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Novatech 1638 Manual

Dew point analyser
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Dew Point Analyser
Model 1638
August 2009

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Summary of Contents for Novatech 1638

  • Page 1 Dew Point Analyser Model 1638 August 2009...

  • Page 3: Table Of Contents

    © Copyright NOVATECH CONTROLS PTY. LTD. - 1996 - 2008 This manual is part of the product sold by Novatech Controls Pty. Ltd. ("Novatech Controls") and is provided to the customer subject to Novatech Controls' conditions of sale, a copy of which is set out herein. Novatech Controls' liability for the product including the contents of this manual is as set out in the conditions of sale.
  • Page 4 If this configuration does not suit or if it is possible for raw fuel to come into contact with a hot oxygen probe or sensor then the Model 1638 analyser with a heated probe or sensor will not be safe in your application.

  • Page 5: Specifications

    SPECIFICATIONS Section Number     MODEL 1638 OXYGEN & DEW POINT ANALYSER ..............4     SERIES 1230 OXYGEN PROBES & SENSORS ................7     PURGE & CALIBRATION CHECK ACCESSORIES ..............11     FILTER PURGE PRESSURE SWITCH ..................11...

  • Page 6: Model 1638 Oxygen & Dew Point Analyser

    MODEL 1638 OXYGEN & DEW POINT ANALYSER DESCRIPTION The Novatech model 1638 oxygen analyser / transmitter provides in-situ measurement for one or two oxygen probes in annealing and other furnaces with protective atmospheres of hydrogen / nitrogen. The analyser provides local indication of oxygen and dew point plus sixteen other selectable variables.
  • Page 7 0 to 1200 mV in 100 mV steps 100 to 1300 mV in 100 mV steps Probe EMF 2 0 to 1200 mV in 100 mV steps 100 to 1300 mV in 100 mV steps August 2009 1638 Dew Point Analyser...
  • Page 8 240 or 110V, 50/60 Hz, 5 VA (unheated probe) Weight • Analyser, 3.75 kg Degree of Protection • IP65 without reference air pump • IP54 with reference air pump Mounting • Suitable for wall or surface mounting. August 2009 1638 Dew Point Analyser...

  • Page 9: Series 1230 Oxygen Probes & Sensors

    All Novatech oxygen probes are designed and manufactured to exacting standards of performance and reliability. Series 1230 probes are the result of extensive research and development by Novatech, industry and government agencies. Novatech Controls provides application and after sales support for oxygen probes, sensors and analysers, worldwide.
  • Page 10 1. Probe insertion length (from process end of mounting thread to probe sensing tip). 2. Mounting thread (process connection), BSP or NPT (for size of thread refer to specifications). 3. Lagging extension length, if required. 4. If model 1232 probe, state preferred thermocouple type (refer to specifications). August 2009 1638 Dew Point Analyser...
  • Page 11 1 kg plus 100 g / 100 mm Notes: 1. Care must be taken to avoid contact with explosive or inflammable gases with 1231 heated probes. Novatech analysers have built in safety protection. 2. Please contact factory for corrosives other than sulphur or zinc. We can provide test materials to try in your atmosphere.
  • Page 12 1. For applications up to 1200°C it may be more economical to use a separate type “K” or “N” thermocouple than the internal “R” thermocouple. It is important that a separate thermocouple senses the same temperatures as the oxygen probe tip. August 2009 1638 Dew Point Analyser...

  • Page 13: Purge & Calibration Check Accessories

    PURGE & CALIBRATION CHECK ACCESSORIES Due to the absolute measurement characteristics of zirconia sensors and the self calibration features of Novatech analysers, probe calibration checks with calibrated gas are not normally required. In some installations however customers prefer the have a calibration check facility.
  • Page 14 August 2009 1638 Dew Point Analyser...

  • Page 15: Description

    AUTO PURGE ..........................17     2.17 RS 485 AND RS 232C PORT ......................17     2.18 AUXILIARY TEMPERATURE THERMOCOUPLE ..............17     2.19 WATCHDOG TIMER ........................17     2.20 BACK-UP BATTERY ........................17 August 2009 1638 Dew Point Analyser...

  • Page 16: The Annealing Process (Or Other Similar Applications)

    With a known hydrogen level, the dew point in the furnace can be calculated. This is provided as an output on a standard Novatech 1638 analyser but we recommend the use of the oxygen output from the same analyser. Both outputs are available simultaneously for operators who are more used to furnace dew point levels.

