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Novatech 1635 User Manual

Water vapour analyser
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Water Vapour Analyser
Model 1635
August 2009

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Summary of Contents for Novatech 1635

  • Page 1 Water Vapour Analyser Model 1635 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 then the Model 1635 analyser with its heated probe may be unsuitable for your application.

  • Page 5: Description & Specifications

        1.15 DRYER OR OVEN TEMPERATURE (AUX) THERMOCOUPLE..........12     1.16 MODES WITH SWITCHING CAL 2 SOLENOID................ 12     1.17 WATCHDOG TIMER ........................12     1.18 BACK-UP BATTERY ........................12 August 2009 1635 Water Vapour Analyser...

  • Page 6: Description

    2. Indirectly Heated Dryers and Ovens, 2 Zones If the dryer or oven has two zones that you would like to measure the humidity level in, a 1635 analyser can be configured to read both zones and independently display and transmit the for each zone on independent channels.
  • Page 7 Most industrial processes operate at high temperatures resulting in low RH levels. For this reason it is normally best to use a reading of % Water Vapour or g/kg of moisture or Dew Point. A dryer or oven temperature thermocouple is only necessary if Relative Humidity percent is to be displayed or transmitted. August 2009 1635 Water Vapour Analyser...
  • Page 8 7.00 6.00 5.00 4.00 3.00 Accuracy Directly Fired 2.00 Repeatability Directly Fired Accuracy Indirectly Heated 1.00 Repeatability Indirectly Heated 0.00 1000 WATER CONTENT (g/Kg) Accuracy & Repeatability of 1635 Water Vapour % Analyer Readings August 2009 1635 Water Vapour Analyser...

  • Page 9: Specifications

    Maximum Head Temperature: 150°C with screw terminals / 100°C with weatherproof connector Reference Gas Connection: 1/8" NPTF. Probe Cable: Supplied with weatherproof connector to specified length, maximum 100 metres Probe Life: Typically 2 to 3 years. August 2009 1635 Water Vapour Analyser...
  • Page 10 Percent Water vapour Measurement in Indirectly Heated Dryer or Oven RGS01 1635 Reference Humidity Gas Sensor Analyser 1231 Vent Oxygen Probe Return Duct Burner Hood Combustion Air Percent Water vapour Measurement in Directly Heated Dryer or Oven (Paper Machine Hood Example) August 2009 1635 Water Vapour Analyser...

  • Page 11: The Zirconia Sensor

    The 1635 uses both these readings to calculate the moisture content in the oven or dryer. The 1635 can then use the moisture content to calculate the dew point, g/Kg and relative humidity.

  • Page 12: The Oxygen Probe

    APPLICATIONS WHERE THE SENSING POINT IS NOT AT ATMOSPHERIC PRESSURE To apply the 1635 analyser to processes that have pressure at the point of measurement significantly above or below atmospheric pressure, then compensation must be applied. Refer to set-up step 41 & 42 in section 4.5.

  • Page 13: Auto Calibration Checking - Probes

    Power Stations, Oil Refineries and similar large fuel users. Novatech probes and analysers provide a ready method of connecting on-line calibration check gases. They provide on- line automatic checking of probe and analyser calibration, as well as a probe purge facility.

  • Page 14: Rs 485 Network (Modbus™) And Rs 232C Port

    The reset function will continue repeatedly after the alarm. If a successful reset is achieved, the alarm will be cancelled and the analyser will continue to run normally. 1.18 BACK-UP BATTERY The analyser’s RAM and real-time clock are backed up by a lithium battery in the event of power failure. August 2009 1635 Water Vapour Analyser...

  • Page 15: Installing & Commissioning

    COMMISSIONING – RUN MODE ....................23     2.20 BURNER BYPASS SWITCH ......................24     2.21 CHECKING THE ALARMS ......................24     2.22 PROBE OR SENSOR CALIBRATION ..................24     2.23 CALIBRATION GAS CHECK ...................... 24 August 2009 1635 Water Vapour Analyser...

