Madur Sensonic 4000 Manual

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Sensonic 4000

CONTENTS

CONTENTS............................................................................................................................................

INTRODUCTION...................................................................................................................................

2.1

USE OF THIS OPERATING MANUAL............................................................................................

2.2

SYMBOLS USED..............................................................................................................................

MAINTENANCE....................................................................................................................................

3.1

Gas sensors.......................................................................................................................................

3.2

Gas system........................................................................................................................................

3.3

Battery..............................................................................................................................................

3.4

Service intervals................................................................................................................................

3.5

Errors during operation....................................................................................................................

3.6

Switching off after use.......................................................................................................................

GENERAL INFORMATION...................................................................................................................

CONSTRUCTION..................................................................................................................................

5.1

Elements of gas circuit......................................................................................................................

5.1.1 Gas probe with in-line filter.........................................................................................................

5.1.2 Gas pump.....................................................................................................................................

5.1.3 Gas chamber................................................................................................................................

5.2

Measurement system.........................................................................................................................

5.2.1 Gas sensors..................................................................................................................................

5.2.2 Ambient air temperature sensor...................................................................................................

5.2.3 Flue gas temperature sensor........................................................................................................

5.2.4 Gas chamber temperature sensor................................................................................................

5.2.5 Differential pressure sensor.......................................................................................................

5.2.6 Analogue inputs.........................................................................................................................

5.3

Data input/output systems...............................................................................................................

5.3.1 Keyboard...................................................................................................................................

5.3.2 Display.......................................................................................................................................

5.3.3 Printer........................................................................................................................................

5.3.4 Interface RS 232C......................................................................................................................

5.4

Power supply..................................................................................................................................

OPERATION........................................................................................................................................

6.1

USE OF THE KEYBOARD.............................................................................................................

6.1.1 Description of the keys...............................................................................................................

6.1.2 Selecting Menu Options.............................................................................................................

6.1.3 Entering Numbers......................................................................................................................

6.1.4 Editing Text................................................................................................................................

6.2

Basic operating instructions...........................................................................................................

6.2.1 Setting-up the analyser..............................................................................................................

6.2.2 Switching on...............................................................................................................................

6.2.3 Switching off / Standby..............................................................................................................

6.2.4 Initial Calibration......................................................................................................................

6.2.5 Measurement Parameters..........................................................................................................

6.2.5.1 Fuel 19

6.2.5.2 Average Time.....................................................................................................................

6.2.5.3 Reference Oxygen parameter.............................................................................................

6.2.5.4 Boiler Parameter................................................................................................................

6.2.5.5 Content of NO in NOx........................................................................................................

6.3

Displaying the measurement results...............................................................................................

6.3.1 Current Values...........................................................................................................................

Averaged Values.................................................................................................................

6.3.2

6.3.3 The Averaging Process..............................................................................................................

6.4

Pressure/Draft Measurements........................................................................................................

6.5

Soot (smoke) Contents Measurement..............................................................................................

6.6

Graphic...........................................................................................................................................

