Page 1 P2000 Analyser Unit Operating Manual Manual Part Revision Reason For Scope of Language status amendment amendment 18-0004 Change to New Version UK English Standard Issue 8 PROTEA page 1...
Page 2 Protea reserves the right to make changes without notice both to this publication and products which it describes. The contents of this publication in the form...
Page 3 Other applicable documents This manual contains all the necessary steps for the installation and operation of the P2000 analyser. This manual should be used in conjunction with other manuals that describe the Control Unit. Two types of analyser controller are available for the P2000. Information for the use of these controllers can be found in the following manuals.
Page 4 Protea P2000 Operating Manual Preamble Explanation of the symbols and pictograms utilised The symbols and pictograms utilised below indicate safety-relevant and important information which must be adhered to when performing an operation and to ensure safe and optimum operation. In the documentation...
Page 5 Protea P2000 Operating Manual Preamble HOT SURFACE HAZARD BIOHAZARD ELECTRO STATIC DISCHARGE (ESD) SENSITIVE HIGH INTENSITY ULTRAVIOLET LIGHT DO NOT OIL READ AND OBSERVE INSTRUCTIONS IN MANUAL GENERAL INFORMATION WEAR PERSONAL PROTECTIVE EQUIPMENT SUITABLE TO THE WORK TASK Issue 8...
Page 6 Reasonably foreseeable inappropriate use Reasonably foreseeable inappropriate use is deemed to have occurred if the P2000 or any accessories are used in any other way than that described in the “intended use”. Reasonably foreseeably inappropriate use includes the use of the product in a manner not intended by the manufacturer or distributor of the product but which may result from foreseeable human behaviour.
Page 7 P2000, to instruct, to recognise possible dangerous situations independently and to execute measures to avoid danger.
Page 8 Protea P2000 Operating Manual Preamble Safety Notes and Warning Messages General Instructions Safety notes indicate the potential hazard and, if appropriate the cause of the hazard, the probable consequence of ignoring the safety note and how the hazard can be avoided.
Page 9 Protea or your Protea authorised distributor for assistance. Always ensure that you have a valid permit to work on the pipework or ducting to which the P2000 analyser unit is to be fitted. Always ensure that you comply with local safety regulations and procedures.
Page 10 Contact Protea or your Protea authorised distributor for assistance. Always ensure that you have a valid permit to work on the pipework or ducting to which the P2000 analyser unit is to be fitted. Always ensure that you comply with local safety regulations and procedures.
Page 11 Customer specific P2000 analysers may contain long wavelength Zinc Selenide lenses. If your P2000 has such optics, this will be stated in the section of this manual entitled Order-Specific Information. DO NOT touch the optical component without using appropriate personal protective equipment (PPE).
Page 12 Protea P2000 Operating Manual Preamble WARNING Inhalation of asbestos fibre presents a Biohazard Serious injury could result from the inhalation of asbestos fibres. Inhalation of asbestos can lead to a condition called asbestosis that leads to an increased susceptibility to cancer.
Page 13 Protea P2000 Operating Manual Preamble WARNING Touching Hot Surface could result in injury Serious injury could result from touching a hot surface Consult your site safety regulations or seek advice from supervisory personnel Be aware of the hot surfaces in the working area...
Page 14 Protea P2000 Operating Manual Preamble ATTENTION Damage to product may result if touched Device or component is sensitive to Electro Static Discharge (ESD) Carefully follow the step by step instructions to prevent damage to the component or product. Care must be given to maintain the highest...
Page 15: Table Of Contents
Contents 1 Introduction About this manual About the P2000 series P2000 - an overview Documentation conventions Analyser Identification Further information 2 Installation Introduction Unpacking the system components Pre-installation information Location Preparing the process gas duct – Re-fitting insulation Drilling the Control Unit Gland Plates...
Page 16 Spares list 7 Disposal Instructions Introduction Disposal of Stored Data 8 Transport & Storage Instructions 9 Order-specific information Appendix A - The P2000 with ATEX/IECEx approvals Introduction Quality assurance during production Allowed environments Maintenance additional requirements Special Conditions for Safe Use...
Page 17 Protea P2000 Operating Manual Contents Services Operation Action on calibration error Viewing the results Electrical connections Appendix D – Quality Standard for Instrument Air Supplied to Protea Analysers Introduction Appendix E – Air Preparation Panel Introduction Appendix F – Power Supply Unit Introduction...
Page 18 Protea P2000 Operating Manual Contents Fitting the In-Situ Steam Heater Appendix K – Steam Heated By Pass Introduction By-Pass description Fitting the Optional Steam Heated By-Pass Appendix L – P2000D (UV Diode) Introduction Maintenance of the P2000D Replacing the UV source...
Page 19: Introduction
1. Introduction 1 Introduction About this manual This manual provides information for use of the P2000 series of analyser units. Information for use is provided so that the product can be used safely, effectively, and efficiently. This information has been prepared in accordance with BS EN 82079-1:2020 Preparation of information for use (instructions for use) of products.
Page 20 Describes the Air Preparation Panel that Protea recommends for use with the P2000 Appendix F Describes the local power supply unit that can be used to supply 24V to the P2000 Appendix G Describes the In-situ Heater and how the in-situ heater should be installed...
Page 21: About The P2000 Series
P2000 - an overview Figure 1-1 shows a diagram of the P2000 system. The in-situ probe of the analyser is fitted into the process duct. The in-situ sample cell consists of sintered panels that allow the gas under study to permeate through the sample cell.
Page 22 Figure 1-1 P2000 Overview Diagram Figure 1-2 shows various interconnections between different parts of the P2000 system. Optional outputs from the P-PC control unit can be connected to external devices such as chart recorder, personal computer, alarm, web browser, printer, digital I/O, network, etc.