  • Page 16: Mounting The Analyser

    Surface mount the analyser case on a flat surface or bracket, using the four mounting brackets provided. 11" 280mm Gland Plate 40mm 200mm 1.6" 8" REAR VIEW REAR VIEW Vertical Mounting Brackets Horizontal Mounting Brackets 12.8" 9.8" 325mm 250mm Case Mounting Dimensions August 2009 1635 Water Vapour Analyser...

  • Page 17: Installing The Oxygen Probe

    PUMP WATER TRAP 1/2" #20 SAMPLING TUBE SAMPLE IN 1231 PROBE FLANGE 1234 OXYGEN SENSOR 1/4"COLLECTOR TUBE NOVATECH CONTROLS EXHAUST SAMPLING TUBE POWER SUPPLY GLAND SIGNAL WIRE GLAND Installation of the reference gas sensor August 2009 1635 Water Vapour Analyser...

  • Page 18: Installing The Dryer Or Oven Thermocouple

    SHIELD CONNECTIONS All external wiring to the 1635 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 19: Electrical Connections

    50 Mains A RGS-01 White 51 Heater #1 White 52 Heater #1 White 53 Heater #2 White 54 Heater #2 SENSOR #1 Connection Diagram for a 1635 Analyser, a 1231 Heated Probe and on optional RGS-01 August 2009 1635 Water Vapour Analyser...

  • Page 20: Heater Interlock Relays

    Gr een Ot he Ter m i nal Shi el d (By I nst al l er ) M ai n Ear t h Ear t Connection of Probe Cable for 1231 Model Heated Probes August 2009 1635 Water Vapour Analyser...

  • Page 21: Connecting The Reference Gas Sensor (Rgs-01) Cable

    The RGS-01 also requires a mains (240 or 115 VAC) power supply, a pair a mains voltage wires from the 1635 analyser to activate the RGS-01 pump and a type ‘K’ thermocouple compensation lead. Connections for a Reference Gas Sensor (RGS) to a 1635 Analyser 2.10 CONNECTING THE DRYER OR OVEN (AUX) TEMPERATURE...

  • Page 22: Connecting The Alarms

    Alarm 2 to 4 Select any one or all of the following for each relay. Refer Section 4.5.39 to 41 Sensor under temperature Calibration check in progress Alarm horn function (Alarm Relay 4 only) August 2009 1635 Water Vapour Analyser...

  • Page 23: Connecting The Automatic Calibration Check System

    For the oxygen probe, 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 1635 Water Vapour Analyser...

  • Page 24: Connecting 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 1.14 and Appendix 3. Network Connections August 2009 1635 Water Vapour Analyser...

  • Page 25: Connecting The Printer

    The upper line of the display will now read ‘% Water Vapour’. If the probe or sensor temperature is not above 650 °C, a “Probe Low Temperature” message will be flashed on the lower line. The probe or sensor temperature can be checked on the lower line of the display. August 2009 1635 Water Vapour Analyser...

  • Page 26: Burner Bypass Switch

    It is better to choose a gas value which provides a reasonable output from the sensor and which is near to the process oxygen level. A cylinder with 8% oxygen in nitrogen is a commonly used calibration gas. The maximum pressure on the calibration check gas cylinder regulators is 100 kPa (15 psi). August 2009 1635 Water Vapour Analyser...

  • Page 27: Operator Functions

    SUMMARY OF ALARMS ......................28     3.3.2 SUMMARY OF ALARMS - SELECTABLE ALARMS ............... 29     3.3.3 ALARM RELAYS .......................... 29     POWER LAMP ..........................29     BURNER BYPASS SWITCH ......................29 August 2009 1635 Water Vapour Analyser...

  • Page 28: Display Button

    15. Dryer Absolute Humidity 2 Kg/Kg* / Mass Fraction 2 g/Kg* / Reference Gas Temperature 16. Run hours * These options become available when the analyser is set to 2 zones, see section 1.1 August 2009 1635 Water Vapour Analyser...
  • Page 29 17. “Probe Temp Low”, when the probe is below 800°C 18. “Gas 1 ON” for Calibration check Gas 19. “Purging Probe” 20. “Probe Thermocouple Wrong Polarity” 21. “Aux Thermocouple Wrong Polarity” Items 17, 18 and 19 will only display as they are occurring. August 2009 1635 Water Vapour Analyser...