  • Page 17: The Zirconia Sensor

    In applications where the process pressure is negative or neutral, a suction pump will be required. A reference air pump is provided in the 1638 oxygen analyser. The internal construction of a probe is shown as follows. Internal electrode wire...

  • Page 18: The Analyser

    THE ANALYSER The 1638 analyser is a transmitter with two 4 to 20 mA outputs. One output is % oxygen or dew point with selectable zero and span. The second output can be selected as dew point, oxygen, auxiliary temperature or sensor EMF. Four alarm relays are provided.

  • Page 19: Auto Calibration Checking - Probes

    The battery module should be replaced every 8 years. (It is the battery shaped device clipped in a socket labelled M1 on the 1630-1 PCB) August 2009 1638 Dew Point Analyser...
  • Page 20 August 2009 1638 Dew Point Analyser...

  • Page 21: Installing & Commissioning

    CHECKING THE ALARMS ......................30     3.21 PROBE CALIBRATION ........................ 30     3.22 FILTER PURGING ......................... 31     3.23 CALIBRATION GAS CHECK ...................... 31     3.24 DUST IN THE FURNACE ......................31 August 2009 1638 Dew Point Analyser...

  • Page 22: Mounting The Analyser

    Although it is rare, occasionally a probe may sense oxygen vastly differently from the average reading in the furnace. If it occurs, then the probe should be moved, or a longer probe installed. This phenomena is normally caused by stratification of the furnace atmosphere. August 2009 1638 Dew Point Analyser...

  • Page 23: Installing The Auxiliary Thermocouple

    SHIELD CONNECTIONS All external wiring to the 1638 analyser should be shielded. Do not connect shields at the field end. Simply clip off and insulate. An extra terminal strip may be required to connect all shields together. This should be supplied by the installer.

  • Page 24: Electrical Connections

    W hite 51 Heater #1 W hite 52 Heater #1 W hite 53 Heater #2 W hite 54 Heater #2 SENSO R #1 Connection Diagram for 1638 Analyser and one or two 1231 Heated Sensors August 2009 1638 Dew Point Analyser...
  • Page 25 50 M ains A PRO BE #2 51 Heater #1 52 Heater #1 53 Heater #2 54 Heater #2 PRO BE #1 Connection Diagram for 1638 Analyser and one or two 1232 Unheated Sensors August 2009 1638 Dew Point Analyser...

  • Page 26: Heater Interlock Relays

    Connect the probe lead as shown in the following drawings. Unheated probe leads have integral reference air tube. An adaptor has been supplied to connect this tube to quarter inch flexible PVC tubing, from the air pump or reference air supply. August 2009 1638 Dew Point Analyser...
  • Page 27 Ot her T er mi nal Shi el ds ( By I ns t al l er ) Ear t h Mai ns Ear t h Connection of Probe Cable for Heated Probes Model 1231 August 2009 1638 Dew Point Analyser...

  • Page 28: Connecting The Auxiliary Thermocouple (Optional)

    High dew point deviation between probes Probe under temperature Calibration check in progress Probe purge in progress Alarm horn function (Relay 4 only) ** These alarms are only available if two sensors are selected August 2009 1638 Dew Point Analyser...

  • Page 29: Connecting The Automatic Purge And Calibration Check System

    A 1/4” tube connector on the analyser should be connected via a nylon, copper or stainless steel tube to the ‘REF’ connector on the probe. If two probes are being used, a “T” union must be supplied to provide reference air supply to both probes. August 2009 1638 Dew Point Analyser...

  • Page 30: Connecting The Dual Fuel Input

    RS-232 protocol for the serial port is eight data bits, one stop bit, no parity. R -232 R Printer or Data Logger 21 R -232 T 22 Network Network + Serial Available for RS-485 Network Serial Port Connections Serial Port Connections August 2009 1638 Dew Point Analyser yser...

  • Page 31: Connecting The Analyser To A Modbus™ Network

    LK2 at each end if the network line. The protocol of the network is – Baud Rate 9600 Parity none Stop Bits RS485 Half Duplex Mode RTU (binary mode) For more details see Section 2.12 and Appendix 6. Network Connections August 2009 1638 Dew Point Analyser...

  • Page 32: Commissioning

    Refer to Section 5.5.11. The probe offset can be tested on site. A small flow of air must be admitted to both the ‘REF’ and ‘CAL’ ports when testing the probe offset. If the probe is in the process, the air must fully purge the probe sensor without interference from the process gas sample. August 2009 1638 Dew Point Analyser...

  • Page 33: Filter Purging

    63 % change from one reading to another. If a probe filter blocks completely in a short period of time, then there is no option but to use the probe without the filter. August 2009 1638 Dew Point Analyser...
  • Page 34 August 2009 1638 Dew Point Analyser...

