D−R 820 F Dust Concentration Meter
GmbH · Kollaustraße 105 · 22453 Hamburg · www.durag.de
D−R 820 F
Translation of the original owner’s manual Document:
man_dr820f_de.doc
Version:
15.09.2008
Last update:
15.08.2008
Printdate:
20.08.2008
This documentation is valid for:
SoftwareSourceVersion 1.15 und 1.73
Dust Concentration Meter D−R 820 F
DURAG GmbH Kollaustraße 105 22453 Hamburg Telephone: Fax : E-Mail: Internet:
+49 (40) 55 42 18 – 0 +49 (40) 58 41 54
[email protected] www.durag.de
This documentation: •
(approx. 122 pages) has been compiled with the greatest care. However, all liability must be excluded.
•
is not intended for the US American market. Documentation in accordance with ANSI Z535 standard can be requested. Reference addresses can be found on page 121.
•
or parts of it may not be duplicated or communicated without the express consent of DURAG GmbH, irrespective of by which method or means, electronic or mechanical, this occurs.
•
refers to the complete equipment in principle, even if individual program modules or devices (device parts) have not been purchased
•
refers to the current status of the equipment design at the time of updating this documentation (see above).
•
can be changed without notice with regard to content.
© DURAG GmbH 2008 Redaktion: Herbert Lange. All rights reserved.
Contents
Contents 0
Foreword
1
General
11
1.1
Brief overview of the contents
11
1.2
Typographical conventions
12
1.3
Meaning of the warnings and notes used
12
2
Safety instructions
17
2.1
General
17
2.2
Blower
18
2.3
Qualified personnel
19
3
Product Description
23
3.1
Notes on delivery
23
3.2
Notes on warranty
23
3.3
Notes on the product (overview)
23
3.4
Identification of the product
24
3.5
Scope of supply
25
3.6
Special accessories
26
3.7
Design
26
3.8
Function
32
4
Assembly
43
4.1
Selection of the measuring point
43
4.2
Installation of the weld-in socket
43
4.3
Installation of the probe
45
4.4
Installation of the rack frame
47
4.5
Electrical connection
48
5
Commissioning
53
6
Operation and Handling
59
6.1
Optical sensor
59
6.2
Display
59
6.3
Operating modes
60
6.4
Operation
61
6.5
Limit value input
62
6.6
Special displays
62
6.7
Parameter input
64
6.8
Calibration menu and reference point
65
D−R 820 F
7
3
Contents 6.9
Parameters
65
7
Decommissioning
75
7.1
Disassembly
75
7.2
Disposal
76
8
Calibration
79
8.1
Device calibration
79
8.2
Dust calibration
79
9
Maintenance
85
9.1
Safety
85
9.2
Maintenance work
86
9.3
Cleaning
86
9.4
Work on the optical sensor D−R 800 F
86
10
Error messages and error elimination
91
10.1
Events
91
10.2
Maintenance status
91
10.3
Maintenance requirement status
92
10.4
Fault status
92
10.5
Events
92
11
Technical data
99
11.1
General
99
11.2
Factory setting
100
12
EC Declaration of Conformity
103
13
Standards and regulations
103
14
Spare and wearing parts
105
15
Glossary
106
16
Index
107
16.1
List of illustrations
5
16.2
List of tables
5
17
Circuit diagrams and drawings
110
18
Menu plan
118
19
DURAG GROUP company addresses
121
4
D−R 820 F
Contents
List of illustrations Figure 3.1: Position of the typeplates Figure 3.2: Probe Figure 3.3: Probe dimensions Figure 3.4: View of probe (right side) Figure 3.5: View of probe (left side) Figure 3.6: View of probe (front) Figure 3.7: Probe ventilation Figure 3.8: Control unit Figure 3.9: Installation panel Figure 3.10: Rack frame Figure 3.11: D−R 820 F Functional diagram with 2 blowers Figure 3.12: D−R 820 F Functional diagram with compressed air supply and probe ventilation Figure 3.13: Gas operating plan in measuring mode Figure 3.14: Gas operating plan in purge mode Figure 3.15: Example signal course for zero and reference point control Figure 3.16: 3/2-way ball valve in MEASUREMENT position Figure 3.17: 3/2-way ball valve in PURGE position Figure 3.18: 3/2-way ball valve side view Figure 4.1: Inlet and outlet section Figure 4.2: Weld-in socket (separate return) Figure 4.3: Weld-in socket (integrated return) Figure 4.4: Installation instructions part 1 Figure 4.5: Installation instructions part 2 Figure 4.6: Rack frame Figure 4.7: Control unit connection Figure 4.8: Probe connections Figure 6.1: Display Figure 6.2: Standard mode Figure 6.3: Service mode Figure 6.4: SET switch Figure 7.1: Disassembly part 1 Figure 7.2: Disassembly part 2 Figure 8.1: Example - Gravimetric calibration Figure 9.1: Position of the optical sensor in the probe housing D−R 820 F
24 27 27 28 29 30 31 31 32 33 34 37 37 38 40 40 40 43 44 44 45 46 47 48 49 59 60 60 64 75 76 81 87
List of tables Table 8.1: Value table for calibration example Table 9.1: Maintenance work Table 10.1: Events Table 11.1: Technical data Table 11.2: Factory setting
D−R 820 F
81 86 96 100 102
5
Foreword
0
Foreword The purpose of this manual is to help you to become acquainted with your DURAG product. In this publication you will find information and technical data on planning, installation / commissioning, operation and maintenance of the D−R 820 F. This information is completed by the functional diagram for both the complete system and the equipment components, as well as a spare parts list. Our aim is to make a decisive contribution to your success with our products and services. We hope that the information provided here will enable us to do so. Should you have any further questions on products or applications from the DURAG GROUP, please use our Support & Service! You will find the relevant addresses and telephone numbers on page 121 (DURAG GROUP company addresses). Further information is also available from www.durag.de Please read the following information carefully! It is important for your safety and for preventing damage to the D−R 820 F and to the environment.
D−R 820 F
7
D−R 820 F
Dust Concentration Meter
01 1
General
1.1
Brief overview of the contents
1.2
Typographical conventions
1.3
Meaning of the warnings and notes used
General
1
General The product described in this manual left the factory in perfectly safe and inspected condition. In order to maintain this condition and to achieve correct and safe operation of this product, it may only be used as described by the manufacturer. In addition, faultless and safe operation of this product requires appropriate transport, correct storage and installation, as well as careful operation and maintenance. This manual contains the necessary information for proper use of the described product. It is intended for technically qualified personnel who have been familiarised with the product, who are specially trained or have pertinent knowledge in the field of measurement and control engineering, referred to as automation technology in the following. The knowledge and technically sound implementation of the safety instructions and warnings contained in this manual are a prerequisite for safe assembly and commissioning, as well as for safety during operation and maintenance of the described product. Only appropriately qualified personnel have the necessary expertise to interpret the safety instructions and warnings provided in a general manner in this document correctly in concrete individual cases and to apply the appropriate procedure. This manual is a fixed constituent of the scope of supply, even if the option of separate ordering or delivery has been provided for logistical reasons. For reasons of clarity, it does not contain all details for all versions of the described product and can also not take account of all conceivable circumstances for installation, operation, maintenance and use in systems. Please pay particular attention to the warning and information texts. If you require further information or if problems occur which are not dealt with in sufficient detail in this document, please ask your competent DURAG GmbH representative for the required information (see page 121 DURAG GROUP company addresses).
1.1
Brief overview of the contents This manual describes the following areas: Information on use of the manual, the pictograms used, safety instructions and requirements on operating and maintenance personnel. Chapters 3 - 5 Information on the product, technical data, function and system descriptions as well as the available options. Chapters 6 - 10 Information on use of the product D−R 820 F, in respect of installation, assembly, commissioning, operation, maintenance, error diagnostics, repair etc. Chapters 11 - 19 Overview of technical data, standards and regulations to be complied with, spare parts list, certifications, glossary, index and company addresses. Chapters 1 + 2
D−R 820 F
11
General
1.2
Typographical conventions In order to make the text of this manual clear, text elements such as safety instructions, warnings, tips, keyboard symbols, menu addresses etc. are displayed differently. The following conventions apply in this manual: • Safety instructions and warnings appear as follows in this manual:
WARNING
Danger from electrical equipment Before removing the housing or accidental-contact protection, the equipment must be disconnected from the power supply.
• A note or tip is shown like this: No control cycle is started during test measurements and simulation.
• If a button is pressed on the control unit, it is shown like this:
• A (¬) indicates that the following term is explained in the glossary. • This manual is also available as pdf-file on CD/DVD! • Unless otherwise specified: all dimensions in mm
1.3
Meaning of the warnings and notes used Please always comply with the following warnings and safety instructions in this manual. They serve to avert dangers to life and limb of users and maintenance personnel and to prevent damage to property. They are highlighted in this manual by the signs defined here. They are also marked by symbols at the points where they appear. The signs used have the following meanings for the purposes of this manual and the information on the product itself:
12
D−R 820 F
General
DANGER
Failure to comply with instructions highlighted in this way can result in severe and even fatal injuries. Also means that substantial damage to property can occur, if the relevant precautions are not taken. > Comply with all hazard warnings, in order to prevent injuries.
WARNING
Failure to comply with instructions highlighted in this way can result in serious injuries or damage to property. > Comply with all warnings, in order to prevent injuries and to ensure safe operation of the system.
CAUTION
Failure to comply with instructions highlighted in this way can result in minor injuries or damage. > Comply with all caution warnings, in order to prevent injuries and to ensure safe operation of the system. In order to specify the potential risk the general warning sign can also be replaced by a special warning sign. General warning sign
Chemical burns
Electric current
Humidity
Danger of crushing
Explosive atmosphere
Hot surface
Electrostatically endangered components (ESD)
Laser radiation
In addition to the warnings and safety instructions, the following general notes and related pictograms are also used to draw your attention to particularly important information: Here you will find interesting information or tips on the product and its use.
Contains information on environmental protection
D−R 820 F
13
D−R 820 F
Dust Concentration Meter
02 2
Safety instructions
2.1
General
2.2 2.2.1 2.2.2 2.2.3 2.2.4
Blower Suction action Blow-out action Temperature Noise development
2.3
Qualified personnel
Safety instructions
2
Safety instructions Safety instructions and warnings are provided at the points in the respective chapters where the information is required. Some warnings are also provided repeatedly for this reason, to ensure that the potential danger arising from a given situation is always highlighted. Always observe and comply with the safety instructions, caution notes and warnings provided in the chapters. Also observe the following warnings and safety instructions. They serve to avert dangers to life and limb of users and maintenance personnel and to prevent damage to property. They apply for all measures and tasks described in this manual, even if they are not explicitly indicated again at the relevant point.
2.1
General WARNING
Only operate the measuring device D−R 820 F in perfect condition and in strict compliance with the safety instructions!