Page 23 Protea P2000 Operating Manual 1. Introduction Stack Control Unit P2000 Optional Inputs Outputs 115V / 230V Local 115V / 230V Calibration Gas Figure 1-2 P2000 system schematic Issue 8 PROTEA page 23...
Page 24 Screen displays Screen displays on the P2000 are presented in this manual as approximations. When values are shown on screens, it should be remembered that these appear by way of example only. It is highly unlikely that the values displayed on your screen will be the same as in this manual.
Page 25: Analyser Identification
All dimensions in this Operating Manual are in mm (millimetres) unless otherwise indicated. Analyser Identification Figure 1-3 Location of P2000 Identification label It is important to identify the analyser and ensure it is correctly located especially in multi analyser systems. The identification label is shown in figure 1-3.
Page 26: Further Information
P2000 system. If you require any further information regarding the system or its use, you should contact Protea Ltd., or your Protea distributor or agent as shown in the panel below:...
Page 27 Protea P2000 Operating Manual 1. Introduction Sales & Manufacturing Customer service and tools Protea Ltd Protea Ltd 2 Venture Park 2 Venture Park Stirling Way Stirling Way Peterborough Peterborough Cambridgeshire Cambridgeshire PE3 8YD PE3 8YD United Kingdom United Kingdom Tel:+ 44 (0)1733 215300 Tel:+ 44 (0)1733 215300 sales@protea.ltd.uk...
Page 28 Protea P2000 Operating Manual 1. Introduction Page intentionally left blank Issue 8 PROTEA page 28...
Page 29: Installation
Protea or your Protea authorised distributor for assistance. Always ensure that you have a valid permit to work on the pipework or ducting to which the P2000 analyser unit is to be fitted. Always ensure that you comply with local safety regulations and procedures.
Page 30 Protea P2000 Operating Manual 2. Installation WARNING Inhalation of asbestos fibre presents a Biohazard Serious injury could result from the inhalation of asbestos fibres. Inhalation of asbestos can lead to a condition called asbestosis that leads to an increased susceptibility to cancer.
Page 31 WARNING NOTICES ATTENTION DAMAGE TO EQUIPMENT Damage to the product may result if the P2000 analyser is inserted into the duct or stack without the instrument air purge being switched on. if electrical installation is not performed as per the installation instructions.
Page 32: Introduction
Retain the documentation pack for future reference Remove the polyurethane packing material The P2000 has a weight of 25 kg (43.3 lbs) without the GRP cover (35 kg (77.2 lbs) with the GRP cover) and should therefore be lifted out of the container by two people.
Page 33 Protea P2000 Operating Manual 2 Installation Location of items accompanying the P2000 Parts required for installation are packaged separately such as the key and wall mounting bracket for the P-HMI or P-PC Control unit. Gaskets for the analyser and in-situ heater flanges are packed...
Page 34 Protea P2000 Operating Manual 2. Installation Material Recyclability Recycling Information Cardboard The cardboard packaging can be recycled or retained for future use (e.g. for the returning of the product to Protea for future upgrade). Wooden The wooden pallet can re-used Pallet or recycled.
Page 35: Pre-Installation Information
(see Order Specific Information). The cable route from the Control Unit to the P2000 is not more than 1,000 metres (greater distances may be possible: please consult Protea).
Page 36: Location
Protea P2000 Operating Manual 2. Installation All the interconnecting cables specified in this installation procedure are available from Protea. In the section of this manual entitled Order-specific information, you will find drawings which may be useful during installation. The precise nature of these drawings will vary, the power source electrical voltage, the options supplied and the configuration.
Page 37: Preparing The Process Gas Duct
This flange may be manufactured from a 3” inch, 150 lb ANSI flange. This flange is available from Protea (Protea Part Number 3-0169). Figure 2-2 Drawing showing optimum flange installation The mating surface of the process duct flange must be of a quality that will allow a gas-tight joint to be made when a gasket is used between the flange and the Analyser Unit (or In-Situ Heater if fitted).
Page 38 Protea P2000 Operating Manual 2. Installation Figure 2-3 Flange Mounting (Protea Part 3-0169) The use of a flange and stub arrangement should be avoided unless absolutely necessary, since this could lead to acidic condensation forming. Figure 2-4 shows the preferred mounting arrangement for the flange.
Page 39 Protea P2000 Operating Manual 2 Installation M16 Studs Preferred Installation – With the flange welded directly to the stack, duct or process pipe. IMPORTANT - Weld should be gas tight with no leaks. Stack, duct or process pipe 50mm Acceptable – With an insulated...
Page 40: Re-Fitting Insulation
Y axis as shown in figure 2-5. This will ensure that the analyser will be at the correct orientation when the analyser is inserted into the stack or duct. Figure 2-5 Orientation of the Protea standard flange Re-fitting insulation Normally, the flange installation process requires the removal of a large section of insulation from the stack wall.
Page 41: Drilling The Control Unit Gland Plates
2 Installation Drilling the Control Unit Gland Plates The P2000 is supplied with either a P-HMI or P-PC type Control unit. The Control Unit is designed to be wall mounted in a control room, shelter or other designated location. A wall mounting bracket is supplied with the P-HMI and the P-PC.
Page 42 Protea P2000 Operating Manual 2. Installation Figure 2-6 P-HMI Control Unit Figure 2-7 P-PC (formerly ACWn) Control Unit Issue 8 PROTEA page 42...
Page 43: Preparing The Analyser Unit For Wiring
GRP cover (see Figure 2-9 below). NOTE - If the junction box on your analyser is different to that shown below refer to your original manual or contact Protea for further information on previous instrument versions. Issue 8...
Page 44 – See Tables 2-1 for diagrams of the different options and the appropriate wiring information. Options Arrangement of Units Option Analyser (AU) → Protea P-HMI Control Unit with Local Power Supply Unit (PSU) Option Analyser (AU) → Protea P-PC Control Unit (formerly ACWn) Software with Local Power...