  • Page 35: Operator Functions

    SUMMARY OF ALARMS – COMMON ALARM ............... 35     4.3.2 SUMMARY OF ALARMS – SELECTABLE ALARMS .............. 36     4.3.3 ALARM RELAYS .......................... 37     POWER LAMP ..........................37     BURNER BYPASS SWITCH ......................37 August 2009 1638 Dew Point Analyser...

  • Page 36: Display Button

    If you hold the display button down as you switch on the power, the maximum ambient temperature which the instrument has been subjected to, will be displayed. This temperature should be less than 50°C. August 2009 1638 Dew Point Analyser...

  • Page 37: Alarm Button

    Section 5.5. This alarm will not reset until the next purge cycle which can be initiated manually or automatically. 13. ‘Gas 1 Cal Err’ Probe does not correctly calibrate to calibration check gas 1. 14. ‘Gas 2 Cal Err’ Probe does not correctly calibrate to calibration check gas 2. August 2009 1638 Dew Point Analyser...

  • Page 38: Summary Of Alarms - Selectable Alarms

    Press the alarm button twice to accept any new alarm and to cancel the horn relay. This is only available on relay 4. August 2009 1638 Dew Point Analyser...

  • Page 39: Alarm Relays

    ON position. While the BURNER BYPASS switch is on there will be an alarm, “Burner Bypass”. If it is not needed to have the analyser interlocked with the combustion appliance terminals 18 & 19 can be connected together. August 2009 1638 Dew Point Analyser...
  • Page 40 August 2009 1638 Dew Point Analyser...

  • Page 41: Setting Up The Transmitter

      SET-UP MODE FUNCTIONS ....................... 40     SET-UP & RUN MODES ....................... 42     FUNCTION SELECT ........................42     ENTER OPTION OR VALUE ....................... 42     SET-UP FUNCTION DETAILS..................... 43 August 2009 1638 Dew Point Analyser...

  • Page 42: Set-Up Mode Functions

    Flue Pressure mm/inches/kilopascals Flue Pressure Value Purge/Cal Time Automatic Purge Set-up steps 38to 40 will be skipped automatically if ‘No’ is selected in set-up step 37. Time Between Purges Purge Duration Purge Freeze Time August 2009 1638 Dew Point Analyser...
  • Page 43 External hydrogen level input span level Set-up step 84 may be skipped automatically, depending on the selection in set-up step 81. Fixed hydrogen level Instrument operating mode. Pre-reaction oxygen or Dew point MODBUS address, 0 for no MODBUS communications August 2009 1638 Dew Point Analyser...

  • Page 44: Set-Up & Run Modes

    ‘ENTER’ button. When a value has been entered an asterisk will appear at the R.H.S. of the lower line. Oxygen1 4.1E-23% Dew Pnt1 -18C POWER ALARM SETUP Alarm Setup Display Function Option Cal 2 Purge Cal 1 Option Enter Function Autocal August 2009 1638 Dew Point Analyser yser...