• The Dust Concentration Meter D−R 820 F may only be connected to the supply voltage shown on the typeplate (standard: 400V, 3~, 50Hz). • The D−R 820 F may only be operated on a power supply with an earthing contact. The protective action must not be cancelled by an extension without an earthing contact. Any interruption in the protective earth conductor inside or outside the device is dangerous and is not permitted. • The D−R 820 F must be protected with a 16 A fuse on the input side. • Before opening any device components, the Dust Concentration Meter D−R 820 F must be disconnected from the power supply by operating the main switch or the series fuse. • Electronic components are becoming ever smaller and more complex. As a result, their susceptibility to electrostatic discharge is also increasing. Modern electronic components are very sensitive to electrostatic discharge. To protect these components, measures must be taken against electrostatic discharges (ESD protection) when performing any work on the open device. To prevent static charging of the human body, we recommend that service personnel are equipped with a personal grounding system. • Use of the D−R 820 F in potentially explosive areas and measurement in explosive gas mixtures is not permitted. • Cables and gas lines should be laid so that risk of accident due to tripping or getting caught on the lines is excluded. • Parts of the probe are electrically heated or come into contact with hot measuring gas and are therefore subject to high temperatures. Never touch these parts without temperature-resistant gloves or when the parts are live. • The measuring system as a whole, as well as the individual components, may only be operated in the original design. If elements are replaced, the manufacturer's genuine parts must be used. • Modifications to the configuration of the measuring system, i.e. the adjustment of parameters which are not normally available to the user, can compromise the safety of the Dust Concentration Meter and are carried out at own risk! Therefore, have configuration modifications carried out by an authorised service technician or by the manufacturer's factory personnel. D−R 820 F
17
Safety instructions • Covers inside the D−R 820 F may only be removed when the system is disconnected from the power supply. • Subassemblies are configured device-specifically and are therefore not interchangeable between different D−R 820 F.
WARNING
Installation, operation, maintenance activities and any repairs must be performed exclusively by qualified personnel of the manufacturer, taking account of the pertinent requirements (Zentralverband der Elektrotechnik- und Elektroindustrie e.V./Central Association of the Electrical Engineering and Electronics Industry).
2.2
Blower
2.2.1
Suction action Warning: Objects, articles of clothing and even hair can be sucked in (risk of injury!). Do not stand near the suction intake during operation. Never operate the blower with the suction intake open. This must be covered with an air filter with fine filter cartridge. Do not reach into the suction intake.
2.2.2
Blow-out action Warning: Very strong blow-out action at the discharge nozzle. Sucked-in objects can be ejected at high speed (risk of injury!). The blower is only suitable for conveying clean air. Foreign bodies or impurities that could be blown out must be filtered out before entry into the blower. The blower must never be operated with the discharge nozzle open and must therefore be covered with a guard in accordance with DIN EN 294. Do not reach into the discharge hole.
2.2.3
Temperature Warning: The blower housing heats up during operation. If the temperature exceeds + 50°C, the blower must be protected from direct contact by the operator (risk of burns!).
2.2.4
Noise development The noises emitted by the blower vary in the range up to approx. 80 dB(A) sound-pressure level LA. In certain unfavourable cases, sound insulation is required (measurements by the operator recommended). The operator must provide this sound insulation to prevent exceeding of the legally permitted maximum values at workstations in the blower environment.
18
D−R 820 F
Safety instructions
2.3
Qualified personnel In the event of unqualified operations on the device or failure to comply with the warnings provided in this manual or affixed to the device, physical injuries and/or damage to property can occur. Only appropriately qualified personnel may therefore perform operations on this device. Qualified personnel for the purposes of the safety-related instructions in this manual or on the product itself are persons who • either as project planning personnel, are familiar with the safety concepts of automation technology • or as operating personnel, are instructed in handling automation technology equipment and are familiar with the contents of this manual relating to operation • or as repair and/or service personnel, have training that qualifies them to repair such automation technology equipment or have authorisation to commission, earth and identify circuits and devices/systems in accordance with the safety-related standards.
D−R 820 F
19
D−R 820 F Dust Concentration Meter
03 3
Product Description
3.1
Notes on delivery
3.2
Notes on warranty
3.3 3.3.1 3.3.2 3.3.3 3.3.4
Notes on the product (overview) Use Features Measuring procedure System design
3.4
Identification of the product
3.5
Scope of supply
3.6
Special accessories
3.7 3.7.1 3.7.2 3.7.3 3.7.4 3.7.5
Design Probe (in GRP protective housing) Control unit (with electrical distribution) Rack frame Blower (optional) Vortex Cooler
3.8 3.8.1 3.8.2 3.8.3 3.8.4 3.8.5
Function Measuring principle Gas ducts Thinning, dilution Zero and reference point 3/2-way ball valve
Product Description
3
Product Description D−R 820 F In this chapter you will find information on scope of supply, special accessories, approvals, guarantee, fields of application - in short, everything relating to the.
3.1
Notes on delivery The respective scope of supply is listed on the shipping documents accompanying the delivery, in accordance with the applicable purchase contract. Check that the delivery is complete and intact. The Dust Concentration Meter D−R 820 F is delivered in two packaging units. The device parts or components listed in chapter 3.5 from page 25 are generally included. We recommend storing the packaging in case the device needs to be returned for service or repair. Please inform the forwarding agent and the DURAG GROUP of all damage in transit immediately. (For addresses see page 121 (DURAG GROUP company addresses).
3.2
Notes on warranty Please note that the contents of this device manual are not part of nor an amendment to a previous or existing agreement, undertaking or legal relationship. The warranty for equipment from the DURAG GROUP is generally 12 months from the date of delivery. All obligations result from the respective purchase contract, which also contains the complete and solely valid warranty regulation. These contractual warranty terms are neither extended nor limited by the comments in this document. Modifications and alterations to the Dust Concentration Meter are not permitted. Any interventions on the device will result in lapsing of the guarantee. Faultless and safe operation of the device also requires appropriate transport, correct storage, installation and assembly as well as careful operation and maintenance by qualified personnel.
3.3
Notes on the product (overview) The DURAG Dust Concentration Meter D−R 820 F is used for the continuous measurement of dust concentration. As well as monitoring the efficiency of filter plants by recording the residual dust quantity, this device also instantaneously reports unacceptably large dust or flue gas emissions. Consequently, it is often possible to intervene directly in the process of the monitored system and thus to ensure reliable observance of the prescribed limit values.
3.3.1
Use The D−R 820 F is used to measure the dust concentration in wet gases. Use with adhesive dusts with a tendency to cake is possible, e.g.: • Measurements in saturated gas after desulphurization plants • After wet cleaning plants • Waste incineration plants • Chipboard manufacture • Urea industry • Manufacture of insulation
D−R 820 F
23
Product Description • Technological processes In all situations where unacceptable dust emissions could result in environmental pollution, DURAG dust concentration monitors reliably monitor adherence to the legal limit values.
3.3.2
Features The D−R 820 F is a highly sensitive system for continuous (¬) extractive dust concentration measurement in accordance with the scattered light principle. It is characterised by the following features: • Compact design • No need for laborious gas removal • Very little maintenance required • In-situ measuring procedure with continuous measurement) ((¬) in situ) • High sensitivity • No laborious device adjustment • Automatic function test with soiling correction
3.3.3
Measuring procedure A defined partial current is removed from the exhaust gas flow. This partial current is continuously heated and diluted with clean, tempered ambient air. The diluted partial current is optically measured in the measuring chamber. The signal that results from the diverted current is a measurement of the dust content of the exhaust gas. For a detailed explanation see chapter 3.8.1 Measuring principle from page 34.
3.3.4
System design The system comprises a special sampling probe, the laser dust monitor, a gas conditioning plant (dilution, tempering), an injector, two blowers and an electronic evaluation unit. The sampling probe and the measuring chamber form a unit. The electronic evaluation unit and one side-channel compressor for operating the injector and one for generating the diluting air are mounted together on a rack frame. For more detailed information on function, see chapter 3.8 from page 32.
3.4
Identification of the product The typeplate is located • on the control unit • on the probe in the GRP protective housing
24
Figure 3.1: Position of the typeplates
D−R 820 F
Product Description
3.5
Scope of supply The Dust Concentration Meter D−R 820 F comprises the following components as standard: D−R 820 F Control unit with electric power supply, fuses etc. Control cabinet key 2 off side-channel compressors or blowers (except for supply with compressed air or nitrogen) Rack frame for mounting the control unit and both blowers (with protective cover) Probe in GRP protective housing Length of measuring lance 800 mm incl. gooseneck 1000 mm
Connection cable 3 m or on demand
Purge air hose with fixing clamps 2 hoses, length 5 m (or on demand, max 10 m) 25 mm, 13 mm diameter Brush set for cleaning the gastransporting parts
Printed brief introduction and detailed manual on CD
Variations may occur in the technical design depending on the ordered configuration.
D−R 820 F
25
Product Description
3.6
Special accessories Flange with welded-in pipe 130 mm (ST37) and seal Alternatively also available in V4A (with separate or integrated return nozzle) Compressed air or nitrogen distribution unit (optional)
1 Vortex Cooler (optional)
3.7
Design The Dust Concentration Meter D−R 820 F comprises the following components:
3.7.1
• Probe (in GRP protective housing)
(described from page 26)
• Control unit (with electrical distribution)
(described from page 31)
• Rack frame
(described from page 32)
• Blower
(described from page 32)
• (optional) Vortex Cooler
(described from page 32)
Probe (in GRP protective housing) The probe of the D−R 820 F comprises several components. The probe or sampling tube is a heated double jacket tube with integrated dilution. The dilution is carried out with a mixing nozzle (see Figure 3.11). Processing of the sampled measuring gas and recording of the measured values occur in the probe. The probe is integrated into a two-piece GRP protective box. This is fixed directly to the flange (see Figure 3.2).
26
D−R 820 F
Product Description
Housing cover
Housing
Housing closure open Plug connector, ext. housing ventilation (optional) Probe ventilation fan filter (installed on the left) Plug connector (signals) Plug connector (power supply) Flange Probe tube (heated)
Sampling tube Plug connector, heat element
dr820f_001_0000_Sonde allgemein_de
Probe ventilation inlet filter Housing closure closed
Diluting air heat element Diluting air heat element connection cable
Diluting air connection
Figure 3.2: Probe
270 mm
ca. 1050 mm
ca. 750 mm
520 mm
dr820f_002_0000_Sonde Abmessungen_eu
155 mm
16 mm ca. 600 mm
470 mm
1.000 mm
Figure 3.3: Probe dimensions
D−R 820 F
27
Product Description
A
A
F B
M B C
D
D
H
H
E
E
P
P dr820f_004_0000_Sonde Ansicht links_eu
dr820f_003_0000_Sonde Ansicht rechts_eu
I
K
O
Figure 3.4: View of probe (right side)
28
L O
N
Figure 3.5: View of probe (left side)
A Probe electronics (optical sensor)
I Diluting air connection
B Measuring chamber
K Exhaust air connection
C Injector
L Injector air connection
D 3/2-way ball valve
M Temperature measurement
E Diluting air distribution
N Diluting air connection
F Δp-Measurement
O Diluting air heat element
H Probe heat element connection
P Solenoid valve
D−R 820 F
dr820f_005_0001_Sonde Ansicht Frontal_eu
Product Description
Figure 3.6: View of probe (front) A
Probe electronics (optical sensor)
K
Exhaust air connection
B
Measuring chamber
L
Injector air connection
C
Injector
M
Temperature measurement
D
3/2-way ball valve
N
Diluting air connection
E
Diluting air distribution
O
Diluting air heat element
F
Δp-Measurement
P
Solenoid valve
G
Filter purge air optical sensor
R
Check valve purge air optical sensor
D−R 820 F
29
Product Description
3.7.1.1 Probe ventilation The probe of the D−R 820 F is thermostatically ventilated with a blower fan or a Vortex Cooler supplied with compressed air or nitrogen, depending on design (see Figure 3.7).