Page 45 IMPORTANT – The power cable between the PSU and the analyser should be less than 5 metres. The communication interconnection cable from the Control Unit to the P2000 should be limited to no more than 1,000 metres. (Please consult with Protea if longer distances are required).
Page 46: Wiring Tables
Protea P2000 Operating Manual 2. Installation Wiring Tables Option 1 - Analyser → Protea P-HMI Control Unit with Power Supply Unit (PSU) Function AU Junction Box Protea Control Unit Cable Specification Data Return R- P2000(1) Tx- TS6 – 1 Cable Type 13...
Page 47 Protea P2000 Operating Manual 2 Installation Option 2 - Analyser → Protea P-PC (formerly ACWn) with Power Supply Unit (PSU) Protea P-PC Customer PC with AU Junction (formerly Comms Convertor Function Cable Specification ACWn) Software Refer to your comms Data Return R-...
Page 48 Protea P2000 Operating Manual 2. Installation Option 3 Analyser → Power Supply with through Comms terminals → Protea P-HMI Control Unit AU Junction Protea Power Supply Assembly Protea Control Cable with Comms Unit Specification Function Cable 1 Cable 1 (IN)
Page 49 Protea P2000 Operating Manual 2 Installation Option 4 Analyser → Protea Power Supply → Protea P-PC (formerly ACWn) Software Local Power Supply Protea P- Customer Cable Assembly with Comms PC with Specification AU Junction Function (formerly Comms ACWn) Converter Software...
Page 50 Protea P2000 Operating Manual 2. Installation Connecting additional Analysers Analyser 1 → Analyser 2 → Analyser 3 → Analyser 4 AU 1 AU 4 Junction Junction AU 2 Junction Box AU 3 Junction Box Function Data Return P2000(1) P2000(2) Tx-...
Page 51 Protea P2000 Operating Manual 2 Installation Analogue Inputs AU Junction Analogue Input Type Function AUX I/P3 + 0-5V or 0-20mA or 4-20mA (Non-isolated) AUX I/P4 + 0-5V or 0-20mA or 4-20mA (Non -isolated) Connecting In-Situ Heater → Analyser Cable Specification...
Page 52: Analyser Covers
IMPORTANT - All unused glands must be sealed before commissioning the analyser Analyser Covers Protea analysers are fitted with two basic types of Cooler / Heater however there are the following exceptions:  Analysers supplied with ATEX / IEC Certification ...
Page 53 NOTE - the analyser is supplied with a 300mm length of hose. If an extended hose is not to be fitted then the 300mm length of hose supplied by Protea should be fitted. The cover also incorporates as standard an Auto Verification Unit internally piped and wired.
Page 54 Verification Unit In-Situ Probe Analyser Junction Box Under Side of Vortex Cooled Electrically Heated P2000 AC/AVU-V-24V Analyser Cover Figure 2-12 Vortex Cooled Electrically Heated P2000 AC/AVU-V-24V The cover is fitted with an electrical heater and vortex cooler which enables the analyser to operate in ambient temperatures of -20 ºC to +65 ºC (-4ºF to 149ºF).
Page 55: Integral Auto Verification Unit
Protea P2000 Operating Manual 2 Installation Services required - A supply of high-pressure plant air at 6.8-8 bar (100 -110 psi) and 311 l/min (11scfm). (see Protea Standard ISO 8573-1:2010 2 4 2 in appendix D). Integral Auto Verification Unit...
Page 56 Protea P2000 Operating Manual 2. Installation The function of the Auto Verification Unit is described in the following. For information relating to the Specification of the Auto Verification Unit please see the Technical Specification chapter of this manual. Function of the AVU The integral Auto Verification Unit has two primary &...
Page 57 NOTE – In the case of a wall mounted regulator that is not supplied by Protea the regulator should have a 3µm filter and a capacity of 10 litres per minute with input pressure range of 6-10 bar and output pressure of 2 bar or less.
Page 58 Protea P2000 Operating Manual 2. Installation flexible PTFE tubing so that the analyser can be withdrawn from the stack or duct without the need to disconnect the air supply.  Source of electrical power 110/230V 50-60Hz suitably rated for the power requirements of all the components of the CEMs system –...
Page 59 Protea P2000 Operating Manual 2 Installation Connection of Zero and Test Gas to the Auto Verification Unit Function From Wall Mounted Regulator Zero / (Part No. 1-0094) Analyser AVU Purge Port 1 Supply Set to provide output of 2 Bar...
Page 60 Protea P2000 Operating Manual 2. Installation Figure 2-15 Location of Needle Valve on AVU Issue 8 PROTEA page 60...
Page 61 Protea P2000 Operating Manual 2 Installation Page intentionally left blank Issue 8 PROTEA page 61...
Page 62: Commissioning
Protea or your Protea authorised distributor for assistance. Always ensure that you have a valid permit to work on the pipework or ducting to which the P2000 analyser unit is to be fitted. Always ensure that you comply with local safety regulations and procedures.
Page 63 3 Commissioning ATTENTION DAMAGE TO EQUIPMENT Damage to the product may result if the P2000 analyser is inserted into the duct or stack without the instrument air purge being switched on. if electrical installation is not performed as per the installation instructions.
Page 64: Introduction
Protea P2000 Operating manual 3 Commissioning Introduction This section describes the order that should be followed to prepare the analyser for operation. Mounting of CEM system components ATTENTION When drilling fixing holes for mounting the cabinets or enclosures described below you must wear appropriate personal protective equipment.
Page 65 Protea P2000 Operating Manual 3 Commissioning 2. You must also fasten the Control Unit to the wall using the additional eyelets located at the base of the Control Unit (as shown in figure 3-2) Figure 3-2 Mounting of Control Unit (Eyelet Fixings) 3.