  • Page 30: Alarm Button

    The digital to analog and voltage isolator circuit has been found to fall outside the normal calibration specifications. This check is only performed when the ‘AUTO CAL’ button is pressed. Refer to Section 2.21. August 2009 1635 Water Vapour Analyser...

  • Page 31: Summary Of Alarms - Selectable Alarms

    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 bridged together. August 2009 1635 Water Vapour Analyser...
  • Page 32 August 2009 1635 Water Vapour Analyser...

  • Page 33: Setting Up The Analyser

    SET-UP MODE FUNCTIONS ....................... 32     SET-UP & RUN MODES ....................... 33     FUNCTION SELECT ........................33     ENTER OPTION OR VALUE ....................... 33     SET-UP FUNCTION DETAILS ..................... 34 August 2009 1635 Water Vapour Analyser...

  • Page 34: Set-Up Mode Functions

    49. Alarm relay number 3 function select 50. Alarm relay number 4 function select 51. Data Logger Data to Print 52. Data Logger Print Period 53. Data Logger Printer Baud Rate 54. MODBUS™ Address 55. Damping Factor August 2009 1635 Water Vapour Analyser...

  • Page 35: Set-Up & Run Modes

    Once the correct option or value is displayed it can be entered into the analyser’s memory by pressing the ‘ENTER’ button. When a value has been entered an asterisk will appear at the R.H.S. of the lower line. August 2009 1635 Water Vapour Analyser...

  • Page 36: Set-Up Function Details

    Select the current minutes for the real time clock. 7. Reference Voltage # 1 (~27.5mV) Options Set the value of the reference voltage as read on a 3 1/2 digit multimeter (See SET-UP 10 for further details). 27.55 mV August 2009 1635 Water Vapour Analyser...
  • Page 37 The calibration constants are retained in battery backed memory unless a ‘COLD START’ is performed. Refer to Section 5.1 in the 1635 manual. Connect a 3 1/2 digit multimeter negative lead to the test point marked ‘C’ to the right of the PCB on the inside of the door (labelled ‘REF VOLTS’).
  • Page 38 This menu item only appears if ‘Set 4mA Trim’ is selected in Set-up 16. Range 0 to 25mA, Default is 4.00mA For full details on the calibration of the 4-20mA output channels, see section 5.3. August 2009 1635 Water Vapour Analyser...
  • Page 39 It is recommended that probes and sensors be refurbished every two years 22. Enter Service Month Enter the current ‘MONTH’. 23. Enter Service Day End the current ‘DAY’ of the month. Altering these values will reset the ‘RUN TIME’. August 2009 1635 Water Vapour Analyser...
  • Page 40 Mode 6 must also configure the operation of a solenoid on terminals 45&46 (cal 2 sol) described in se-up 27. Mode 7 requires an external input 4-20mA scaled 0-25% on the AUX INPUT, CN16. Mode 8 requires an external input 4-20mA scaled 0-400°C on the AUX INPUT, CN16. August 2009 1635 Water Vapour Analyser...
  • Page 41 Range 0.1 – 21.0% oxygen in 0.1% steps. Default is 2.0%. 29. Sensor 1 Type Options Model No. Enter the probe or sensor model number in use 1. 1231/1234 Heated Probe at 720°C 1232 Unheated Probe August 2009 1635 Water Vapour Analyser...
  • Page 42 2 Kg/Kg Mass Fraction g/Kg 0 - 900 100 - 1000 100 g/Kg Relative Humidity % 0 - 90 10 - 100 Oxygen % 0 - 99 1 - 100 Output Scaling Channel 1 August 2009 1635 Water Vapour Analyser...
  • Page 43 39. Centigrade / Fahrehheit Selection Select whether displays and outputs are to be in degrees Celsius or degrees Fahrenheit Options 1. Celsius (Centigrade) 2. Fahrenheit Only available in 2 zone mode, see section 1.1 August 2009 1635 Water Vapour Analyser...
  • Page 44 If there is a difference between the gravimetric test results and the display of water vapour on the 1635 analyser, this factor can be used to fine-tune the reading on the analyser display.
  • Page 45 50. Printer Baud Rate Select the correct BAUD rate for data to be transmitted out of the port to the printer. Options 1200 2400 4800 9600 Only available in 2 zone mode, see section 1.1 August 2009 1635 Water Vapour Analyser...
  • Page 46 A value of one entered here will mean that every new reading from the probe or sensor will be sent to the display unaltered. The damping factor is used for humidity measurements in both zones is “Indirect, 2 Zone” is selected in set up step 18. Range 1 to 20 August 2009 1635 Water Vapour Analyser...