Housing fan Inlet filter
Compressed air / N 2
Cooling medium
Outlet filter
dr820f_006_0000_Sondenbelüftung_Vortex Cooler_de
Outlet filter
Vortex Cooler
Figure 3.7: Probe ventilation
30
D−R 820 F
Product Description
3.7.2
Control unit (with electrical distribution) The control unit is designed as a three-piece 19" protective box (48.3 cm). The complete electrical connection, the signal calculation and the display and output of the measured dust values take place in the control unit. The display and control unit can be accessed by opening the inspection window. The following illustration explains the components of the control unit.
Valve position: MEASURING Manual maintenance switch Valve position: PURGE RS 232
Maintenance ON/OFF
dr820f_007_0000_Bediengerät DURAG_de
SET switch (behind the cover)
Cable entry Cable entry
Figure 3.8: Control unit
The installation panel is installed inside the control unit.
X01 F01
dr820f_008_0000_Bediengerät Montageplatte_de
K01
S01
S02
F02 - K02 K04 F06
X03
K03
Kabeleinführung Cable entry
Figure 3.9: Installation panel
D−R 820 F
31
Product Description
3.7.3
Rack frame The control unit and the two blowers are mounted on a rack frame. This can be easily fixed to a wall or the floor. ca. 430 mm
A
ca. 1.750 mm
B
dr820f_009_001_Gestellrahmen_de
C D
E
ca. 600 mm
ca. 550 mm
Figure 3.10: Rack frame A Control unit
D Blower diluting air
B Cable run
E Blower injector air
C Air filter
3.7.4
Blower Information on the blower can be found in the Service Manual.
3.7.5
(optional) Vortex Cooler Information on the optional Vortex Cooler can be found in the Service Manual.
32
D−R 820 F
Product Description
3.8
Function The Dust Concentration Meter D−R 820 F is a highly sensitive system for continuous, optical, extractive dust or dust concentration measurement. A defined partial current is removed from the exhaust gas current. This partial current is continuously heated and diluted with clean, tempered ambient air. The partial current is optically measured in the measuring chamber. The signal that results from the diverted current is a measurement of the dust content of the exhaust gas. The microcontroller integrated into the control unit generates a dustproportional signal. This is output as a 4 ... 20 mA signal. In addition, the current measured value is displayed on the control unit display. Various parameters (e.g. relating to the display) can be entered and adjusted using the keyboard.
Figure 3.11: D−R 820 F Functional diagram with 2 blowers The D−R 820 F can alternatively be operated with compressed air or nitrogen. These can also be used to cool the probe housing. This can be seen in a variant of the functional diagram Figure 3.12.
D−R 820 F
33
dr820f_011_0001_Funktionsschema mit Druckluftversorgung und Sondenbelüftung_de
Product Description
Figure 3.12: D−R 820 F Functional diagram with compressed air supply and probe ventilation
3.8.1
Measuring principle
3.8.1.1 General This Operating Manual describes all aspects of extractive dust measurement. The design and measuring principle of the optical sensor are described in the Appendix.
3.8.1.2 Functional diagram of the optical probe The optical probe of the D−R 820 F operates according to the forward scattering principle. The concentrated and modulated light of a laser diode penetrates the measuring volume. The light scattered by the dust particles is largely scattered forwards, therefore the receiving lens is positioned here. The scattered light is generated in proportion to the dust concentration present, so the more dust, the more scattered light. The light is guided by an optical waveguide to the receiving diode, where it is processed to the desired end size by a sensitive electronic unit. The obtained measuring result is calibratable and can, in accordance with directive EN 13284-1, be displayed on the dust concentration in mg/m³.
For the automatic function test and the legal control cycle, a beam splitter with a shutter has been used inside the electronic housing in this system. It swit-
34
D−R 820 F
Product Description ches between the actual optical measurement and the comparison path. Consequently, there are no moving parts in the corrosive exhaust gas. This also ensures that the termination between optical probe and electronic housing is gas-tight. The basic calibration of the system can be carried out by software. A pollution measurement is performed every 5 min in order to record dust deposits on the optical boundary surfaces and the ageing of the optical elements.
D−R 820 F
35
Product Description
3.8.1.3 Extractive dust measurement In the case of the D−R 820 F, another mathematical relationship results between the physical values in relation to the optical in-situ measurement (see also chapter 3.8.1 Measuring principle from page 34). The optical signal Cal (scattered light) is dependent on the dust content of the measuring gas, the set dilution of the extracted measuring gas, the temperatures and absolute pressures of the gases. The mathematical relationship therefore appears as follows:
⎡ cal ⋅ F ⎤ Ci.B. = A ⋅ ⎢ ⎥+D ⎣ F − C ⋅ FD ⎦
ci.B.
Dust concentration [mg/m³]
cal
Measuring signal [V] (corresponds to scattered light)
F
Volume flow [m³/h]
A, D
Constants from the dust calibration
B, C
Constants from the device adjustment (input after production)
(Indices: "without" measuring chamber, "D" diluting air and "M" measuring gas) The relationship with the measuring gas results from:
FM ≈ F − FD
FM
Extracted measuring gas volume flow [m³/h]
F
Volume flow in the measuring chamber [m³/h]
FD
Volume flow diluting air [m³/h]
A contamination-related decrease in the volume flow and an environmentrelated temperature change are corrected with this correction. The absolute pressures and TM are preset as constants! The D−R 820 F outputs the dust-proportional signal CiB on the display and at the analog output (4 ... 20 mA). CiB then corresponds to the above-specified relationship. In addition, the cal signal (scattered light) is always provided via an analog output. The unit [V] for the cal signal was defined during the development of the Dust Concentration Meter D−R 820 F. The two parameters for gravimetric correction of the dust signal A and D are preset at delivery. A and D are determined during a gravimetric comparison measurement and can be stored in the control unit. Default setting: A=1 D=0 (see chapter 8.2 Dust calibration page 79)
36
D−R 820 F
Product Description
3.8.2
Gas ducts The course of the measuring gas can be seen in Figure 3.13. The D−R 820 F continuously samples a partial current from the exhaust gas (suction is performed by an injector). As the measuring gas usually contains a strong concentration of the particles to be measured, a defined (heated) diluting air current is added to the extracted partial gas current at the probe input of the D−R 820 F (see 3.8.3 Thinning, dilution page 38) , i.e. the measuring gas is diluted to a defined extent. At the same time, the gas mixture is heated up to a set temperature (see 11.2 Presetting page 100), at which the moisture is evaporated, but the particles to be measured are present in solid state. This extracted, diluted and heated measuring gas then passes the measuring cell and then leaves the measuring device. The course of the measuring gas can be seen in Figure 3.13.
Control valve
Heating Diluting air
dr820f_012_0000_Gaslaufplan Messbetrieb_de
Purge valve
Blower Diluting air
Air filter
Measuring gas
Heated probe
3/2-way ball valve
Ball valve Measuring cell
Blower Injector air
Air filter
Injector Exhaust air
Figure 3.13: Gas operating plan in measuring mode For diagnostic and cleaning purposes, the D−R 820 F automatically executes a purge operation. This includes a zero and reference point control (see 3.8.3 Thinning, dilution page 38) and cleaning of the ducts that conduct the measuring gas (see 3.8.5 3/2-way ball valve page 39). The purge operation is illustrated in Figure 3.14.
Control valve
Heating Diluting air
dr820f_013_0000_Gaslaufplan Spülbetrieb_de
Purge valve
Air filter Blower Diluting air
Purge gas
Heated probe
3/2-way ball valve
Ball valve Blower Injector air
Measuring cell
Air filter
Injector Exhaust air
Figure 3.14: Gas operating plan in purge mode
D−R 820 F
37
Product Description
3.8.3
Thinning, dilution Thinning or (¬) dilution is a measure for the concentration of the extracted measuring gas. The dilution is specified in [%].
⎛ M& ⎞ ⎛F ⎞ D = ⎜⎜ m ⎟⎟ ⋅ 100 ≈ ⎜ M ⎟ ⋅ 100 & ⎝ F ⎠ ⎝ M ⎠
D
Dilution / thinning [%]
& M m
Extracted mass flow rate [kg/s]
& M
Mass flow rate in the measuring chamber [kg/s]
FM
Extracted measuring gas volume flow [m³/h]
F
Volume flow in the measuring chamber [m³/h]
Normal values for the dilution are in the range between 35.0 % and 70.0 %. Where the following apply: D = 100 % no diluting air D=0% only diluting air (theoretical value, means FM = 0 m³/h)
3.8.4
Zero and reference point To guarantee a precise measurement, the D−R 820 F performs an automatic zero and reference point control every 4 hours (default value, starting with switch-on). First of all the current zero point of the sensor is checked. This is followed by checking of the pollution and then the reference value of the sensor, in comparison with the calibrated reference value (see chapter 8 Calibration page 79). In this way the sensor is checked for correct functioning. If the deviations are too large, this indicates a maintenance requirement or a fault (see chapter 10 Error messages and error elimination page 91). The following figure provides an example of the signal course: 14
10 8 6 4 2
09:00
08:30
08:00
07:30
07:00
06:30
06:00
05:30
05:00
04:30
04:00
03:30
03:00
02:30
02:00
01:30
01:00
00:30
0 00:00
dr820f_014_0000_Bsp Null-Referenzpunkt
Dust content [mg/m³]
12
Time
Figure 3.15: Example signal course for zero and reference point control
38
D−R 820 F
Product Description
3.8.5
3/2-way ball valve For self-diagnosis and cleaning of the probe's measuring gas-conducting elements, the 3/2-way ball valve and the purge valve are set to the purge position every 24 hours (default value), so that the probe is cleaned. Ball valve and purge valve are actuated automatically. This cleaning procedure is also executed when a fault is detected in the (¬) extractive Dust Concentration Meter D−R 820 F, in order to protect the measuring device from heavy pollution. The volume flows and temperatures are monitored with the aid of the preset parameters. Further internal tests are also carried out on the measuring device to check correct functioning (e.g. internal memory, communication sensor - control unit, sensor temperature) The ball valve can also be operated manually for diagnostic purposes. For this purpose it is possible to change between PURGE and MEASURING with the and keys on the control unit of the D−R 820 F. Alternatively, the rotary switch on the ball valve can also be operated manually. For this purpose the Automatic/Manual adjusting hand wheel on the left side of the ball valve must be set to MANUAL (the ball valve must be reset after completing the diagnosis or maintenance activity).
CAUTION
For continuous dust measurement, the Automatic/Manual adjusting handwheel must be in the AUTOMATIC position!
After switching from purge to measurement, the D−R 820 F remains in Purge/Maintenance status for another minute! If the D−R 820 F is in fault status, the ball valve cannot be moved into the measurement position!