Page 66 Protea P2000 Operating manual 3 Commissioning Figure 3-3 Mounting of the Power Supply Unit 5. You should then secure the instrument air preparation panel to a wall or suitable structure using the four M5 fixing holes (as shown in figure 3-4).
Page 67: Connection Of Instrument Air Supply
6. You should next connect the inlet of the Air Preparation Panel to the air supply. The input air must be supplied from an oil free compressor (see Protea Instrument Air standard ISO 8573-1:2010 0 3 1 see Appendix D).
Page 68: Connections To The Ac Power Source
11. You should then connect the PSU to the isolated AC power supply (50-60Hz 110/230V AC 240W (480W for P2000 UV/LED analyser). Isolate the AC power source to the PSU before making your connections.
Page 69 Protea P2000 Operating Manual 3 Commissioning D. If filter wheel is not rotating and the above checks have been completed then please contact Protea or your Protea Distributor or Agent for further assistance. Figure 3-5 Checking the status of the filter wheel...
Page 70: Insertion And Wiring Of In-Situ Heater
Protea P2000 Operating manual 3 Commissioning Insertion and wiring of In-Situ Heater 14. If an In-Situ Heater is supplied then you must first fit the In- Situ Heater gasket on to the stack or duct flange. 15. You must then insert the In-Situ heater into the process stack or duct.
Page 71: Stack Process Conditions & Operational Readings
Protea P2000 Operating Manual 3 Commissioning Stack Process Conditions & Operational Readings NOTE - The analyser will take a period of time (typically 1 hour) to reach the process temperature or the sample temperature set point in the case of an analyser fitted with an in-situ heater.
Page 72 Protea P2000 Operating manual 3 Commissioning Figure 3-6 P2000 Analyser Test Screen (S-PC (formerly ACWn)) software 23. If after 1 hour the sample temperature has not reached the set point then the analyser should be left for a further hour.
Page 73 On the TEST SCREEN select the AUTOZERO menu and from the pull-down list select the AUTO-ZERO NOW option. 26. After the P2000 has completed the AUTOZERO the analyser should then be in the monitoring mode measuring the gas concentrations in the process.
Page 74 Protea P2000 Operating manual 3 Commissioning Page intentionally left blank Issue 8 PROTEA page 74...
Page 75: Operation
4. Operation 4 Operation Introduction The P2000 Analyser Unit must be operated as part of a system incorporating a Protea Control Unit. There are no user accessible controls or indicators on the P2000 as the whole system operates under the control of the Control Unit. Full operating instructions for...
Page 76 Protea P2000 Operating manual 4. Operation Page intentionally left blank Issue 8 PROTEA page 76...
Page 77: Technical Specification
Protea P2000 Operating Manual 5. Technical Specification 5 Technical Specification Introduction The method by which the P2000 utilises the theory of infra-red spectroscopy for gas measurement is provided in a technical note that is available from Protea upon request. P2000 Technical Specification...
Page 78 T6, which indicates a maximum surface temperature of 85ºC (185ºF), and is approved for the ambient temperature range -20ºC to 40ºC (4ºF to 104ºF). ATEX/IECEx - The P2000 also has a surface Operating temperature classification of T4, which indicates Temperature a maximum surface temperature of 135ºC...
Page 79 Protea P2000 Operating Manual 5 Technical Description Calcium fluoride (optical components), 316 stainless steel (probe) & graphite (gaskets). Materials in contact with Customer specific applications may include other process gas materials such as Inconel, Hastelloy and Zinc Selenide optical components 25 kg (46.3 lbs) without GRP cover...
Page 80 Protea P2000 Operating manual 5. Technical Specification P2000 Electrical and Air Service Requirements P2000 Voltage 24V 240W (provided by Power Supply Unit) Requirements P2000D UV/IR Voltage 24V 480W (provided by Power Supply Unit) Requirements Power Supply Unit Voltage 50-60Hz, 110/230V AC 240W (provided by...
Page 81 Protea P2000 Operating Manual 5 Technical Description Control Outputs (24V Switching) for Output 1 - Zero Gas (air purge) Output 2 - Cal Cas 1 Output 3 - Cal Gas 2, Output 4 - Special Purge, Eductor or Electrical Outputs...
Page 82: Auto Verification Unit Specification
Protea P2000 Operating manual 5. Technical Specification Auto Verification Unit specification Auto Verification Unit Specification Material Stainless steel, nitrile rubber (seals), techno- polymer aluminium (valve body) Dimensions Length 115mm x Width 50mm x Depth 30mm Weight 1.4 Kg (3lbs) Number of Inlet...
Page 83 Protea P2000 Operating Manual 5 Technical Description Page intentionally left blank Issue 8 PROTEA page 83...
Page 84: Inspection Schedules
Contact Protea or your Protea authorised distributor for assistance. Always ensure that you have a valid permit to work on the pipework or ducting to which the P2000 analyser unit is to be fitted. Always ensure that you comply with local safety regulations and procedures.
Page 85 Contact Protea or your Protea authorised distributor for assistance. Always ensure that you have a valid permit to work on the pipework or ducting to which the P2000 analyser unit is to be fitted. Always ensure that you comply with local safety regulations and procedures.
Page 86 6 Inspection Schedules ATTENTION DAMAGE TO EQUIPMENT Damage to the product may result if the P2000 analyser is inserted into the duct or stack without the instrument air purge being switched on. if electrical installation is not performed as per the installation instructions.
Page 87: Introduction
It is strongly recommended that if a P2000 system is purchased, a service contract is taken out. This will cover regular cleaning, calibration and routine preventative maintenance.
Page 88: Nature And Frequency Of Inspections
1. You should undertake a visual inspection of the exterior of the analyser for physical signs of damage. Protea recommends that you check cables for damage to the insulation and that you also check gas pipe connections to ensure that they are correctly sealed.