40PLUS_E.DOC/06.97

CONTENTS

Table of Contents

Summary of Contents for Madur Sensonic 4000

Page 1: Table Of Contents
Sensonic 4000 CONTENTS CONTENTS CONTENTS............................INTRODUCTION........................... USE OF THIS OPERATING MANUAL.................... SYMBOLS USED..........................MAINTENANCE............................ Gas sensors............................Gas system............................Battery.............................. Service intervals..........................Errors during operation........................Switching off after use........................GENERAL INFORMATION........................CONSTRUCTION..........................Elements of gas circuit........................5.1.1 Gas probe with in-line filter......................
Page 2 CONTENTS Sensonic 4000 Flow measurement.......................... Options............................6.8.1 Device Info..........................6.8.2 Sensors............................6.8.2.1 Auto-Calibration O 2 ......................6.8.2.2 Analogue Inputs......................... 6.8.2.2.1 Gas temperature sensor - TH GAS................30 6.8.2.2.2 Ambient temperature sensor - PT AMB..............30 6.8.2.2.3 External thermocouple- - T1 EXT and T2 EXT............30 6.8.2.2.4 External resistance thermometer - T3 EXT and T4 EXT..........30...
Page 3 Regular maintenance will help to keep your analyser ready for use at all times. USE OF THIS OPERATING MANUAL Keep this manual with the analyser Sensonic 4000, and take it with you when carrying out measurements. Here is a short description of the sections of this manual.
Page 4 The Sensonic 4000 will not normally allow the instrument to be switched off if there are still traces of flue gas in the system. The analyser will continue to operate until the signals from the gas cells are nearly zero.
Page 5 Sensonic 4000 MAINTENANCE The [OFF] key must be pressed twice to switch the instrument off completely. Pressing the key once will put the analyser in the standby mode and the instrument will remain in this mode until it is activated again by pressing "C"...
Page 6: General Information
A further 10 fuels can be programmed by the operator to cover all eventualities. The RS232C interface fitted to the Sensonic 4000 allows all stored data to be read for later treatment or the instrument can be used on-line with the computer.
Page 7: Construction
The probe pipe is attached to the probe holder with a threaded connector. The gas tubing in the Sensonic 4000 is protected from the dust and moisture present in the flue gases by a filter (4). The filter elements (3) should be changed when dirty to ensure a free flow of gas. The condensate should be removed from the condensate traps when necessary.
Page 8: Measurement System
(20.95%) is determined. The toxic gases are also measured using electrochemical cells Table 1 presents all the gas sensors available. Any of them can be used in Sensonic 4000 system. To guarantee long-lasting, trouble-free function of electrochemical sensors the following points are important: ### the stated maximum measuring range of the sensor should not be exceeded.
Page 9: Differential Pressure Sensor
5.2.5 Differential pressure sensor The Sensonic 4000 is fitted with a precise semiconductor differential pressure sensor. Stubs marked +/- PRESSURE situated on the left side of the front panel are used to measure pressure. Negative pressure in flue gas channel (chimney draught) can be measured with the one stub only; differential pressure measurement is possible using both stubs.
Page 10 CONSTRUCTION Sensonic 4000 The analogue inputs are connected to the sockets U/I1, TEMP1 on the front of the analyser. Table 4 shows the use of the pins in the sockets (seen from the socket side). Picture 2 Socket for analogue inputs...
Page 11: Data Input/Output Systems
5.3.3 Printer The Sensonic 4000 is fitted with an EPSON dot matrix printer capable of printing the data as graphic or in the form of tables. All the screens seen on the analyser may be printed.
Page 12: Interface Rs 232C
5.3.4 Interface RS 232C The Sensonic 4000 is fitted with a serial RS232C interface. The socket is mounted on the front of the instrument and marked RS232C. The interface allows the Sensonic 4000 to communicate with a PC and the software WINFGA is available for carrying out extensive analysis of the stored results.
Page 13 Sensonic 4000 CONSTRUCTION ### Orange - analyser switched on and mains supply present. The battery is charging. The maintenance-free 12 V battery used has a capacity of 2 Ah. A fully charged battery will power the instrument for about six hours.
Page 14: Operation
OPERATION Sensonic 4000 OPERATION USE OF THE KEYBOARD 6.1.1 Description of the keys - Switches to the STORE menu STORE Switches to the first results screen. From the current results, the use of this key DATA switches between MEASURE and HOLD.
Page 15: Entering Numbers
Sensonic 4000 OPERATION PARAMETER  Title line FUEL  Option line STORE Command line 11 % Data line FOOTER Switch line Here is an explanation of the movement between the various menu options:   - move the cursor vertically in the menu ...