  • Page 45: Set-Up Function Details

    (labelled ‘REF VOLTS’). Measure the four voltages on the test point marked 1 to 4 with the positive lead. Refer to Figure 6.2 in the 1638 manual. Enter the measured values in set-up items 7 to 10. Whenever new values are entered the D/A section should be re-calibrated, Refer to Section 6.3.
  • Page 46 This menu item only appears if ‘Set 4mA Trim’ is selected in Set-up 13. Range: 0 to 25mA, Default is 4.00mA For full details on the calibration of the 4-20mA output channels, see section 6.3. August 2009 1638 Dew Point Analyser...
  • Page 47 K thermocouple, and a 1232 will usually have an R thermocouple. Options 1. K Check in the manual Section 1 2. R for the probe model number. 3. NO T/C If no TC type is to be used for an Auxiliary use. August 2009 1638 Dew Point Analyser...
  • Page 48 PRE-REACTION OXYGEN #1 and #2 0 fixed oxygen 1 to 10.0% oxygen 0 to 4.0% Note: The last four items (average of probe 1 and 2) are only available if two sensors are selected in set-up 1 August 2009 1638 Dew Point Analyser...
  • Page 49 Note that the reducing oxygen span is shown on the display as the exponent only. -1 represents 10 % oxygen. 32. Centigrade/Fahrenheit Selection Select whether displays and outputs are to be in ° Celsius or Fahrenheit Options: 1. Celsius (Centigrade) * 2. Fahrenheit August 2009 1638 Dew Point Analyser...
  • Page 50 For some oil and coal fired plant, probe filters are necessary and should be back-purged with sufficient frequency to avoid blocked filters. The outputs will be frozen during purging. If no purge is required, set-up steps 38, 39 and 40 will be skipped. Options: August 2009 1638 Dew Point Analyser...
  • Page 51 45. Period Between Gas 1 Autocals Set the number of hours between autocal Gas 1. A typical time would be 24 or 168 hours. (Daily or weekly). Range: 1 to 1999 hours. The default setting is 1 hour. August 2009 1638 Dew Point Analyser...
  • Page 52 If the alarm level is set to -18, an alarm will be initiated (after the time set in set-up 58) if the oxygen measured by probe 1 is 1.0 %or higher. This menu item will only appear if Dew point is selected in set-up 85. Range: -10 to -25. The default setting is -18. August 2009 1638 Dew Point Analyser...
  • Page 53 100 times or 2 decades higher than the other. This menu item will only appear if Dew point is selected in set-up 85. Range: 1-25 % oxygen decades. The default setting is 2. August 2009 1638 Dew Point Analyser...
  • Page 54 7. Dew point deviation 8. Probe temperature 9. Gas calibration in progress 10. Purging probe in progress 72. Alarm Relay #3 Alarm relay #3 has the same functions available as alarm relay #2. See SET-UP 71. August 2009 1638 Dew Point Analyser...
  • Page 55 Note: If ‘Internal’ is selected, and a reference airflow sensor is connected to CN8 on the 1630-2 (terminal) PCB, the pump is cycled on and off within a minute. Options Internal External Instrument air August 2009 1638 Dew Point Analyser...
  • Page 56 If the hydrogen level in the furnace varies by more than 15% of the hydrogen value, automatic on line compensation can be made by feeding the hydrogen level into the 1638 analyser. The signal must be proportional to hydrogen, but can represent any range (zero and span ) from 0 to 100%.
  • Page 57 85. Pre-reaction Oxygen or Dew Point Instrument Mode Selection The 1638 has been designed to measure oxygen in a hydrogen/nitrogen atmosphere. However, to simplify the operation of the instrument, the 4-20mA output ranges, the alarms and the lower line displays will tailored to suit the selected instrument mode.
  • Page 58 August 2009 1638 Dew Point Analyser...

  • Page 59: Maintenance

    TEST EQUIPMENT REQUIRED ....................60     TESTING A PROBE OR SENSOR ....................61     6.10 PROBE OR SENSOR THERMOCOUPLE ..................61     6.11 HEATER FAILURE ........................61     6.12 FILTER BLOCKAGE ........................61 August 2009 1638 Dew Point Analyser...

  • Page 60: Cold Start

    The analyser will read these references every minute and update its zero and span correction factors. See Section 5.5.7 to 10. These references should be checked every 12 months. An AUTOCAL of the analog output section should always be performed if these references are altered. See Section 6.3. August 2009 1638 Dew Point Analyser...

  • Page 61: D/A (4-20Ma Output Channels) Calibration

    The memory module must be purchased from Novatech Controls or an agent of Novatech Controls. After replacing the battery, re-enter all set-up mode functions.

  • Page 62: Installing A New Probe Or Sensor

    TEST EQUIPMENT FOR HEATED PROBES If a 1638 analyser is available at the test location then no other equipment will be required. If not, then a controllable power source for the heater is required. A Variac (variable transformer), set to approximately 100 or 240 volts will regulate the sensor temperature to 720°...

  • Page 63: Testing A Probe Or Sensor

    Filters are normally cleared with back purging. However fine fly-ash, or other particles can ultimately completely block a filter necessitating filter replacement. A new probe filter can be fitted August 2009 1638 Dew Point Analyser...

  • Page 64: Appendix 1 Probe Or Sensor Emf Tables

    11.0 13.881 99.518 10.5 14.881 114.347 'K' Type TC 29.965 mV @ 720°C (1320°F) These tables are based on the Nernst equation: ⎛ ⎞ ⎜ ⎟ ⎝ ⎠ Where T is temperature° K − August 2009 1638 Dew Point Analyser...
  • Page 65 24.527 28.455 32.371 36.256 40.087 43.846 47.513 These tables are based on the Nernst equation: ⎛ ⎞ ⎜ ⎟ ⎝ ⎠ Where T is temperature° K − Thermocouple information from NIST ITS-90 data tables August 2009 1638 Dew Point Analyser...
  • Page 66 1.32E-26 -60.09 1.97E-22 -58.67 1350 8.29E-27 -61.80 1.33E-22 -60.14 1360 5.19E-27 -63.48 8.93E-23 -61.59 1370 3.25E-27 -65.14 6.01E-23 -63.02 1380 2.04E-27 -66.77 4.05E-23 -64.43 1390 1.28E-27 -68.38 2.72E-23 -65.82 1400 8.01E-28 -69.96 1.83E-23 -67.20 August 2009 1638 Dew Point Analyser...