D−R 820 F
39
Product Description Please note following positions of the ball valve: Purge/Measuring adjusting handwheel
Automatic/Manual adjusting handwheel Plug connector
dr820f_015_0000_Kugelhahn Messen
MEASURING
PURGE
Figure 3.16: 3/2-way ball valve in MEASUREMENT position
Purge/Measuring adjusting handwheel
Automatic/Manual adjusting handwheel Plug connector
dr820f_016_0000_Kugelhahn Spülen
MEASURING
PURGE
dr820f_017_0000_Kugelhahn Seitenansicht
Figure 3.17: 3/2-way ball valve in PURGE position
Adjusting handwheel: Position: Automatic
Adjusting handwheel: Position: Manual
Figure 3.18: 3/2-way ball valve side view
40
D−R 820 F
D−R 820 F
Dust Concentration Meter
04 4
Assembly
4.1
Selection of the measuring point
4.2
Installation of the weld-in socket
4.3
Installation of the probe
4.4
Installation of the rack frame
4.5 4.5.1 4.5.2
Electrical connection Control unit Probe
Assembly
4
Assembly
4.1
Selection of the measuring point The installation position of the probe should meet the requirements of the guidelines applicable in-situ (e.g. EN 13284-1) (in Germany VDI 2066 page 1). In case of doubt, we recommend that the installation position is determined by the responsible measuring institute (measuring point in accordance with §§ 26/28 (¬) BImSchG/Federal Immission Control Act). We recommend that the inlet and outlet section is at least 5 x diameter of the exhaust gas channel.
3 x D VDI 2066 p. 1
dr820f_018_0000_Auswahl der Messstrecke; Ein- und Auslaufstrecke
5 x D EN 13284-1
Correct!
3 x D VDI 2066 p. 1 5 x D EN 13284-1
Incorrect! Correct! 10 m!) to the mounting flange is expedient.
D−R 820 F
43
Assembly
Channel wall
dr820f_019_0001_Einschweißstutzen (separate Rückführung)
2°...5°
Mounting flange
2°...5°
Return nozzle (optional)
Figure 4.2: Weld-in socket (separate return)
dr820f_020_0001_Einschweißstutzen (integrierte Rückführung)
Channel wall
2°...5°
Mounting flange Return nozzle (optional)
Figure 4.3: Weld-in socket (integrated return) In principle the sample gas recirculation could take place back into the room, because it is a matter of highly diluted (injector and diluting air) stack gas. But this gas has a lot of heat energy and will warm-up the room. A recirculation out-of-doors is more suitable. In either case it should be seen that the hose is correctly laid to prevent a blocking. The sample gas leaves the probe with a temperature of over 70° C. By compliance with the max. length of hose (10 m), there is no probability that the hose would freeze. The mounting of the weld-in socket on the measuring channel has to carry the weight of the socket (approx. 10 kg) and the weight of the complete probe (approx. 60 kg). If necessary the channel has to be strengthened by a supporting structure.
44
D−R 820 F
Assembly
4.3
Installation of the probe Danger of contamination of the measuring cell! For mounting and during the time up to commissioning the ball valve has to be set to MANUAL and PURGE! For mounting the probe it is recommended to do the following steps: 1. Set the ball valve to MANUAL and PURGE, 2. remove optical sensor while mounting (unfasten 4 nuts, separate screwed cable gland and remove sensor), 3. insert probe into flange (don’t forget gasket!), 4. tighten probe with the 4 nuts and bolts provided, (Installation position as in picture: angle plug on the left towards the center of the D−R 820 F unit). 5. reinsert optical sensor, 6. set check valve vertically (purge air optical sensor), Flow arrow of valve points upwards (to optical sensor). Always pay attention that the check valve, above the purge air filter of optical sensor, is in an upright position. (see „R“ in Figure 3.6 on page 29). A. Insert probe (2. Insert probe) 1. CAUTION: FIRST set the ball valve to MANUAL + PURGE!
Optical sensor
dr820f_021_0000_Einbauvorschrift Teil 1
(3. Screw probe tightly to flange 4x)
Exhaust gas/flue gas Exhaust gas duct/chimney
Figure 4.4: Installation instructions part 1 7. connect plug of cable from control unit with matching part on probe 8. connect hoses of blower outlet with inputs of the probe . 9. connect hose (di=25mm) from recirculation socket with output of the probe (see Figure 4.2 and Figure 4.3 on page 44).
D−R 820 F
45
Assembly B. Connect cables and hoses (Representation of probe+chimney rotated)
(4. Connect cables) Control unit
Analog and status signals
Power supply
Heating Diluting air Injector air max. 10 m, di=25 mm Blower Diluting air
Blower Injector air (5. Connect hoses) Air filter
Exhaust gas duct/chimney
dr820f_022_0001_Einbauvorschrift Teil 2
Deluting air max. 10 m, di=13 mm
(6. Screw frame to periphery e.g. open-mesh floor, guard rail or wall)
Figure 4.5: Installation instructions part 2 Hoses and cables between rack frame and probe have to be connected according to Figure 4.5.
46
D−R 820 F
Assembly
4.4
Installation of the rack frame The rack frame is manufactured from easily assembled profiled supports. It can be easily fixed to a wall or the floor. The control unit and the two blowers are permanently installed and wired on the rack frame. This arrangement should not be changed. The maximum distance between rack frame and probe is specified in chapter 11.1 Technical data General on page 100. ca. 430 mm
A
ca. 1.750 mm
B
dr820f_009_001_Gestellrahmen_de
C D
E
ca. 600 mm
ca. 550 mm
Figure 4.6: Rack frame A Control unit
D Blower Diluting air
B Cable run
E Blower Injector air
C Air filter
D−R 820 F
47
Assembly
4.5
Electrical connection
4.5.1
Control unit All connections are implemented as screw terminals in the control unit. A distinction is made between different terminal strips, see Figure 4.7. The terminal strips can be accessed after opening both doors of the control unit (using the control cabinet key). • Terminal strip X01: Internal voltage distribution • Terminal strip X03: Outputs for customer • Terminal strip X04: Probe connection
X01 F01
S01
S02
F02 - K02 K04 F06
dr820f_008_0000_Bediengerät Montageplatte_de
K01
X03
K03
K b l i füh
Figure 4.7: Control unit connection -F01
Main fuse 10 A
-S02
Diluting air blower protective motor switch
-F02
Power unit miniature fuse 5 A slow-blow
-K01
Probe heat element Solid State relay
-F03
Probe heat element miniature fuse 4 A slow-blow
-K02
2-changeover relay, 3/2-way ball valve / solenoid valve
-F04
Miniature fuse, 3/2-way ball valve -K03 / solenoid valve 0.25 A slow-blow
Diluting air heat element Solid State relay
-F05
Diluting air heat element miniature fuse 4 A slow-blow
2-changeover relay, probe blower
-F06
Probe housing fan miniature fuse -X01 0.25 A slow-blow
Voltage distribution terminal strip
-S01
Injector air blower protective motor switch
Signal transfer terminal strip
-K04
-X03
The configuration of terminals and connectors is specified in the Appendix.
48
D−R 820 F
Assembly
4.5.2
Probe Three sockets are located on the right side of the probe housing for the electrical connection of the probe (signals, power supply and diluting air heat element). The pin configuration of the connectors is specified in the Appendix (see chapter 17 Circuit diagrams and drawings from page 110)
Housing cover
Housing
Housing closure open Plug connector, ext. housing ventilation (optional) Probe ventilation fan filter (installed on the left) Plug connector (signals) Plug connector (power supply) Flange Probe tube (heated)
Sampling tube Plug connector, heat element
dr820f_001_0000_Sonde allgemein_de
Probe ventilation inlet filter Housing closure closed
Diluting air heat element Diluting air heat element connection cable
Diluting air connection
Figure 4.8: Probe connections
D−R 820 F
49
D−R 820 F
Dust Concentration Meter
05 5
Commissioning
Commissioning
5
Commissioning CAUTION
Risk of measuring cell pollution! Before commissioning, the 3/2-way ball valve must be set to PURGE and AUTOMATIC (see 3.8.5 3/2-way ball valve page 39)!
Figure 5.1: Mounting position optical sensor 1. After removing the housing cover (GRP cover) first insert the optical sensor (D−R 800 F) with its measuring lance into the measurement chamber. There is no need to open the device for that purpose. The adjustment is done as shown in Figure 5.1 (arrow), with angle plug towards middle of the device. Tighten optical sensor with the self-locking nuts to the flange. 2. Check wiring at control unit and sampling probe. 3. Connect external series fuse. 4. Check value and direction of rotation of voltage (400 V) at control unit input. 5. Connect main fuse F01. 6. Connect fuses F02 to F04 and the two protective motorswitches S01 and S02 one after another.
Figure 5.2: Mounting position ball valve injector air 7. The valve on the blower for the injector air (blue lever in Figure 5.2) is closed during dispatch. Now it has to be opened for operating, but only approx. 80%. D−R 820 F
53
Commissioning
It is advisable, to remove the blue lever after commissioning and keep it readily available nearby, fastened for example with a cable connector. For this reason it is prevented that the valve position (80%) is modified unchecked.
Figure 5.3: Mounting position valve for allocation of diluting air 8. Inside the probe the valve for allocation of diluting air (Figure 5.3) has to be opened. This valve is also closed during dispatch. It is secured by a twopiece pipe clamp. It is sufficient to untighten only the left side of the pipe clamp. After this, the valve can be opened with some turns. Finally the pipe clamp protection is tightened on the opened valve. 9. Wait until the diluting air has reached a value of min. 1 m³/h.The value is shown in the display behind identifier FD. 10.Connect the diluting air heat element with fuse F05 11.Connect the probe ventilation with fuse F06
dr820f_028_0000_DURAG Display+_eu
CAUTION
54
Condensate formation! Risk of measuring cell pollution! Cancellation of the preheating is not recommended!
12. The device is in the mode Preheating = ON (see 6.9.11 Set probe heat element | page 72). The preheating time ends after 30 minutes. 13. After expiry of the preheating time, the device switches to measuring mode. 14. After switching from purge (preheating) to measurement, the device remains in maintenance status for 1 minute. 15.The measured values, shown in the display of the control unit (Value T and TD is displayed alternately), should be consistent with the values specified in Table 5.1. If the displayed value FD (volume flow) is not yet in the range of approx. 3 ... 6 m³/h, the valve of the blower injector air has to be opened or closed respectively (see point 7 above).
D−R 820 F
Commissioning
Temperature T (setpoint value):
e.g. 120 °C Volume flow F:
8 ... 12 m³/h
Temperature TD (setpoint value):
e.g. 120 °C Volume flow FD:
aprox. 3 ... 6 m³/h
Table 5.1: Reference values 16. To alter operating or device parameters (see chapter 6.9 from page 65) remove the narrow cover on the right side of the display and activate the push-button behind (see Chapter 6.7 and Figure 6.4 on page 64). 17. Calibrate device Î probe calibration (see chapter 8 Calibration page 79) 18. Check, set and save software parameters (see 6.9.12 Output parameters | Send to terminal page 72)
WARNING
D−R 820 F
Risk of burns! Parts of the probe are electrically heated, wear safety gloves!