Page 16: Basic Operating Instructions
OPERATION Sensonic 4000  - switches the keyboard into either digital or alphabetical mode. When in digital mode the cursor has a block form on the screen, in the alphabetical mode it has the shape of an underlining  ...
Page 17: Initial Calibration
Sensonic 4000 OPERATION The following screen is shown in the STANDBY mode. ** STANDBY ** m a d u r TIME: 1h 23min >OFF< - TURN OFF >C< - TURN ON By pressing [OFF] the instrument can be switched off completely. If [C] is pressed the instrument switches ON again.
Page 18: Fuel
OPERATION Sensonic 4000 * MENU * PARAMETER  PRESSURE  SOOT TEST  GRAPHIC  OPTIONS    - move the cursor to the PARAMETER option  - select the option. The following screen will appear:  PARAMETER SELECT FUEL ...
Page 19 Sensonic 4000 OPERATION ------------------------ - LIGHT OIL *- NATURAL GAS - TOWN GAS - COKE-OVEN GAS - LIQUID GAS - BIO-DIESEL - EXTRA LIGHT OIL - HEAVY OIL - COAL-TAR OIL - NATURAL GAS/FAN - TOWN GAS/FAN - PROPANE WITH FAN...
Page 20: Average Time
OPERATION Sensonic 4000 NAME - Name of the fuel CO2max - the maximum concentration of CO 2 (for complete combustion, O 2 =0 %) A1, B - factors for Siegert's formula (Sec. 7.7)  ALPHA - fuel specific parameter (Sec. 7.7) ...
Page 21: Boiler Parameter
Sensonic 4000 OPERATION - select with YES/NO whether or not the Boiler Parameters shall appear on the ENTER printout, respectively being stored in a Protocol  - if YES was selected, this key moves to the Boiler Parameter menu. The boiler parameters can be entered in the screen shown below..:...
Page 22: Current Values
OPERATION Sensonic 4000  CURRENT VALUES  VOL. Rel. [ppm] 3% O2 CURRENT VALUES  TEMP1 EXT. °C TEMP2 EXT. °C TEMP3 EXT. °C TEMP4 EXT. °C U/I1 EXT. 1.25 U/I2 EXT. 4.64 PRESSURE 7.12 SOOT - switches between AVERAGED VALUES and CURRENT VALUES ENTER - switches On/Off the HOLD function („freezing“...
Page 23: The Averaging Process
STANDBY mode Pressure/Draft Measurements It is possible to measure differential pressure with the Sensonic 4000 . To do so the stubs PRESSURE (-) and (+) on the front plate are used. The measurement is performed as follows:...
Page 24: Soot (Smoke) Contents Measurement
OPERATION Sensonic 4000  - leaves the option. The displayed value will be stored until a new one is stored or either a printout of the measured values or of a protocol is performed. Soot (smoke) Contents Measurement To perform a soot test it is essential to prevent the flue gas from condensing on the filter. Therefore it is necessary to use a heated probe holder.
Page 25: Graphic
Sensonic 4000 OPERATION After the soot test the filter is compared with a scale, and the evaluated soot number is entered.??????????? SOOT TEST  SOOT NUMBER: 5 ENTER THE SOOT NUMBER - enter the detected soot number - confirm the soot number...
Page 26 OPERATION Sensonic 4000 Tamb [°C] 0. Tamb [°C] NORMAL AUTO - switches ON/OFF the inserted MENU-on Graphic screen MENU The individual lines of the menu have the following meanings: ### Number (0..9) and name of the measured value [ppm] NORMAL...
Page 27 Sensonic 4000 OPERATION There are two ways of changing the currently displayed variable. By selecting the number on the keyboard corresponding to the number of the variable (0..9), or by moving the selection bar to the first line of graphic menu and pressing the [ENTER] key until the desired variable appears.
Page 28 OPERATION Sensonic 4000 Flow measurement The screen FLOW MEASUREMENT is reached from the main menu as follows:   - move the cursor to FLOW MEASUREMENT option  - select the option, the following screen appears:  FLOW MEASUREMENT 0 m/s C - ZEROING CORR.
Page 29 Sensonic 4000 OPERATION DEVICE INFO  SERIAL NO.: 20123014 SERVICE...: 18.01.94 OPER. TIME: 670 h SERVICE IN: 130 h GAS FLOW 90 l/h BATTERY...: 12.65 V BAT.CAP. 75 % FGA LICENCE: The DEVICE INFO screen shows the serial no. of the instrument, the date of the last service, the operating time, the time until the next service, the speed of the sucked flue gas , the battery charge, the battery capacity and whether or not the communication with the WINFGA software is locked.
Page 30 OPERATION Sensonic 4000  CALIBRATION O2 CALIBRATES THE O2 SENSOR AT 20,95% O2 = 20,25% - CONFIRM ENTER - confirms the calibration ENTER 6.8.2.2 Analogue Inputs Get from the screen SENSORS to the option ANALOGUE INPUTS as follows:  ...
Page 31 Sensonic 4000 OPERATION 6.8.2.3 Sensor calibration Besides O every electrochemical sensor needs to be calibrated with calibration gas. To calibrate the sensors they are fed one by one with calibration gas of a known concentration. After a few minutes the sensor supplies a stabilised signal which can be stored as calibration value.
Page 32 OPERATION Sensonic 4000  CALIBRATION: Sensor Signal Stored 1206 1208 GAS [ppm]: * STORE * - in the GAS [ppm] line, starts editing of the standard gas concentration ENTER 0 to - enter the concentration of the standard gas [ppm]in the line GAS [ppm] - in the GAS [ppm] line.
Page 33 Sensonic 4000 OPERATION CONTRAST  50 %   - CHANGE ENTER - STORE 6.8.3.3 Date/Time This option allows to be adjusted the internal clock.   - move the cursor to TIME/DATE  - select option  TIME/DATE 12:34 TIME : 17.34.54...