Page 89 Signal levels should be within +/- 20% of the original values Step 6 If signals are outside this range then you should contact Protea or your Protea Distributor or agent to seek further advice and assistance Issue 8 PROTEA page 89...
Page 90 Pressure Step 1 Record the sample pressure with process gas in the probe Step 2 Cross check the P2000 Pressure reading with the value from an independent pressure sensor monitoring the process. Step 3 Is the pressure value correct? Step 4 Turn the Manual Purge (see the Control Unit manual).
Page 91 Step 2 Record the process temperature with an independent temperature sensor. Step 3 Does the P2000 temperature reading equal the reading from an independent temperature sensor? Step 4 If an in-situ heater is fitted then check the Control Unit software configuration for the in-situ heater temperature set point.
Page 92 A “System Fault” alarm will also be triggered. The wheel speed value on the Test screen will be coloured RED. If a “System Fault” occurs you should contact Protea or your Protea Distributor or agent to order a replacement motor. Issue 8 PROTEA...
Page 93: Annual Schedule
Protea P2000 Operating Manual 6 Inspection Schedules 5. Regular calibration checks of the P2000 may be required by regulatory authorities. For Calibration (see Field calibration checks within this section) Annual Schedule The annual scheduled inspection of the analyser DOES NOT require removal of the analyser from the stack or duct.
Page 94: Obtaining Further Data In The Case Of A Fault
Protea P2000 Operating Manual 6 Inspection Schedules 6. Regular calibration checks of the P2000 may be required by regulatory authorities. For Calibration (see Field calibration checks within this section) Obtaining further data in the case of a fault Should a non-conformance be noted during the quarterly or annual...
Page 95: Cleaning
Contact Protea, or your Protea Distributor or agent, for a cleaning service. If you attempt to clean optical surfaces and cause damage, the warranty on the P2000 system may be voided or limited. Under no circumstances must any oil be applied to the sinter panels.
Page 96  A gas regulator with appropriate stem for connection to outlet of gas cylinder.  PTFE tubing to connect gas cylinder to AVU calibration gas port.  A Protea Field Calibrator is required if undertaking a water vapour concentration check. Gas Calibration For US EPA instruments see Appendix C) In order to carry out the Gas calibration check of the analyser the testing engineer must be at ENGINEER access level –.
Page 97 Protea P2000 Operating Manual 6 Inspection Schedules 3. Connect the outlet of the gas cylinder via the necessary fittings and regulator to the AVU CAL port. The CAL ports are located on the underside of the AU outer cover (Use Port 4 for CAL gas 1 or Port 5 for CAL gas 2)).
Page 98 Protea P2000 Operating Manual 6 Inspection Schedules 13. After selecting CALIBRATE COMPONENTS the Manual Calibration settings window will open (see figure 6-3). To calibrate the gas in question, select the gas from the drop- down text box, enter into the EXPECTED VALUE box the ACTUAL Gas cylinder concentration, and then click the ADJUST BUTTON.
Page 99: Fault-Finding And Repair Policy
Protea Distributor or agent. Protea will then provide targeted assistance to remedy the fault reported. Fault-finding processes and repairs to the P2000 system should only be undertaken by Protea’s own trained support staff, or by those of its Protea Distributors world-wide.
Page 100: Spares List
The figure in the right-hand column is the quantity of that part fitted to the analyser or the accessory described. If you wish to order a spare part, please contact Protea, or your Protea Distributor or agent. IMPORTANT -When ordering spare parts for the P2000, please state whether the P2000 analyser is used in an area with an explosive gas atmosphere (e.g.
Page 101 Protea P2000 Operating Manual 6 Inspection Schedules Protea Ltd. reserves the right to change the prices, specifications or manufacture of any component parts without notice. UK Sales & Manufacturing Customer service and tools Protea Ltd Protea Ltd 2 Venture Park...
Page 102 Protea P2000 Operating Manual 6 Inspection Schedules Page intentionally left blank. Issue 8 PROTEA page 102...
Page 103: Disposal Instructions
P2000 are safely disposed of in accordance with all local environmental statutes and regulations which are lawfully in force. If you are ever in any doubt about how to dispose of the P2000, you may return it to Protea in the United Kingdom, carriage-paid.
Page 104 Customer specific P2000 analysers may contain long wavelength Zinc Selenide lenses. If your P2000 has such optics, this will be stated in the section of this manual entitled Order-Specific Information. DO NOT touch the optical component without using appropriate personal protective equipment (PPE).
Page 105 Protea P2000 Operating Manual 7 Disposal Instructions Page intentionally left blank. Issue 8 PROTEA page 105...
Page 106: Transport & Storage Instructions
Protea P2000 Operating Manual 8. Transport & storage Instructions 8 Transport & Storage Instructions IMPORTANT - Please read the Safety Warnings below before performing any function set out in this section of the manual. DANGER Single person lift could cause injury...
Page 107 Protea P2000 Operating Manual 8. Transport and Storage Instructions DANGER Touching Hot Surface could result in injury Serious injury could result from touching a hot surface Consult your site safety regulations or seek advice from supervisory personnel Be aware of the hot surfaces in the working area...
Page 108 Protea 2000 Operating Manual 8. Transport and storage instructions Packaging for Transportation The P2000 analyser is packed inside a cardboard container. The analyser is protected by moulded polyurethane packing material that protects the analyser from impacts and vibration. Accessories such as the Control Unit and in-situ heater are normally packed in the same container as the analyser and similarly protected by moulded polyurethane packaging material.
Page 109 Protea P2000 Operating Manual 8. Transport and Storage Instructions Procedure for lifting and handling analyser ATTENTION Two persons are required to lift and carry the analyser. The persons tasked with lifting and carrying the analyser should lift by applying upward force at the opposite ends of the analyser. The analyser is supplied with a foam inlay as part of the packaging material.