55
D−R 820 F
Dust Concentration Meter
06 6
Operation and Handling
6.1
Optical sensor
6.2
Display
6.3
Operating modes
6.4
Operation
6.5
Limit value input
6.6
Special displays
6.7
Parameter input
6.8
Calibration menu and reference point
6.9
Parameters
Operation and Handling
6
Operation and Handling
6.1
Optical sensor The optical sensor is described in detail in a separate manual (D-R 800). However, this information is generally irrelevant for use as a measuring probe in the D−R 820 F, as all necessary settings are performed and monitored by the D−R 820 F system. Therefore the user does not need to perform any settings on the sensor. The D−R 820 F is operated with the factory setting. Do not change any settings on the optical sensor! Otherwise, control by the D−R 820 F and functioning of the complete system will no longer be guaranteed. Checking or changing the settings of the D−R 800 F is only necessary and expedient in exceptional cases. Checks or changes should therefore only be carried out after consulting the Service department. You will find the relevant addresses and telephone numbers on page 121 (DURAG GROUP company addresses)
6.2
Display
dr820f_028_0000_DURAG Display
The D−R 820 F displays all necessary information for operation of the measuring device in a 4-line display. 1. Current measured values (measuring and operating variables) 2. Error messages
Figure 6.1: Display
The display has two different operating modes: Standard mode and service mode. You can switch between standard and service mode by means of parameter input (see 6.9.5 Ouput mode | Select output mode page 69).
D−R 820 F
59
Operation and Handling
6.3
Operating modes
6.3.1
Standard mode In standard mode, the display shows the corrected value of the dust content at the measuring point, the currently set measuring range and the operating variables temperature and volume flow. Any status messages are displayed cyclically in the bottom line (until the fault or event has ended).
T
1 1 9 . 7 ° C
F
1 1 . 2 C _ i B f i x
D
T TD
alternately: Measuring cell temperature [°C] Diluting air temperature [°C]
D
Dilution of measuring gas [%]
F
Total volume flow in the measuring chamber [m³/h]
m g / m 3
FD
Volume flow diluting air [m³/h]
r a n g e * *
CiB
Dust content of exhaust gas [mg/m³]
„*“
Heat element states: Star 1: "*" = Diluting air heat element = On Star 2: "*" = Probe heat element = On
8 5 . 2
F D
%
2 . 1 m 3 / h 1 2 . 6
m e a s u r e
Figure 6.2: Standard mode The measured values for temperature and volume flow relate to operating variables in the measuring device!
6.3.2
Service mode In service mode, the uncorrected measured value of the dust sensor (cal/scattered light), the differential pressures P1/P2 and the temperature T/TD are output. Service mode can be switched on and off by means of parameter input (see chapter 6.9.5 on page 69). In service mode the D−R 820 F is in maintenance status!
S 1 = T
1 . 9
= 1 0 . 4
P 1 = f i x
6 . 4
S 2 =
1 . 6
%
T D = 1 0 . 2
m A
P 2 =
m A
8 . 2
m e a s u r e
r a n g e * *
cal
Sensor measured value [V]
T
Temperature in the measuring chamber [mA]
Ts
Diluting air temperature [mA]
P1
Differential pressure via measuring chamber [mA]
P2
Differential pressure of diluting air (via measuring orifice) [mA]
Figure 6.3: Service mode
60
D−R 820 F
Operation and Handling
In service mode, the signals cal (measuring range as set) and pollution of the optical sensor are output at analog outputs 1 and 2 in percent as 4 ... 20 mA. In addition, the automatic measuring range switching for CiB is not active.
6.4
Operation
6.4.1
Keys The D−R 820 F is operated using the keyboard. The keys have the following meaning: MODE -> Call Limit Values or Special Displays menu right -> Continue, move cursor to the right, etc. Down -> To the left in the main menu, exit submenu ENTER -> Select menu, accept value, store value, etc.
6.4.2
...
0, 1, 2, 3, 4, 5, 6, 7, 8, 9 -> Numeric input, menu selection
/
+, - -> Change preceding sign, switch between PURGE and MEASUREMENT in standard mode
Numeric input A mathematical notation is used for numeric input. The representation is:
= + 1 .0000 E + 0
In this example the view means:
1 = + 1 ⋅ 10
Example 2
0
= 1
+ 5.300E + 2 = 5,3 ⋅ 10 2 = 530 Numeric input in the example: Input factor A
A
Ö Move the cursor to the corresponding position with
=
+ 1 . 0 0 0 0 E + 0 P o s i t i o n S e t
Ö Change preceding sign with <
- >
< E N T E R >
and
>
Ö Set desired value at the position with
to
Ö Save value and exit sub-item with
D−R 820 F
61
Operation and Handling
6.5
Limit value input The D−R 820 F can monitor two independent limit values. A message is generated in the display (only in standard mode) to indicate that the limit value has been reached or exceeded, the corresponding relay is opened and the relevant digital output is set. The value for the limit value can be entered with key to enter the limit values.
the keyboard. Press the i n p u t
l i m i t
v a l u e s
Selection of the limit value to be entered:
l i m i t
v a l u e
1
Ö
Press
to enter limit value 1
l i m i t
v a l u e
2
Ö
Press
to enter limit value 2
Ö
Press
e n d
<
l i m i t
v a l u e
+ 5 . 0 0 0 0 E + 2
v a l u e
+ 5 . 0 0 0 0 E + 2 P o s i t i o n
6.6
Example: Input limit value 1:
1
<
to end input and store limit values
Ö
- >
Standard: 500 mg/m³
>
< E N T E R >
l i m i t
e n d
>
m g / m 3
P o s i t i o n e n d
- >
.
Example: Input limit value 2:
2
Ö
m g / m 3 <
- >
Standard: 500 mg/m³
>
< E N T E R >
Special displays The D−R 820 F makes different displays available if you repeatedly press the key. These are identical in standard and service mode. After approx. 60 seconds without keyboard input, the display automatically returns to the current operating mode (not for Special displays | Alternative values and Special displays | Current signals!).
62
D−R 820 F
Operation and Handling
6.6.1
Special displays | Language
d i s p l a y
l a n g u a g e
i s
e n g l i s h c h a n g e
<
>
Change language (German/English)
s e t
< E N T E R >
Save, return to current value display
6.6.2 T D F
- >
Special displays | Alternative values 1 1 9 . 7 ° C
1 1 . 2
8 5 . 2
F D
c a l f i x
D
%
2 . 1 m 3 / h
FD/FM (extracted measuring gas volume) alternately cal signal
1 . 2 0 V
m e a s u r e
T/TD alternately
r a n g e * *
Status display + heat element
This display does not change back automatically!
6.6.3
Special displays | Current signals
T i m e :
1 5 : 3 3
1 2 . 0 6 . 0 7
Date and time
I 1 =
5 . 2 0
I 3 =
4 . 0 0
m A
Act. current at output 1 and 3
I 1 =
5 . 7 2
I 3 = 1 4 . 3 1
m A
Act. current at output 2 and 4
r a n g e * *
Status display + heat element
f i x
m e a s u r e
This display does not change back automatically!
6.6.4
Special displays | SW version 1
C u s t o m e r :
A B C D E F G H
Customer's name (factory setting)
s e r . : N o
1 2 3 4 5 6 7 8
Control unit serial number (factory setting)
s w - v e r s i o n :
1 . 1 5 a
Control unit software version
F r e e R T O S . o r g :
4 . 1 . 2
Control unit software version + operating system type
D−R 820 F
63
Operation and Handling
6.6.5
Special displays | SW version 2
b u i l d
t i m e :
b . d a t e
:
1 4 : 5 7 : 4 3
A p r
0 4
s e n - s w - v e r : s e n - s n o :
6.7
Compilation time of control unit SW
2 0 0 8
Compilation date of control unit SW
1 . 1 7
Software version of optical sensor in the probe
1 2 3 4 5 6 7 8
Serial number of sensor in the probe
Parameter input The D−R 820 F has an operating or parameterisation level for the input of specific parameters and for calibrating the device. You can access this level by pressing the SET switch see Figure 6.4. The cover on the right of the keyboard must be unscrewed to access the SET switch. Input of the parameters is largely self-explanatory (see above). The arrangement of the individual input values and the key sequence can be found under point 6.9 Parameters page 65 .
Valve position: MEASURING
dr820f_024_0000_SET-Schalter_de
Valve position: PURGE
RS 232 SET switch (behind the cover)
Figure 6.4: SET switch After pressing the SET switch, you have two options: Calibration and parameter input.
c h a n g e o r
r
p a r a m e t e r
c a l i b r a t i o n
c a l i b r a t e c h a n g e
>
Call up Calibration menu
< E N T E R >
Call up Parameter menu
<
- >
The normal functioning of the D−R 820 F is not interrupted during parameter input! The Dust Concentration Meter is only put into Maintenance status.
The complete menu plan can be found in Appendix on page 118.
64
D−R 820 F
Operation and Handling
6.8
Calibration menu and reference point In the Calibration submenu you can enter calibration factors, i.e. the analysis function after a gravimetric comparison (see chapter 8.2 Dust calibration from page 79) or define the reference point (see chapter 8 Calibration on page 79). 8 Calibration page 79 The electric zero points of the sensor electronics and the sensors are defined during the device calibration. 8.2 Dust calibration page 79 During the dust calibration, the display and the analog signal output of the D−R 820 F are adjusted to the actual dust content in the system.
c a l i b r a t e
p r e s e t
c o n s t a n t
c a l i b r a t i o n
6.8.1
<
- >
>
Ö
o f
Ö
is used to call up the calibration menu
is used to call up the parameter input for the calibration
< E N T E R >
Calibration | Reference point In the following menu, the device calibration can be started or the set referkey. ence value can be displayed with the The reference point of the optical sensor is defined during device calibration. The 3/2-way ball valve should be set to purge for device calibration!
When defining the reference point, a control cycle is started on the optical sensor. When it has finished, the new reference value is defined. The reference value should be between 60 and 80%!
6.8.2
Enter calibration parameters Parameter:
• Values for calculating the dust concentration C_iB (after a gravimetric calibration of the device) • A and D: Factors for calculation of dust C_iB
The mathematical relationship can be seen under point 3.8.1.3.
6.9
Parameters
6.9.1
Automatic measuring range switching | Autom. measuring range switching Parameter: Value range:
D−R 820 F
• Autom. measuring range switching of the current output CiB • Measuring range switching On / Off
73
Operation and Handling Meaning:
• Switches the automatic measuring range switching for CiB on or off
Setting of the measuring range in mg/m³ occurs under point 6.9.7 Dust and raw signal measuring ranges | page 71
Auto range = On: • Automatic measuring range switching is active. The dust measuring ranges are defined as follows: Ö Measuring range 1 = value range CiB, see 6.9.7 Dust and raw signal measuring ranges | page 71 Ö Measuring range 2 = 3 x value range CiB Auto range = Off: • Automatic measuring range switching is inactive. The dust measuring range is defined as follows: Ö Measuring range = value range CiB, see 6.9.7 Dust and raw signal measuring ranges | page 71
6.9.2
Device parameters | Set device parameters Parameter: Meaning:
• Set device parameter • Internal device parameters for volume flow and temperature
The device parameters are a factory setting and should not be changed!
6.9.2.1 Device parameters | Set device parameters | Range p Parameter: Meaning:
• Range p • Measuring range of the Δp-transmitter for measuring the differential pressure via the measuring gas pipe. The volume flow in the measuring chamber is calculated from this.
6.9.2.2 Device parameters | Set device parameters | Factor K Parameter: Meaning:
• Factor K • Construction factor for measuring gas differential pressure measurement. Result of factory calibration.