Page 34 OPERATION Sensonic 4000  PRINTER SETTINGS AUTOM. PRINTOUT: NO NO. OF COPIES ADDRESS NO. ENTER ADDRESS  - Address - 4 - lines free editable AUTOMATIC PRINTOUT - switches between YES/NO. If the option is activated, automatic printouts will be...
Page 35 Sensonic 4000 OPERATION ITALIANO   - move the cursor to the selected language - confirms the selection ENTER 6.8.3.6 Acoustic Alarm - select YES/NO whether or not an acoustic alarm warns if an error occurs. ENTER 6.8.3.7 Soot Test...
Page 36 OPERATION Sensonic 4000  MEASURED VALUES CO I ..CO II (H2) PRESSURE TH GAS PT AMB. T1 EXT T2 EXT T3 EXT T4 EXT BATTERY U/I1 EXT U/I2 EXT 6.8.4.2 CONTROL LIST The option CONTROL LIST displays a similar list to the one above. The list shows which subassembly functions correctly (OK), or which is defective (ERROR).
Page 37 Sensonic 4000 OPERATION - selects the menu STORE STORE STORE REPORTS  BANKS  REPORTS ERASING  BANKS ERASING  Store free used REPORTS. BANKS BLOCKS Explanation of the Table: Store -type of storage free - availability of memory (number of free Reports, Banks or Blocks) used -occupied memory (number of free Reports, Banks or.
Page 38 OPERATION Sensonic 4000   - move the cursor to STORE REPORT NO. XX  - if all 30 Reports are occupied, -- is displayed instead of a number and it is not possible to store the Report. At least one Report has to be erased before a new one can be stored.
Page 39 Sensonic 4000 OPERATION REPORT NO.: 12  11:23.52 16.01.94 -------------------- 4 - lines free editable -------------------- FUEL O2R..: AVERAGE TIME: 10 min -------------------- POWER 40.0 kW CONSUM.: 1.5m3/h TEMP. 270 °C -------------------- Temp Amb: 21 °C Temp Gas: 327 °C O2 ..:...
Page 40 OPERATION Sensonic 4000 6.9.1.3 Erasing Reports All protocols can be erased in that option.   - move the cursor to ERASING REPORTS  - select option, the following warning appears  ATTENTION ! ALL REPORTS WILL BE ERASED - YES ENTER ...
Page 41 Sensonic 4000 OPERATION Set or check the averaging time.  (6.2.5.2) - start the storing, the word ACTIVE appears ENTER - the measured/calculated values are shown, storage is active DATA Stopping the continuous storing of results - call the STORE menu STORE ...
Page 42 The inclusion of analogue inputs as shown below and the possibility of storing these results enables the Sensonic 4000 to operate as a data-logger as well. The analyser is fitted with the following inputs: two currents or voltages (V / mA) ...
Page 43 Sensonic 4000 OPERATION m a d u r Sensonic 4000 19.12.93 13:23.41 ------------------------ FLUE: NATURAL GAS AVERAGE TIME: 30 min ------------------------ POWER 42.0 kW CONSUMPTION.: 8.4 l/h TEMP..: 230 °C ------------------------ 21 o C 168 o C 8.2% 7.60 %...
Page 44 0 95 If the optional sensor of the Sensonic 4000 analyser is the NO 2 sensor there is no need to calculate the amount of NO 2 . Then the NO x concentration is calculated by the analyser as a simple sum of measured NO and NO 2 concentrations.
Page 45 (where = 1, so O 2 = 0%). Mass concentrations of gas components Sensonic 4000 also makes calculations of mass concentration expressed in [mg/m3] from the concentration expressed in [ppm]. Mass concentration of gas elements depends on the gas pressure and temperature. To make comparison of results possible, the idea of standard conditions was introduced, that is standard temperature and pressure values at which the mass concentration of the elements is calculated.
Page 46 The parameter O 2ref - reference oxygen is a standard value. Standards recommend different values of this parameter for various types of fuel. In the system SENSONIC 4000 the value of reference oxygen can be accepted automatically in the process of fuel selection (the so-called a u t o m a t i c reference oxygen choice) or entered by the operator from the keyboard (the so-called m a n u a l selection of reference oxygen).
Page 47 Sensonic 4000 BASIC PRINCIPLES OF CALCULATING RESULTS                   where: - chimney loss - the percentage of heat produced in combustion process, which is convected with the combustion gases.
Page 48 BASIC PRINCIPLES OF CALCULATING RESULTS Sensonic 4000 The last combustion parameter calculated by Sensonic 4000 is the excess air factor . This factor expresses how many times the amount of air supplied to the boiler is larger than the minimum amount which is necessary to burn the fuel completely.
Page 49 Sensonic 4000.
Page 50 BLOCK DIAGRAM Sensonic 4000 BLOCK DIAGRAM GAS PROBE FILTER Pt 500 + PRESSURE - RS 232 C TEMP1, TEMP2 PROBE GAS CHAMBER GAS PUMP PRESSURE O2 CO NO SENSOR THERMISTOR NTC U1, U2, I1, I2 TH1, TH2, Pt1, Pt2 CONVERTER...
Page 51 Sensonic 4000 Błąd: Nie znaleziono źródła odwołania...
Page 52 MENU STRUCTURE Sensonic 4000 MENU STRUCTURE Structure of the main menu P aram et er F uel C h oos e fue l V iew /de fine A verag e t im e O 2R N O in N O x...
Page 53 Sensonic 4000 MENU STRUCTURE Structure of the menu STORE S TORE Reports S tore Report No. List of Reports V iew Report E dit Header E dit D ata B anks A ctivate/Lock List of B anks V iew List...

Madur Sensonic 4000 Manual

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