Power on gt e POWER OXYGEN TRANSMITTER indicator indicator a m 5 23 Lower line Probe 1 TC 720 3 C Secondary measurements ZABT 13 34 33 In SETUP mode the RUN display is replaced with a menu driven interface All other functions of the transmitter reading calculating and transmitting etc aside from the keypad and display will continue to operate as normal TELEDYNE ANALYTICAL INSTRUMENTS Action indicator see Operators Manual for details Model 90607 Manual 5 2 OXYGEN DISPLAY UNITS The measured oxygen content displayed on the top line of the transmitter for probe 1 and on the lower line for probe
85. ten ee 33 Setup mode 17 34 Software Upgrade qud out Do qui dun RUNE 55 SPECIFICATIONS 12 Specifications 11 Specifications SOTTWAFe Moe IND M M AM NM UE 14 SSR Bault Correcto M 46 Pt 28 TEMPCrature UNITS 02 40 Troubles NOE aE 57 58 Voltage Mains a5c 0sadanieadieesoutdaaadiaceaduedadousdoanpusacencdbeideudlacesdueaoedeheaguvlatasdeccaauddentsuesagliateatdiddege 11 IEEE 7 56 TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual APPENDIX 1 CONSTITUENT VALUES FOR VARIOUS FUELS If the transmitter is set up to have readout or output of combustibles oxygen deficiency maximum carbon dioxide or combustion efficiency then the fuel constituents must be entered Any or all of the variables can be modified and entered in COMMISSIONING menu functions 50 to 56 See chapter 7 2 23 Your fuel supplier or chemist should be able to give you all these values is the heat of combustion of the fuel gram atom of contained carbon H is the H C atom ratio in the fuel 0 is the O C atom ratio in the fuel N atom ratio in the fuel S is the S C atom ratio in the fuel _ isthe
86. the 9060H 9060UL UH probe The model 9060Z oxygen transmitter is based on the well known model 9060H transmitter It includes a number of hardware and software improvements such as a graphic display larger characters faster microprocessor simplified set up menu alarm logging faster probe heater control and more calculated values such as burner efficiency The 9060Z Oxygen Transmitter has a variety of user selectable functions They are simple to use because each selection is menu driven For options you are not sure about read the manual on that particular item in chapter 6 Setup Mode Features include Inputs Two zirconia oxygen probes heated or unheated Oxygen read 0 196 to 0 10096 Furnace kiln or flue thermocouple field selectable as type K J Ror S Main flame established safety interlock for heated probes only 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 two wire 5 485 MODBUS for connection to a computer DCS PCL for diagnostics of the transmitter probe or combustion process Display Multi font graphical display Large font characters for the oxygen on the top line Selectable lower line items for the secondary display functions ie Probe temperature Oxygen second probe Alarm display mode that
87. tion or purge event energizes the solenoid 38 gt TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual 7 2 16 Solenoid 1 amp 2 Post Freeze Duration of time the transmitter waits before resuming live readings following a gas calibration or purge event See also chapter 7 2 10 7 2 17 Oxygen Content Calibration Gas 1 amp 2 When configured as a gas calibration check solenoid this value specifies the oxygen content of the calibration gas 7 2 18 Maximum Calibration Gas 1 amp 2 Positive Negative Error Specifies the maximum positive amp negative error levels used during the gas calibration check If the difference between the specified oxygen content and the measured process gas exceed these thresholds a gas calibration error alarm will be triggered immediately 7 2 19 Process Alarms The oxygen measurements are continuously monitored by the transmitter for process alarm conditions Process alarms must be enabled in the Set up menu The limits and the alarm time delays are configurable for the Very Low Oxygen alarm Low Oxygen alarm High Oxygen alarm and the Oxygen Deviation alarm 7 2 20 Alarm Relay 1 2 and 3 Function There are 3 user configurable alarm relays Any of the 3 relays can be configured to be triggered on the following alarm conditions In addition any of the alarm conditions that are disabled from the common alarm relay can also be configured to trigger these 3 relays Multiple selections can be made Ox