  • Page 67: Appendix 2 % Oxygen Scale To Logarithmic

    APPENDIX 2 % OXYGEN SCALE TO LOGARITHMIC OXYGEN FULL SCALE 0.15 7.65 13.1 20.7 26.2 33.8 39.2 43.5 51.1 56.5 64.2 69.6 77.3 82.7 86.9 90.4 93.3 95.8 August 2009 1638 Dew Point Analyser...

  • Page 68: Appendix 3 Sample Log Print Out

    Humidity 43% Sensor 1 Imp 5.7K Next Purge at 06:00:00 17-10-1995 Next Print at 06:27:00 17-10-1995 06:00:11 04-07-1995 Heater 1 Fail Is Active 06:00:13 04-07-1995 O2% Low Is Active 02:33:17 04-07-1995 RefPump Fail Accepted August 2009 1638 Dew Point Analyser...

  • Page 69: Appendix 4 Circuit Schematics

    APPENDIX 4 CIRCUIT SCHEMATICS August 2009 1638 Dew Point Analyser...
  • Page 70 Ser-[1..5] SVcc Svee August 2009 1638 Dew Point Analyser yser...
  • Page 71 P5-[0..7] P4-7 P4-1 P4-0 L4-[3..6] August 2009 1638 Dew Point Analyser...
  • Page 72 August 2009 1638 Dew Point Analyser yser...
  • Page 73 August 2009 1638 Dew Point Analyser...
  • Page 74 DAC-PS-[0..5] August 2009 1638 Dew Point Analyser yser...
  • Page 75 P5-7 August 2009 1638 Dew Point Analyser...
  • Page 76 L2-[0..7] L6-[0..7] August 2009 1638 Dew Point Analyser yser...
  • Page 77 August 2009 1638 Dew Point Analyser...

  • Page 78: Appendix 5 Modbus™ Register Map And Application Notes

    WriteHolding Register Function 6 ( for allowable addresses only ) Introduction. The 1638 Analyser implements the MODBUS™ slave protocol, it is intended to work in conjunction with a MODBUS™ master. This is accomplished by setting the MODBUS™ address to some non-zero value in the range 1-31, setting the jumper positions to select the RS485 half duplex configuration, and re-starting the analyser.
  • Page 79 Dew Point average of 2 probes 2072 Ambient temperature 246 = 24.6 2074 Ambient RH 561 = 56.1 2076 ALRM-ARRAY Array of current alarm status. See below 2092 ALRM-TIMES Array of timestamp of alarms August 2009 1638 Dew Point Analyser...
  • Page 80 24. Sensor 2 Fail (Impedance too high) 25. Probe 2 thermocouple open circuit 26. Probe temperature below 650 °C 27. Gas calibration check in Progress 28. Probe Purging in progress 29. Alarm horn 30. Probe Temperature high August 2009 1638 Dew Point Analyser...
  • Page 81 For checking alarms via Modbus, it is recommended to treat all alarms in a 'timer' state the same as inactive. 16-bit Byte Order Architecture The 1638 Analyser uses 'big endian' byte architecture, meaning that for a 16-bit address block, the most significant byte (msb) appears first, followed by the least significant byte (lsb) second.
  • Page 82 I hereby declare that the equipment specified herein conforms to the above I hereby declare that the equipment specified herein conforms to the above directive(s) and standards(s). directive(s) and standards(s). Full Name: Fraser Chapman Position: R & D Manager August 2009 1638 Dew Point Analyser yser...
  • Page 83 Novatech Controls Pty. Ltd. ABN 57 006 331 700 Conditions of Sale were not manufactured by or approved in Interpretation Acknowledgment regarding facilities for writing by the seller; In these conditions: repairs or parts (iii) any contamination or leakages caused or The buyer acknowledges that the seller does not `Seller' means Novatech Controls Pty.
  • Page 84 Novatech Controls Pty. Ltd. ABN 57 006 331 700 Conditions of Sale such part of the proceeds of any such sale as liability, loss, expense or demand for or arising from 14.2 represents the invoice price of the goods sold or used...

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