Page 110 Protea 2000 Operating Manual 8. Transport and storage instructions Storage Conditions Parameter Storage Conditions Storage -20ºC to +50ºC (-4ºF to 122ºF) Temperature ideally Store in a dry, clean, well ventilated area at room temperature between 15ºC and 25ºC (59ºF- 77ºF) Humidity <...
Page 111 Protea P2000 Operating Manual 8. Transport and Storage Instructions Page intentionally left blank. Issue 8 PROTEA page 111...
Page 112: Order-Specific Information
9 Order-specific information Introduction This section contains summary installation diagrams and information specific to the P2000 series system with which you have been supplied. The following standard drawings of the version current at date of publication are included as a guide only.
Page 113 Protea P2000 Operating Manual 9. Order-specific information Page intentionally left blank Issue 8 PROTEA page 113...
Page 114: Appendix A - The P2000 With Atex/Iecex Approvals
Appendix A Appendix A - The P2000 with ATEX/IECEx approvals Introduction Versions of the P2000 have been granted ATEX II 2 G Ex db IIB T6 Gb approval (Type Examination Certificate Number Baseefa 18ATEX0060X) and IECEx Ex db IIB T6 Gb approval (Certificate of Conformity Number IECEx BAS 18.0040x) both for use in...
Page 115: Allowed Environments
The standards above detail the gases, and environments, in with which approved equipment is allowed to be used. Reference may be made to them.  The P2000 is approved for use in potentially explosive gas atmospheres classified as IIB  The P2000 should be mounted horizontally and the sample temperature should not exceed 200°C (392°F)
Page 116: Maintenance Additional Requirements
Protea or your Protea Distributor. NOTE - Special precautions are essential in hazardous areas because if certain parts of the P2000 are changed, this may affect the analyser’s certification status. When ordering spare parts for the P2000 from either Protea or your...
Page 117 M8 threaded holes provided must be no more than 6.75 mm thereby leaving one free thread. The main lens is potted and can only be replaced by Protea. Do not attempt to disturb or maintain. The joint surfaces of the enclosure and its cover shall be clean before re-assembly.
Page 118: Special Conditions For Safe Use
CERTIFICATE: Baseefa18ATEX0060X IECEx BAS 18.0040x Summary of Special Conditions for Safe Use P2000:  It is the responsibility of the user to ensure that the gas passed through the enclosure (purge) is instrument air or inert gas, and that the inlet pressure does not exceed 0.1bar (10 kPa or 1.45 psi).
Page 119 12 or 24 hours depending on application.  Clean and dry instrument air (Protea Standard ISO 8573- 1:2010 0 3 1 see Appendix D) for the analyser purge, auto- zero and sample cell protection should be available adjacent to where the AU will be fitted.
Page 120 –20°C to +60°C (4°F to 140°F). The solenoid and enclosure lids should not be removed or any changes or maintenance carried out (contact Protea for support). A bulkhead plate that aligns with the autozero/cal gas and purge ports is attached to the cover.
Page 121 90-264VAC 1.5A Max ATEX Analyser Cooler The analyser cooler is a standard accessory which is fitted over the casting assemby of the P2000 anayser. It is used to reduce the ambient temperature of the analyser and reduce the fluctuations in temperature...
Page 122 30mm (as per drawing 1-0174A). The cover should not be removed or any changes or maintenance undertaken – please contact Protea for support regarding the ATEx cover. The Vent hole in the cover is aligned with the flame arrestor to prevent an obstruction to the head purge air vent (as per drawing 1-0174A).
Page 123 Protea P2000 Operating Manual Appendix A The plate below is placed on cover to align with the vent, the plate warns against obstructing the vent as in the figure below. The plate below, that indicates the ATEx approval, is also fastened to the cover.
Page 124: Appendix B - P2000 With Mcerts Approval
Protea P2000 Operating Manual Appendix B Appendix B - P2000 with MCERTS approval Introduction The P2000 with the Control Unit have been granted MCERTS Certification No Sira 050060. The full certificate detailing the performance criteria test results, precautions, application, environment and maintenance requirement can be viewed at https://www.csagroupuk.org/wp-...
Page 125: Quality Assurance During Production
Sira each year and an MCERTS Design Schedule is re-issued each year to Protea for this Certificate by Sira to show confirmation of authorisation for all changes to design or manufacture. Note this also applies to all changes (up issues) to the Control Unit Control Unit software.
Page 126: Maintenance Additional Requirements
“test screen” readings with those previously logged. 2. Select zero gas purge and verify the P2000 indicates zero within 2% of span, then select span gas and verify it is within 2% FSD of the cylinders' certified concentrations.
Page 127: Appendix C - Protea Analysers For Us Epa Compliance
This appendix describes the implementation of US EPA 40 CFR Part 75 in the P2000. It must be read in conjunction with the main technical manual. Services The following services are required for this option: ZERO GAS Clean, dry instrument air at a continuous 0.5...
Page 128: Operation
Protea 2000 Operating Manual Appendix C Operation Manual operation of Auto-Zero is carried out using the following steps; 1. If not already on the TEST screen select the EYE symbol to navigate there. 2. Select AUTOZERO from the menu, this will give a drop- down menu giving the serial number of the Analyser head S- PC (formerly ACWn) is looking at.
Page 129 Protea P2000 Operating Manual Appendix C During the first Auto-Zero cycle after midnight a calibration routine is included in the operation, this data will be recorded once per day over a 7-day period. This data can be inspected and printed as described in Viewing the results.
Page 130 Protea 2000 Operating Manual Appendix C Span Gas Zero Gas Default Solenoid Phase Name Function Solenoid Duration State (Cal State (AIR) Gas) Normal Analyser Energised ANALYSE 12 hours energised Operation on (CLOSED) (CLOSED) Process Introduce zero gas ZERO (air), thereby...