88. transmitter to another but can be trimmed by setting the actual voltages into CALIBRATION menu functions 1 to 4 The calibration should be done 30 minutes or more after the instrument has been on approximately once every year The calibration constants are retained in battery backed memory unless a COLD START is performed See chapter 10 2 Cold Start Connect a 3 1 2 digit multimeter negative lead to the test point marked COM in the centre of the 1732 1 PCB labeled V REFS Measure the four voltages on the test point marked 1 to 4 with the positive lead of the multimeter Enter the measured values in the CALIBRATION menu functions 1 to 4 Whenever new values are entered the D A Section should be re calibrated See chapter 10 1 2 10 1 2 CALIBRATION OF THE OUTPUTS The easiest way to calibrate the outputs is to select Auto Calibrated in CALIBRATION menu functions 5 and 8 If this is selected the outputs will be directed away from the output terminals and back into an analogue input of the transmitter The outputs are then tested and a zero and span calibration factor is recorded If a more accurate calibration is required select Manually Calibrated in CALIBRATION menu functions 5 and 8 This will inhibit the automatic calibration system overwriting the calibration factors However the zero and span factors will need to be manually set To set the calibration factors use the following steps for each output 1 Select
89. tter has proved an extremely reliable instrument The trouble shooting guide here is based on an analysis of the potential problem that may occur after many years of operation in the field A current list of problems and solutions can be found on the Teledyne Analytical Instruments web site at www teledyne ai com when any are identified 13 1 FIRST APPROACH The probe will not heat up Turn the power off remove and check 2 x 20mm glass fuses If either of them is blown check the probe heater resistance between the two white wires that come from the probe It should be 110 15 ohms and both wires should be open circuit to earth If not replace the probe Is the B shown on the bottom left hand corner of the display If not check that the burner is enabled with either a link between terminals 10 amp 11 BURNER INPUT or is enabled with a connection to a voltage free contact from the main fuel valve to these terminals The display is blank and there is no backlight on Measure the power supply voltages at the test points labeled COMM and 5v at the right hand side of the main PCB 1732 1 It should be 5 0 15v Turn off the power and remove the main shield Check that the plug in fuse FS1 has not blown It should only be replaced with a 1A 250v fuse if it has blown Is the mains power being supplied to terminals 36 amp 37 and is it between 100 and 240VAC If may be necessary to replace the switch mode power supply PS5 APC 5S An
90. ue o nad Eo eaa 38 7 2 10 Calibration Freezes 5 55254 d cud rd uil cx rideau nd cada o R RR 38 7 2 11 Solenoid 1 amp 2 38 7 2 12 Solenoid 1 amp 2 Automatic 38 7 2 13 Solenoid 1 amp 2 Start TII usce 38 7 2 14 Solenoid 1 8 2 cli a dn d 38 7 2 15 Solenoid 1 amp 2 Duration ded eda lel kid 38 7 2 16 Solenoid 1 amp 2 Post pro 39 7 2 17 Oxygen Content Calibration Gas 1 amp 2 39 7 2 18 Maximum Calibration Gas 1 amp 2 Positive Negative Error 39 7 2 19 Process Alal MS EDU 39 7 2 20 Alarm Relay 1 2 and 3 Function 1 1 1 1 1 39 7 2 21 Common Alarm Relay 1 1 39 7 2 22 Operation of the Alarm Relays when an Alarm is Accepted 40 7 2 23 Selecting the Correct Fuel orar nora sarah ydo ehe aka xvn OD n ror redd d ed ds 40 7 2 24 Reference Air Pump OptiOons
91. up procedure it will enter RUN mode and enable the keypad The key functions in this mode are as follows 28 gt TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual SETUP RUN key Pressing this key will put the transmitter into one of the menu driven SETUP COMMISSIONING or CALIBRATION modes see chapters 6 7 and 8 for details The function of all the keys will then change to the functions that they have in the SETUP mode DISPLAY UP DOWN keys The display keys are used to scroll the lower line up and down through the variety of measurements that are available on the lower line For a complete list of options see chapter 6 3 2 Lower Line Items ALARM UP key If 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 For more details on the alarm mode and keys see chapter 9 Alarms The SETUP light will flash slowly to show that the transmitter is now in the alarm display mode ALARM DOWN key When the transmitter is displaying active alarms the ALARM UP key has been pressed the ALARM DOWN key and the ALARM UP key allow the operator to examine the date time of the alarm and the date time that the alarm was acknowledged If the transmitter was in RUN mode when this key is pressed it will go into the alarm log display mode See chapter 9 for more details ALARM ACCEPT key Th