  • Page 47: Maintenance

    TEST EQUIPMENT REQUIRED ....................48     TESTING A PROBE OR SENSOR ....................49     5.10 PROBE OR SENSOR THERMOCOUPLE ..................49     5.11 HEATER FAILURE ........................49     5.12 FILTER BLOCKAGE ........................49 August 2009 1635 Water Vapour Analyser...

  • Page 48: Cold Start

    See Section 5.3. 16 Way Ribbon Cable 40 Way Reference voltage Door Shield Ribbon Cable test points. Reference voltage 1630-1 PCB common point. Location of Calibration Test Points August 2009 1635 Water Vapour Analyser...

  • Page 49: D/A (4-20Ma Output Channels) Calibration

    It is recommended that service be performed on a change-over circuit board basis. A fast turn-around or replacement service is available from Novatech or accredited service agents. Other service aids, including a test EPROM firmware package and probe or sensor input simulator is also available.

  • Page 50: Installing A New Probe Or Sensor

    HEATED PROBES OR SENSORS If a 1635 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 volts will regulate the probe or sensor temperature to 720°C approximately.

  • Page 51: Testing A Probe Or Sensor

    For oxygen probes with filters in installations with entrained solids in the gas, it is sometimes necessary to replace the filter. Filters are normally cleared with back purging. However particles can ultimately completely block a filter necessitating filter replacement. A new probe filter can be fitted. August 2009 1635 Water Vapour Analyser...

  • Page 52: 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 1635 Water Vapour Analyser...
  • Page 53 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 1635 Water Vapour Analyser...

  • Page 54: Appendix 2 Circuit Schematics

    APPENDIX 2 CIRCUIT SCHEMATICS August 2009 1635 Water Vapour Analyser...
  • Page 55 Ser-[1..5] SVcc Svee August 2009 1635 Water Vapour Analyser...
  • Page 56 P5-[0..7] P4-7 P4-1 P4-0 L4-[3..6] August 2009 1635 Water Vapour Analyser er...
  • Page 57 August 2009 1635 Water Vapour Analyser...
  • Page 58 August 2009 1635 Water Vapour Analyser er...
  • Page 59 DAC-PS-[0..5] August 2009 1635 Water Vapour Analyser...
  • Page 60 P5-7 August 2009 1635 Water Vapour Analyser er...
  • Page 61 L2-[0..7] L6-[0..7] August 2009 1635 Water Vapour Analyser...
  • Page 62 August 2009 1635 Water Vapour Analyser er...

  • Page 63: Appendix 3 Modbus™ Register Map And Application Notes

    WriteHolding Register Function 6 ( for allowable addresses only ) Introduction. The 1635 Analyser implements a subset of 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 64 Alarm Array: There are 30 alarms and states in the 1635 analyser which can be individually read from the alarm array. Each alarm uses a single byte, so in reading the alarm array each 16-bit holding register contains two alarm states.
  • Page 65 Model Number: 1630 Series Transmitter 1231 Oxygen Probe 1234 Oxygen Sensor I hereby declare that the equipment specified herein conforms to the above directive(s) and standards(s). Full Name: Fraser Chapman Position: R & D Manager August 2009 1635 Water Vapour Analyser...
  • Page 66 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 67 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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