Page 131: Action On Calibration Error
Protea P2000 Operating Manual Appendix C Action on calibration error If a calibration error occurs, the action required depends on the scale of the error:  If the error is less than 2.5% of full scale, no action is required as the calibration is within specification ...
Page 132: Electrical Connections
Protea 2000 Operating Manual Appendix C Electrical connections The electrical connections to enable the Calibration Gas controls are detailed on the Installation Drawing Issue 8 PROTEA page 132...
Page 133: Appendix D - Quality Standard For Instrument Air Supplied To Protea Analysers
If the air is shown to be inadequate, please install an Air Preparation Panel (see appendix E). Quality Standard for Instrument Air Supplied to Protea Analysers The quality of air is defined in ISO8573-1:2010 Compressed Air - Contaminants and Purity Classes.
Page 134 Appendix D For example, A is the figure for Solid Particulates The Protea standard for Instrument Air defines A as being equal to the Particulate parameters in Class 0 (A=0). Defined as: - The Maximum number of particulates per m allowed whose size is between 0.1µm and 0.5µm diameter is 100, and the...
Page 135 Appendix D The Protea standard for Compressed Air supplied to the Vortex should be ISO 8573-1:2010 2 4 2 Where Particulates A=2 The Maximum number of particulates per m allowed whose size is between 0.1µm and 0.5µm diameter should be less than or equal to 400,000, and the Maximum number of particulates per m allowed whose size is between 0.5 and 1.0µm diameter is less than...
Page 136: Appendix E - Air Preparation Panel
As stated, the instrument air supplied to the analyser must conform to the specification as laid out in the document: Quality Standard for Instrument Air Supplied to Protea Analysers On installations where the quality of instrument air does not meet the required specification it is strongly recommended that the optional Air Preparation Panel is installed.
Page 137 Remove Lower section of housing to access Dryer element Active Carbon Remove Filter Bowl to access element Filter Please refer to section 7 Inspection Schedules – Spares List for spare parts for the Air preparation panel Issue 8 PROTEA page 137...
Page 138: Appendix F - Power Supply Unit
Protea P2000 Operating Manual Appendix F Appendix F – Power Supply Unit Introduction The system wiring details are shown in the “Wiring Table” in section 2 of this manual which also includes connection to remote Power Supply Unit (PSU). Please note:- ...
Page 139 Power Supply Unit Part Number 1-0093 It is strongly recommended that the Protea PSU is installed. However, if a third-party PSU or a 24V DC plant supply is used then please note the DC supply should be 24V ±1% with a load capability of at least 240w per analyser.
Page 140: Appendix G - In-Situ Heater
Regulation of the ISH is from the P2000 and is automatic. The additional power requirement for the In-Situ Heater is 1 kW. Issue 8...
Page 141: Technical Specification
Protea P2000 Operating Manual Appendix G Technical Specification Parameter Range EXTERNAL OPERATING -10°C to 55°C (14ºF to 131ºF) TEMPERATURE STACK AMBIENT 50°C to 350°C (122ºF to 662ºF) TEMPERATURE SAMPLE TEMPERATURE 120°C to 350°C (248ºF to ACHIEVED 662ºF) SIZE INSERT LENGTHS...
Page 142: Control Cable Specification
Protea P2000 Operating Manual Appendix G NOTE - THE INSTALLER IS ADVISED TO USE RING CRIMPS FOR THE LIVE CONNECTION (M4-5) AND THE EARTH CONNECTION (M6) AND A CRIMP BLADE OR FERRULE FOR NEUTRAL CONNECTION – THESE SHOULD SPECIFIED FOR >85°C (>185ºF)
Page 143 Do not attempt to connect any mains cable (line cord) to the ISH if the voltage configuration of the ISH differs from your local electrical supply voltage. Contact Protea, or your Protea-authorised Protea Distributor. Using an incorrect supply voltage will result in the In- Situ Heater failing to function properly.
Page 144 Protea P2000 Operating Manual Appendix G IT IS ESSENTIAL FOR CONFORMANCE WITH EN61010 THAT A FIXED MAINS INSTALLATION HAS AN ISOLATOR FITTED IN THE SUPPLY CLOSE TO THE ISH, THIS ISOLATOR MUST BE LABELLED WITH “ISH SUPPLY” AND MUST DICONNECT BOTH LIVE AND NEUTRAL LINES, AND THIS SHOULD BE PROVIDED BY THE SITE SUPPLY DISTRIBUTION POINT.
Page 145 Connecting the mains voltage to the ISH BEFORE CONNECTING THE MAINS ENSURE AN EARTH BOND LEAD IS FITTED FROM THE P2000 TO THE LOCAL STACK EARTH – THIS IS ONLY REQUIRED WHEN INSTALLING AN ISH When you are satisfied that the voltage configuration of the ISH and...
Page 146 Protea P2000 Operating Manual Appendix G During installation of the In-Situ Heater, you may need to refer to the relevant installation drawing in the Order-specific information section of this manual, particularly if you will be making up your own interconnecting cables.
Page 147: Appendix H - Hot Access Port
Introduction The Hot Access Port has been added to the reflector tube on the P2000 analyser (See Figure H2 for location) to enable water vapour injection while minimising condensation in the analyser probe. This will hence enable water vapour based re-calibration on site from a suitably accurate water vapour generator.
Page 148 Protea P2000 Operating Manual Appendix H Water Vapour Line Fitting P2000. On completion of tests remove the connecting line and replace it with the hot access port plug, a 1/8 BSP taper plug using PTFE tape to seal the thread. Ensure this is tightened to form a gas tight seal.
Page 149: Drawings
Protea P2000 Operating Manual Appendix H Drawings Figure H1 – Insulation Jacket. Issue 8 PROTEA page 149...
Page 150 Protea P2000 Operating Manual Appendix H Figure H2 – Reflector Tube Issue 8 PROTEA page 150...