92. ver the main fuel valve is closed The principle of safety is that if the main fuel valve is open then main flame has been established With this primary source of ignition on the probe heater can be safely switched on The most dangerous situation is if fuel leaks into the combustion appliance when the fuel valve is closed When power is removed from the main fuel valve the heater should also be switched off To achieve this protection connect a main fuel valve voltage free contact to the BURNER INPUT terminals 10 amp 11 When the main fuel valve is open the voltage free contact should be closed For installations where there is no risk of explosion connect a link between terminals number 10 amp 11 For safety contacts must be open BURNER INPUT if the main fuel valve is closed Heater Supply Interlock Connection for Heated Probes If a safety interlock is not required a wire must be connected between terminals 10 amp 11 to enable e The heaters on heated probes e Process alarms e Auto purge and auto cal checking e Runtime timer 4 7 CONNECTING AN OXYGEN PROBE CABLE Connect the probe lead as shown in the following drawings Unheated probe leads have integral reference air tube An adaptor has been supplied to connect this tube to quarter inch flexible PVC tubing from the air pump or reference air supply 20 TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual connected to the EARTH screw in the transmitter Not
93. within the transmitter and the probe The other three alarm relays relate to the process gas All relays have user defined actions If one of the alarm events is removed from the common alarm using COMMISSIONING menu function 49 then this alarm event can be programmed for one of the other 3 alarm relays When the alarm mode has been entered the SETUP light flashes once a second until the SETUP key is pressed to return the transmitter to RUN mode All relays have fail safe alarm contacts That is When the transmitter is turned off the contacts are open circuit When the transmitter is on but there are no alarms the contacts will be closed When there is a current unaccepted alarm event the contacts will be open circuit When there is a current accepted alarm event the state of the contacts will depend on the selection in the commissioning menu 50 See chapter 7 2 22 Operation of the alarm relay when an alarm is accepted All alarms drive the alarm light on the front 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 acknowledged The light will be on steady if there are current alarm s that have not been cleared The light will flash faster as more alarms occur 9 1 COMMON ALARMS The events that drive the common alarm are 1 Probe 1 Heater Fail 2 Probe 2 Heater Fail A heated probe model 9060H has been turned on for more than 20 minutes but is sti
94. ygen 1 Low Oxygen 2 Low Oxygen 1 Very Low Oxygen 2 Very Low Oxygen 1 High Oxygen 2 High Oxygen Deviation 7 2 21 Common Alarm Relay Function The common alarm relay can be configured to be triggered on any of the following Instrument Alarms Probe 1 Heater Fail Reference Air Pump Fail Heater SSR Leakage Probe 2 Heater Fail Reference Air Pump Overload Probe 1 Filter Blocked Probe 1 High Impedance Alarm Log Fail Probe 2 Filter Blocked Probe 2 High Impedance Gas 1 Calibration Error Probe 1 Thermocouple Open Circuit Gas 2 Calibration Error Probe 2 Thermocouple Open Circuit Auxiliary Thermocouple Open Circuit Are only available in dual probe mode 39 TELEDYNE ANALYTICAL INSTRUMENTS Model 90607 Manual All of the items in this list are selected as the default setting Any of these items can be disabled from the common alarm by pressing the ENTER key and they will then appear on the list in the other alarm relays 7 2 22 Operation of the Alarm Relays when an Alarm is Accepted An option is available to in the commissioning menu to change the operation of the alarm relay when an alarm has been accepted The states for the alarm relay contacts are shown in the following table Alarm state Accepted Relay hold setting Accepted Relay hold setting Enabled Disabled No alarm condition Closed circuit Closed circuit Open circuit All alarms accepted Closed circuit Alarms self cleared C

Teledyne 9060Z Oxygen Equipment User Manual

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