The probe factor K is dependent on the design and is set in the factory. If the elbow is exchanged for the ball valve, a new factor may need to be entered here!
6.9.2.3 Device parameters | Set device parameters | Range pd Parameter: Meaning:
66
• Range pd • Measuring range of the Δp-transmitter for measuring the differential pressure via the measuring orifice in the purge air connection. The volume flow of the purge air is calculated from this. D−R 820 F
Operation and Handling
6.9.2.4 Device parameters | Set device parameters | Factor KD Parameter: Meaning:
• Factor KD • Construction factor for purge air differential pressure measurement. Result of factory calibration.
6.9.2.5 Device parameters | Set device parameters | Measuring range temperature Parameter: Meaning:
• Measuring range temperature • Measuring range for temperature measurement.
6.9.2.6 Device parameters | Set device parameters | C Parameter: Meaning:
6.9.3
• Calibration factor C • Calibration factor C for compensating the dilution. • Result of factory calibration.
Operating parameters | Set operating parameters Parameter: Meaning:
• Set operating parameters • Measuring point-specific parameter for temperature, pressure and gas composition in the exhaust gas channel
6.9.3.1 Operating parameters | Set operating parameters | TM Display shows:
Parameter: Meaning:
T
Opened by button
• Temperature in exhaust gas channel at the measuring point • Device-internal operand (corresponds to the temperature in the exhaust gas channel at the measuring point in the main operating status)
6.9.3.2 Operating parameters | Set operating parameters | p Display shows:
Parameter: Meaning:
p
Opened by button
• Absolute pressure of measuring chamber • Input value
6.9.3.3 Operating parameters | Set operating parameters | pd Parameter: Meaning:
• Absolute pressure of purge air (via measuring orifice) • Input value
6.9.3.4 Operating parameters Set operating parameters | pM Parameter: Meaning:
• Static pressure in exhaust gas channel at the measuring point • Input value
6.9.3.5 Operating parameters | Set operating parameters | O2 Display shows:
Parameter: Meaning: D−R 820 F
Vol
Opened by button
• Gas composition, oxygen component [vol%] • Input value, oxygen component of exhaust gas volume flow
67
Operation and Handling
6.9.3.6 Operating parameters | Set operating parameters | CO2 Parameter: Meaning:
68
• Gas composition, carbon dioxide component [vol%] • Input value, carbon dioxide component of exhaust gas volume flow
D−R 820 F
Operation and Handling
6.9.3.7 Operating parameters | Set operating parameters | H2O Parameter: Meaning:
• Gas composition, water vapour component [vol%] • Input value, water vapour component of exhaust gas volume flow
The nitrogen component of the exhaust gas volume is calculated!
Example:
Dry air
Example of combustion exhaust gases
O2
21 Vol%
11 Vol%
CO2
0 Vol%
20 Vol%
H2O
0 Vol%
14 Vol%
N2
79 Vol%
55 Vol%
6.9.3.8 Operating parameters | Set operating parameters | RSL Display shows:
Parameter: Meaning:
R
Opened by button
• Gas constant of purge air • Input value
Danger of incorrect measurement! The operating parameters are measuring point-specific parameters. Some of them must be set in-situ during commissioning!
D−R 820 F
69
Operation and Handling
6.9.4
Integration time | Set integration time Parameter: Value range: Meaning:
6.9.5
Ouput mode | Select output mode Parameter: Value range: Meaning:
6.9.6
• Select output mode • Standard / Service • Switches between the standard and service operating modes, see 6.3 Operating modes page 60.
Zero and reference point control | Test zero and reference point Parameter: Meaning:
70
• Set integration time • 1 ... 60 seconds • Integration time via the measured value in seconds.
• Test zero and reference point • Executes a check of the zero and reference point (inspection values are not stored, only displayed). The difference between the actual and the calibrated values is output in %.
D−R 820 F
Operation and Handling The displayed values must meet the following conditions: D−R 820 F in order:
Value < 4 %
D−R 820 F in need of maintenance:
4 % < Value < 6 %
D−R 820 F in fault condition:
Value > 6 %
When the check is complete, the D−R 820 F waits for an input at the next menu item.
6.9.7
Dust and raw signal measuring ranges | Select dust output range Parameter: Value range: Meaning:
6.9.8
• • • •
Select dust output range CiB: 15 ... 500 mg/m³ Cal: 5 ... 300 V Sets the measuring ranges of the analog outputs for dust (CiB) and raw signal (Cal).
Volume flow measuring ranges | Select vol.flow output range Parameter: Value range:
Meaning:
• Select vol.flow output range • Volume flow F: 0 ... 20 m³/h (measuring chamber volume flow) • Limit Fmin: 0 ... 20 m³/h (measuring chamber min. volume flow) • flow range FD: 0 ... 20 m³/h (diluting air volume flow) • Limit FDmin: 0 ... 20 m³/h (diluting air min. volume flow) • Sets the measuring ranges of the analog outputs for volume flow (F and FD) and the limit values of the volume flow monitoring (Fmin and FDmin)
If the value falls below the set limit values for F and FD, the D−R 820 F goes into maintenance requirement status, and at 80% of this value the D−R 820 F goes into fault status. An attempt is made to improve this value by backflushing the probe!
6.9.9
Test current outputs | Test current outputs Parameter: Value range: Meaning:
• Test current outputs • 4 ... 20 mA • The current outputs for all analog outputs have preset analog values (forcommissioning, troubleshooting and functional testing)
6.9.10 Read error log | Read out error log Parameter: Meaning:
D−R 820 F
• Read out error/event log • Displays the last 100 (0..99) error messages of the D−R 820 F. The last error is in position 0, the last but one in position 1 etc.
71
Operation and Handling Example - error/event display: 0 0 / 5 6 S t a t u s
1 4 : 2 1
No./event code time and date
1 4 . 0 6 . 0 7
M a i n t e n
a n c e N e x t
<
- >
E n d
<
E N T E R
Display previous event
>
End log reading
>
6.9.11 Set probe heat element | Preheating mode Parameter: Value range:
Meaning:
• • • • •
Preheating mode Temperature: 0 ... 180 °C Preheating time: 0 ... 60 minutes Presetting: 30 minutes Sets the setpoint value for the probe temperature or measuring chamber temperature, the purge air temperature and the preheating time
CAUTION
The temperatures should not exceed 180 °C! The ball valve is not designed for higher temperatures!
CAUTION
Risk of pollution! Cancellation of the preheating phase is not recommended! During preheating, the probe tube is heated to a high temperature, to prevent the moisture from condensing out of the measuring gas! The remaining preheating time is displayed in minutes in the status line (normal or service display). Parameters etc. can be input during this time. The preheating time can be cancelled prematurely with the key (measuring).
6.9.12 Output parameters | Send to terminal Parameter: Setting: Meaning:
• Send to terminal • 9600 baud, 8 bit, no parity, 1 stop bit • Outputs the parameters of the D−R 820 F at the serial interfaceof a terminal program (e.g. Hyperterminal) (a serial extension cable must be used).
6.9.13 End or further input Meaning:
72
• Store or repeat parameter
D−R 820 F
D−R 820 F
Dust Concentration Meter
07 7
Decommissioning
7.1
Disassembly
7.2
Disposal
Decommissioning
7
Decommissioning WARNING
Risk of burns! The probe tube is heated to a high temperature. Do not touch the probe tube. Wear safety gloves when working with the probe.
1. Set 3/2-way ball valve to MANUAL + PURGE position see Figure 3.17 and purge for 10 to 30 minutes or switch to Purge with the key. 2. Switch off fuses F02 to F05 one after another, then protective motor switches S01 and S02 and finally fuse F01. 3. Switch off series fuse
7.1
Disassembly The probe is disassembled according to Figure 7.1. First of all, the ball valve must be set to MANUAL + PURGE. A. Remove cables and hoses (Representation of probe+chimney rotated) 1. CAUTION: FIRST set the ball valve to MANUAL + PURGE!
Control unit
Heating Diluting air
(2. Remove hoses)
dr820f_025_0001_Demontage Teil 1
Exhaust gas duct/chimney
Blower Diluting air
Blower Injector air
Air filter
(4. Unscrew frame from periphery e.g. open-mesh floor, guard rail or wall )
Figure 7.1: Disassembly part 1 D−R 820 F
75
Decommissioning B. Remove probe (5. Remove probe)
(4. Unscrew probe from flange 4x)
dr820f_026_0001_Demontage Teil 2
2 ... 5 degrees
Exhaust air feedback integrated or separate
Exhaust gas/flue gas Exhaust gas duct/chimney
Figure 7.2: Disassembly part 2
7.2
Disposal Note
Disposal of the D−R 820 F must occur in accordance with the applicable country-specific environmental protection regulations.
The D−R 820 F must be treated as hazardous waste for disposal.
76
D−R 820 F
D−R 820 F
Dust Concentration Meter
08 8
Calibration
8.1 8.1.1 8.1.2
Device calibration Device calibration; General Performing calibration
8.2 8.2.1 8.2.2 8.2.3
Dust calibration Dust calibration; General Mathematical relationship Performing calibration
Calibration
8
Calibration
8.1
Device calibration
8.1.1
Device calibration; General As a highly sensitive measuring device, the D−R 820 F is subject to the fine fluctuations of the components and materials used. For this reason the reference point of the optical sensor is compared, in order to detect any errors in the sensor in good time. The zero point of the optical sensor does not have to be calibrated. The actual reference point is defined during the device calibration. This calibration exclusively relates to the electronics of the D−R 820 F and not the gravimetric calibration (generally by test institute). This is at the customer's discretion.
8.1.2
Performing calibration The device is calibrated in accordance with the instructions under point 6.8 page 65. The calibration takes approx. 3 minutes. When calibration is complete, the D−R 820 F returns to the Calibration menu. The new reference value can be checked with the
key.
The 3/2-way ball valve should be set to purge for device calibration! The displayed reference value should be between 60 and 80%!
8.2
Dust calibration
8.2.1
Dust calibration; General The measured value acquisition is subject to a wide variety of influences, due to the different technological conditions at the relevant measuring points. Variable influence factors include type of dust, gas speed and temperature. The dusts to be measured vary, for example, in particle size, density, particle shape, charge and other dust and gas characteristics. Consequently, a different characteristic curve results for the output signal in relation to the dust content for each case of operation of a D−R 820 F. The signals of the D−R 820 F must therefore be calibrated with gravimetric comparison measurements (in accordance with VDI 2066 and VDI 3950 in Germany). The results of the calibration, i.e. the parameters, can be entered directly in the D−R 820 F, and the device outputs a signal proportional to the dust content.
D−R 820 F
79
Calibration
8.2.2
Mathematical relationship The dust signal is calculated in accordance with the following mathematical relationship (see 3.8.1.3 Extractive dust measurement page 36):
⎡ cal ⋅ F ⎤ Ci . B. = A ⋅ ⎢ ⎥+D − ⋅ F C F D ⎦ ⎣
ci.B.
Dust concentration [mg/m³]
cal
Measuring signal [V] (corresponds to scattered light)
F
Volume flow [m³/h]
A, D
Constants from the dust calibration
C
Constants from the device adjustment (input after production)
(Indices: "without" measuring chamber, "D" diluting air and "M" measuring gas)
8.2.3
Performing calibration Before starting the calibration, you must ensure that the device (point 6.9.2 page 66) and operating parameters (point 6.9.3 page 67) are correctly entered. You must also ensure that the error "MB sensor too small*" does not occur during calibration (status line, or erorr log)!! * (MB ≙ Hardware measuring range; see also Events page 92 The following steps are recommended for execution of the gravimetric calibration: 1. Check the 2. Device parameters | Set device parameters 3. Perform gravimetric dust calibration (in the case of an official dust measurement in Germany this is performed by a measuring body approved in accordance with §§ 26, 28 (¬) BImSchG). 4. Record analog signal CiB and form means over the period of the gravimetric comparison measurement. The calibration parameters A and D must be the following default values for calibration:
A
Ö1
C
Ö 1.1 (factory setting)
D
Ö0
On condition that A = 1 and D = 0, a CiB’ is displayed, which is used for the calibration. '
Ci.B. = A ⋅ Ci.B. + D The parameter C must not be adjusted.
80
D−R 820 F
Calibration
Gravimetric dust measurement - C I.B. [mg/m³]
dr820f_027_0000_Gravimetrische Kalibrierung
15
12
9
Ci.B.= A C' +i.B. D Ci.B.= 1.07 C' +i.B.0.09 R² = 0.8
6
3
0 0
3
6
9
12
15
Device display D-R 800 F - C'i.B.[mg/m³]
Figure 8.1: Example - Gravimetric calibration 5. Determine parameters A and D from the correlation. 6. Enter parameters A and D (see 6.8 Calibration menu and reference point page 65). Measuring signal Device display Grav. dust content Ci.B. D−R 820 F if A = 1 and D−R 820 F if A = 1 and [mg/m³] D = 0 [mA] D = 0 [mg/m³] 4.00 4.00 4.00 5.81 7.52 7.41 5.81 6.24 6.45 6.11 6.82 6.33 8,29 6.91 7.52 6.67 7.50 7.41
0.00 0.00 0.00 1.70 3.30 3.20 1.70 2.10 2.30 1.98 2.64 2.18 4.02 2.73 3.30 2.50 3.28 3.20
0.00 * 0.00 * 0.00 * 0.92 4.05 2.90 1.53 2.45 2.76 2.42 3.60 2.83 3.82 3.95 2.68 3.18 4.33 2.91
* (zero point hypothesis) Table 8.1: Value table for calibration example D−R 820 F
81
Calibration
If the optical sensor outputs the error "MB sensor too small" (MB Hardware MessBereich/Measuring Range) during the gravimetric comparison measurement, then this measurement cannot be used for the dust calibration and must therefore be repeated! (see error log) This applies similarly for every error that puts the D−R 820 F into fault condition. In addition, it should be noted that the D−R 820 F performs the zero and reference point test automatically, and no data are available for the comparison measurement during this time.
82
D−R 820 F
D−R 820 F
Dust Concentration Meter
09 9
Maintenance
9.1
Safety
9.2
Maintenance work
9.3
Cleaning
9.4 9.4.1
Work on the optical sensor D−R 800 F Reset of the optical sensor
Maintenance
9
Maintenance The provision of warranty performances assumes the correct execution of maintenance. Maintenance has the following aims: • To preserve the measuring accuracy of the D−R 820 F, • To guarantee operational reliability, • To increase the lifetime of the measuring device. In addition, maintenance forms the basis for warranty performances.
9.1
Safety WARNING
Danger from electrical equipment Before removing the housing or accidental-contact protection, the equipment must be disconnected from the power supply and protected against unauthorised re-activation.
WARNING
Danger of burns Never touch parts that could be hot without temperature-resistant equipment or safety gloves.
CAUTION
Damage to electronic components from electrostatic discharge (ESD) DURAG devices are protected from uncontrolled electrostatic discharge (ESD) during closed operation. If the device is opened (e.g. for service or maintenance tasks), appropriate ESD protection measures must be taken beforehand.
Optical sensor: CAUTION
D−R 820 F
Danger from laser light! Risk of blinding! Laser protection class II (radiant power < 1 mW at 655 nm) is only guaranteed if the manufacturer's setting for the laser potentiometer is unchanged (sealed). When using the device always comply with the following points: - Never look directly into the beam path - Do not direct the laser beam of the D−R 820 F at people - Look out for reflections of the laser beam.
85
Maintenance
9.2
Maintenance work Maintenance work must be performed by trained maintenance personnel in accordance with the Service Manual. Time
Activity
Monthly
• Check plausibility of values for F, FD
3 months
• Check temperature of measuring chamber and diluting air • Check suction intakes of blower • Clean complete probe
3 – 6 months
6 months
• Check filters for probe ventilation (optionally also optical sensor filter) – clean or replace if required • Depending on degree of pollution, clean probe housing or tubing (sampling elbow, Injector, probe tube, ball valve etc.) with special brushes • Check suction filter of blower – replace if required • A linearity test must be performed before each gravimetric dust calibration (annually as a rule)
Table 9.1: Maintenance work
9.3
Cleaning The Dust Concentration Meter D−R 820 F must be cleaned at intervals of at least 3 to 6 months. The frequency of the cleaning tasks to be performed depends on the selected measuring point or measuring medium (particularly the dust content) and the environmental and climatic conditions. Whenever performing cleaning tasks on the D−R 820 F, please note:
CAUTION
Risk of burns! Wear safety gloves! Parts of the D−R 820 F are electrically heated or operated with hot measuring gas! Cleaning work must be performed by trained maintenance personnel in accordance with the Service Manual.
9.4
Work on the optical sensor D−R 800 F The optical sensor receives all necessary settings from the D−R 820 F system. Consequently, the user does not generally need to make any settings on the sensor. The is operated D−R 820 F with the factory setting. Detailed information on the optical sensor can be found in the D-R 800 Manual. Maintenance work can be performed with the help of this manual, after appropriate training.
86
D−R 820 F
Maintenance
dr820f_005_0001_Sonde Ansicht Frontal_eu
A Optical sensor
Figure 9.1: Position of the optical sensor in the probe housing D−R 820 F
Do not change any settings on the optical sensor! Otherwise, control by the D−R 820 F and functioning of the complete system will no longer be guaranteed. Checking or changing the settings of the optical sensor is only necessary and expedient in exceptional cases. Checks or changes should therefore only be carried out after consulting the Service department. You will find the relevant addresses and telephone numbers on page 121 (DURAG GROUP company addresses)
9.4.1
Reset of the optical sensor In the event of an error, it is possible to reset the settings of the D−R 800 F. To do this, press all 4 keys on the sensor control pad inside the probe housing D−R 820 F simultaneously for approx. 1 s. The device is restarted with the current settings (not with the factory settings!)
D−R 820 F
87
D−R 820 F
Dust Concentration Meter
10 10
Error messages and error elimination
10.1
Events
10.2
Maintenance status
10.3
Maintenance requirement status
10.4
Fault status
10.5
Events
Error messages and error elimination
10
Error messages and error elimination The D−R 820 F outputs status signals for monitoring, indicating error states and troubleshooting. These are made available on the display in plain text and at the status contacts (see connection diagram) as a potential-free contact. The error messages are divided into the classes maintenance, maintenance requirement and fault. All current events are shown one after another in the status line of the display. The last 100 errors and events are stored in the error log of the D−R 820 F. You can also see the dependency of the events here, based on time and sequence. After exiting the Calibration or Parameter menu with the key (see Figure 6.4: SET switch on page 64), all events are deleted, i.e. the status display is reconfigured and any new events are written to the error log. If the messages/causes of the maintenance requirement category cannot be eliminated, please inform the competent Service department! (DURAG GROUP company addresses see page 121)
10.1 Events Provided that no maintenance, maintenance requirement or fault is present, all displayed events are only informative in nature. After calling the parameter setting or calibration with the key, any maintenance requirement or fault message present is reset.
10.2 Maintenance status "Maintenance status" is shown in the display. Maintenance operating status occurs at the following times: • Service mode or parameter input active • 4-hour zero and reference point control active (see point 3.8.4 Zero and reference point page 38) • Device is in purge position (see chapter 3.8.5 3/2-way ball valve page 39) • Manual maintenance switch is on (see Figure 3.8: Control unit, page 31) • The device is switched to maintenance status via a remote control (serial communication) (the device keyboard is locked during remote maintenance!) • The optical sensor is in maintenance status After switching from purge to measurement, the D−R 820 F remains in purge/maintenance status for another minute! When the maintenance switch (see Figure 3.8: Control unit, page 31) is in the maintenance position, the ball valve is not automatically set to purge if FX is less than 80%FXmin and in the event of a sensor error !
D−R 820 F
91
Error messages and error elimination
10.3 Maintenance requirement status "Maintenance requirement" is shown in the display. If the messages/causes of the maintenance requirement category cannot be eliminated, please inform the competent Service department! (DURAG GROUP company addresses see page 2)
10.4 Fault status "Fault status" is shown in the display. If the ball valve is moved into the "Measurement" position via the control key) when a fault is present, all events are deleted and the status display/error evaluation is reconfigured. If the messages/causes of the maintenance requirement category cannot be eliminated, please inform the competent Service department! (DURAG GROUP company addresses see page 2)
10.5 Events Legend: Table 10.1: Events • Status display/Event memory: "-" not used, "x" used (only if active)
0
Measures /Remark
Auxiliary value (no entry)
•
-
x
-
-
-
x
1
switched on
Info: D−R 820 F switched on or after • reset (control unit)
2
EEPROM error
Error: Writing or reading internal parameter memory
• •
RESET If error recurs -> Service
x
x
Error: Program error
• •
RESET If error recurs -> Service
x
x
Find and eliminate cause Adjust measuring range I1 Display is maintained for 20sec
x
x
RESET Test wiring If error recurs -> Service
x
x
3,4,6,1 Program error 6,19,37
92
Meaning
Error log
Message (Text)
Status display
Error number
• Abbreviations: "ERR" - fault, "WB" - maintenance requirement, ® - automatic reset ERR/WB when cause is no longer present, "PT100" - temperature sensor.
5
Error: Output range of current I1 too • Range I1 too small small (cal), if 15 minutes without • interruption -> WB •
8
Error: When sending a command to • sensor if after 5 attempts or if no • sensor data after RESET • -> ERR ®
Sensor error
D−R 820 F
Meaning
MB sensor too small
Error: Sensor input value too large, if 15 minutes without interruption -> WB
Wait for sensor
11
Measures /Remark
•
Error log
Message (Text)
Status display
Error number
Error messages and error elimination
• •
Dust pollution too great, sensors or measuring chamber polluted or defective -> clean x Increase dilution/temperature Display is maintained for 20sec
x
Info: Wait for sensor
•
-
x
-
Sensor error
Error: Sensor not ready after 120 seconds -> ERR
• • •
RESET Test wiring Test sensor function
x
x
14
Event error
Error: Internal event not expected (program error) -> ERR
• •
RESET If error recurs -> Service
x
x
15
Error reading RTC
Error: Reading RTC (internal time) / not important for function of ED, • continue with local time
-
-
x
17
New parameters
Info: New/modified parameters (restart all calculations!)
•
-
-
x
18
Recalibrated
Info: D−R 820 F recalibrated (new device calibration)
•
-
-
x
Ball valve error
Error operating ball valve If also second attempt error -> ERR
• • • •
Test fuse Test wiring x Is adjusting lever on "automatic" ? Test manual rotation
x
21
Current input T
Error: Measurement current input T (measuring chamber: 20.5mA) -> ERR ®
• • •
Test wiring x Test PT100 Test transmitter, test analog signal
x
22
Current input TD
Error: Measurement current input TD (dilution: 20.5mA) -> ERR ®
• • •
Test wiring x Test PT100 Test transmitter, test analog signal
x
Current input p
Error: Measurement current input p • (measuring chamber: 20.5mA) • -> ERR ®
Test wiring Test transmitter, test analog signal x Check seat of hoses at pressure sensor
x
24
Current input pd
• Error: Measurement current input pd • (dilution: 20.5mA) • -> ERR ®
Test wiring Test transmitter, test analog signal x Check seat of hoses at pressure sensor
x
25
Autoreset ERR
Info: Fault reset, as cause was no longer present
-
-
x
9
20
23
D−R 820 F
•
93
Meaning
Measures /Remark
Error log
26
Autoreset WB
Info: Maintenance requirement reset, as cause was no longer present
•
-
-
x
28
Zero point
Error: Result of zero point test, if greater than 6% -> ERR ® if greater than 4% -> WB ®
• •
Check installation conditions Check sensor for pollution
x
x
Reference point
Error: Result of reference point test if greater than 6% -> ERR ® if greater than 4% -> WB ®
• •
Check sensor for pollution Increase dilution/measuring chamber temperature Check sensor standardisation (parameters)
x
x
Clean sensor Check installation conditions Check optical sensor
x
x
- (see 21..24)
x
x
Test wiring Test sensor function
x
x
Error number
Message (Text)
Status display
Error messages and error elimination
30
94
• • • •
31
Pollution
Error: Result of pollution test if greater than 60% -> ERR ® if greater than 30% -> WB ®
32
Error current input
Info: Current input not in valid range •
33
Error measuring values
Error: Missing or invalid measuring values -> ERR ®
38
• Error: Output range for current I2 Range I2 too small too small (CiB), if 15 minutes without • interruption -> WB ® •
Find and eliminate cause Adjust measuring range I2 Display is maintained for 20sec
x
x
39
Range I3 too small
Error: Output range for current I3 too small, if 15 minutes without interruption -> WB ®
• • •
Find and eliminate cause Adjust measuring range I3 Display is maintained for 20sec
x
x
40
Error: Output range for current I4 Range I4 too small too small, if 15 minutes without interruption -> WB ®
• • •
Find and eliminate cause Adjust measuring range I4 Display is maintained for 20sec
x
x
41
Error AD conversion
Error: Analog-digital conversion of current measurement -> fault
• •
RESET If error recurs -> Service
x
x
42
Measured values packet lost
Error: Measured values packet lost, -> ERR ®
• •
Test wiring Test sensor function
x
x
44
Sensor temperature
Error: Sensor temperature, if >55°C -> WB ® if >65°C -> ERR ®
• • •
Test probe fan Test probe fan fuse Test probe ventilation
x
x
46
Reset WB/Fault
Info: Reset events in event of fault/maintenance requirement
•
After exiting menu called with the key
-
x
• •
D−R 820 F
Meaning
Error log
Message (Text)
Status display
Error number
Error messages and error elimination
CAUTION: D−R 820 F cannot be operated via keyboard ! (disconnect cable from RS232 if necessary - free again after 2 min D−R 820 F)
x
x
Measures /Remark
• Remote control
Info: Remote maintenance via RS232 (write access)
Initialisation
Info: Initialisation (wait for sensor)
•
-
x
-
Fixed measuring range
Info: Fixed measuring range for current output I2 (CiB)
•
-
x
-
Purge maintenance
Info: Purge mode
•
CAUTION: After switching ball valve to measuring, 1 more minute of "purge mode"
x
-
Service display
Info: Service output mode
•
The D−R 820 F is in maintenance x status
-
54
Protected access
Info: Access to protected area
•
Only by manufacturer (Service)
-
x
55
Maintenance requirement
Info: Maintenance requirement D−R 820 F
•
Evaluate the displayed errors
x
x
56
Fault status D−R 820 F
Info: Fault D−R 820 F
•
Evaluate the displayed errors
x
x
•
With specification of minutes remaining Cancellation of preheating at any x time with key (Caution: Condensation can result in the measuring chamber)
-
The D−R 820 F is in purge mode, in zero or reference point testing, parameter setting or the maintenance switch is on In error log only if maintenance through user operation
x
x
Check blower function (fuse) Check that hose connections are tight-fitting Check gas duct for pollution Check pressure sensor hose connections In the event of a fault, the D−R 820 F goes into purge mode
x
x
47
Preheating xxx min Info: Preheating D−R 820 F
•
• 58
Maintenance status
Info: Maintenance D−R 820 F •
60
Flow F too small
D−R 820 F
Error: Flow F (measuring chamber) too small, < Fmin -> WB ® (in 15min) < 80% Fmin -> ERR ® (in 15min) ERR ® (in 10sec) (in case of ERR attempt to increase the value by purging)
• • • • •
95
61
62
63
Meaning
Flow Fd too small
Error: Flow FD (purge air) too small < FDmin -> WB ® (in 15min) < 80% FDmin -> ERR ® (in 15min) ERR ® (in 10sec) (in case of ERR attempt to increase the value by purging)
Temp T too small
Error : Temperature T (measuring chamber) too low, < 80% Tnom -> WB ® (in 15min) < 70% Tnom -> ERR ® (in 15min) ERR ® (in 10sec)
Status ED Temperature TD (purge air) too small, Temp Td too small < 80% TDnom -> WB ® (in 15min) < 70% TDnom -> ERR ® (in 15min) ERR ® (in 10sec)
Measuring range = Info: Display act. measuring range, x with "auto" measuring range Limit value 1 ON
Info: Limit value 1 exceeded
Limit value 2 ON
Info: Limit value 2 exceeded
Measures /Remark
• •
Error log
Message (Text)
Status display
Error number
Error messages and error elimination
Check compressor function (fuse) Check that hose connections are tight-fitting Check gas duct for pollution x Check pressure sensor hose connections In the event of a fault, the D−R 820 F goes into purge mode
x
Test fuse Check switching of heat relay (LED) Check PT100 or temperature Check Flow F, if F < 1m³/h and not in purge mode, the heat element for T is off!
x
x
x
x
•
Test fuse Check switching of heat relay (LED) Check Flow Fd, if Fd < 0.5m³/h and not in purge mode, the heat element for Td is off! Check PT100 or temperature
•
-
•
The display remains for another 10sec after the value has fallen below the limit value
x
-
•
The display remains for another 10sec after the value has fallen below the limit value
x
-
• • • • • • •
• • •
Table 10.1: Events
96
D−R 820 F
D−R 820 F
Dust Concentration Meter
Appendix 11
Technical data
11.1
General
11.2
Presetting
12
EC Declaration of Conformity
13
Standards and regulations
14
Spare and wearing parts
15
Glossary
16
Index
17
Circuit diagrams and drawings
18
Menu plan
19
DURAG GROUP company addresses
Technical data
11
Technical data
11.1 General Feed
400 V, 50 Hz, 3~, 16 A (max. 5 x 4 mm²)
Class of protection
1
Readiness for operation
After 5 to 15 minutes (without preheating time)
Rack frame Dimensions (W x H x D)
600 x 1,750 x 550 mm
Space requirement (W x H x D)
850 x 1,750 x 1050 mm
Weight
approx. 60 kg
Blower class of protection
IP 65
Control unit Dimensions (W x H x D)
600 x 400 x 410 mm (including lock + PU)
Space requirement (W x H x D)
1,200 x 400 x 410 mm
Weight
approx. 20 kg
Class of protection
IP 65
Ambient temperature
- 20 °C ... + 50 °C
Probe Dimensions (W x H x D)
600 x 1050 x 1,500 (500 + 1000)mm
Immersion depth
1,000 mm (see ordering data!)
Weight
approx. 45 kg
Class of protection
IP 65
Ambient temperature
- 20 °C ... + 50 °C
Temperature at ball valve
>/Time
1
1
2
2
0
1
1
1
1
3
1
1
2
Legend: X - displayed according to status (Numeric values only by way of example)
2
The input of numeric values is limited to preset minimum and maximum values! Limit is briefly displayed and adopted as default value for value input.
2
3
2
1
1
2
2
3
4
1
3
Output in case of an incorrect input (e.g. time), last valid value is displayed as default value again.
1
Error EEPROM: 4
5
After factory setting ->
1
1
Menu plan D-R 820 F
118
(Ver. 1.15_uk) part 1
D−R 820 F
Menu plan
0
1
1
2
1
0
1
1
2
2
2
1
1
2
2
3
Menu plan D-R 820 F
D−R 820 F
(Ver. 1.15_uk) Part 2
119
DURAG GROUP company addresses
19
DURAG GROUP company addresses DURAG GmbH
DURAG France Sarl
Kollaustr. 105 ▪ 22453 Hamburg Tel. +49 40 55 42 18 – 0 ▪ Fax +49 40 58 41 54 E-Mail:
[email protected]
Parc GIP Paris Charles de Gaulle 49 rue Léonard de Vinci BP 70166 95691 GOUSSAINVILLE France Tel. +33 1 30 18 11 80 ▪ Fax +33 1 39 33 83 60 E-Mail:
[email protected]
DVN – DURAG Vertrieb Nord
Kollaustr. 105 ▪ 22453 Hamburg Tel. +49 40 55 42 18 – 0 ▪ Fax +49 40 58 41 54 E-Mail:
[email protected] DVO – DURAG Vertrieb Ost
Meißner Ring 4 ▪ 09599 Freiberg Tel. +49 37 31 30 04 – 0 ▪ Fax +49 37 31 30 04 – 22 E-Mail:
[email protected] DVS – DURAG Vertrieb Süd
Weidenweg 16 ▪ 73087 Bad Boll Tel. +49 71 64 9 12 25 – 0 ▪ Fax +49 71 64 9 12 25 – 50 E-mail:
[email protected] DVW – DURAG Vertrieb West
An der Pönt 53a ▪ 40885 Ratingen Tel. +49 21 02 74 00 – 0 ▪ Fax +49 21 02 74 00 – 28 E-Mail:
[email protected]
DURAG UK Office
Honeysuckle Cottage Ridding Bank Stoke-on-Trent Staffordshire, ST4 8SB Great Britain Tel. +44 17 82 65 76 66 ▪ Fax +44 17 82 64 60 20 E-Mail: durag.uk@durag .de DURAG, Inc.
Southridge Business Center, 1355 Mendota Heights Road, Suite 200 Mendota Heights, Minnesota MN 55120 USA Tel. +1 65 14 51 – 17 10 ▪ Fax +1 65 14 57 – 76 84 E-Mail:
[email protected] Durag India Instrumentation Private Limited
#143/16, 4th Main Road, Industrial Town, Rajajinagar Bangalore 560 044 India Tel.: + 91 80 23 14 56 26 & 23 14 56 27 Fax: + 91 80 23 14 56 26 & 23 14 56 27 Extn. 30 E-Mail:
[email protected]
D−R 820 F
121
GmbH · Kollaustraße 105 · 22453 Hamburg · www.durag.de