Page 151 Protea P2000 Operating Manual Appendix H Figure H3 – Water Vapour Line Fitting P2000 Issue 8 PROTEA page 151...
Page 152: Appendix I - By Pass
Control of the Heater is from the P2000 and is automatic. The additional power requirement for the By-Pass In- Situ Heater is 1 kW.
Page 153 Appendix I either branch of the By-Pass. A proportion of the stack / process gas is diverted through the By-Pass and passed into the P2000 In- Situ Cell enabling the gas concentrations to be monitored. The stack gas is driven through the By-Pass by both the action of the scoop and a “Chimney”...
Page 154: Fitting The Optional By-Pass
Protea P2000 Operating Manual Appendix I Mains Cable Specification Parameter Range INSULATION >1500V CURRENT RATING 4.5A (230V), 9A (110V) TEMPERATURE RATING >85°C (>185ºF) OUTSIDE DIAMETER 5mm to 9mm RECOMMENDED WIRE SIZE 1.0 mm NOTE - THE INSTALLER IS ADVISED TO USE RING CRIMPS...
Page 155  Heated By-Pass - main wetted parts Hastelloy C276 / Heater Assy Inconel 825 Other order specific By-Pass assemblies may be supplied, contact Protea Ltd or the local Protea Distributor to obtain the appropriate installation drawing. The By-Pass consists of three main components ...
Page 156 Protea P2000 Operating Manual Appendix I 24mm Note Flange Orientation 136.0m 8 x M16 Studs Equally 229mm Spaced 190.5 Welded to Flange NOM Figure showing Stack Mounting Flange Mounting By-Pass to the stack. The scoop should be attached to the appropriate branch before installation of the By-Pass.
Page 157 Protea P2000 Operating Manual Appendix I Heater Assembly The By-Pass is supplied with the Heater Assembly fitted, it can be removed for inspection and cleaning. If removed a new gasket should be used on re installation. Working on the Heater Assembly...
Page 158: Connecting The Heater
Heater differs from your local electrical supply voltage. Contact Protea, or your Protea- authorised Protea Distributor. Using an incorrect supply voltage will result in the In-Situ Heater failing to function properly. Connecting the By-Pass Heater to the Mains Supply.
Page 159 CONNECTED EQUIPMENT. 1. Determine voltage of supply 110V or 230V (Otherwise consult Protea Ltd or Protea Distributor) 2. Remove and retain the four screws securing the cover of the Heater junction box. 3. Feed through one end of the Heater power cable through the cable gland in the Heater junction box.
Page 160 Connecting the mains voltage to the Heater BEFORE CONNECTING THE MAINS ENSURE AN EARTH BOND LEAD IS FITTED FROM THE P2000 TO THE LOCAL STACK EARTH – THIS IS ONLY REQUIRED WHEN INSTALLING AN ISH When you are satisfied that the voltage configuration of the Heater...
Page 161 Protea P2000 Operating Manual Appendix I Fault on the HEATER When a HEATER is fitted, the TEST screen will display the heater power level. This should start at 100% when the analyser is cold, and then reduce to a lower percentage as the analyser warms up and reaches its set point.
Page 162: Appendix J - In-Situ Steam Heater
Protea P2000 Operating Manual Appendix J Appendix J - In-Situ Steam Heater Introduction Some P2000 systems are supplied with an optional In-Situ Steam Heater (ISSH). This Appendix describes this option, and describes how the ISSH should be installed. For the following applications...
Page 163: Fitting The In-Situ Steam Heater
Protea P2000 Operating Manual Appendix J Fitting the In-Situ Steam Heater Fitting the In-Situ Steam Heater During installation of the In-Situ Steam Heater, you may need to refer to the relevant installation drawing in the Order-specific information section of this manual.
Page 164 Protea P2000 Operating Manual Appendix J 6. Observe the temperature of the sample (T Sample) on the TEST screen of the Control Unit, adjust the Steam Regulator until T Sample is maintained at the calibration temperature (T Cal), as stated in the Analyser Configuration Sheet supplied with the Analyser documentation pack.
Page 165: Appendix K - Steam Heated By Pass
Protea P2000 Operating Manual Appendix M Appendix K – Steam Heated By Pass Introduction Some P2000 systems are supplied with an optional Steam Heated By-Pass Assembly For the following applications  For small diameter Stacks / Ducts < 900mm (< 3 ft) in...
Page 166: Fitting The Optional Steam Heated By-Pass
The assembly also includes a sample scoop which can be fitted to either branch of the By-Pass. A proportion of the stack / process gas is diverted through the By-Pass and passed the P2000 In-Situ Cell enabling the gas concentrations to be monitored. The stack gas is driven through the By-Pass by both the action of the scoop and a “Chimney”...
Page 167 Protea P2000 Operating Manual Appendix K 24mm Note Flange Orientation 136.0m 8 x M16 Studs Equally 229mm Spaced 190.5 Welded to Flange NOM Stack Mounting Flanges Steam Heater The By-Pass has an integral steam heater Working on the Steam Heated By-Pass Heater...
Page 168 Protea P2000 Operating Manual Appendix K Mounting By-Pass to the stack. Flange 3 in 150lb The scoop should be attached appropriate branch before installation of the By- Stack Pass. The By-Pass is supplied Mounting with graphite gaskets, these Flange should be inspected before 4 in 150lb installation.
Page 169 Protea P2000 Operating Manual Appendix K Over Heating If the sample temperature is higher than the Heater set point it is necessary to reduce the flow through the By-Pass this can be achieved by introducing an Orifice plate in the branch which does not have the scoop attached.
Page 170: Appendix L - P2000D (Uv Diode)
Protea P2000 Operating Manual Appendix L Appendix L – P2000D (UV Diode) IMPORTANT - Please read the Safety Warnings below before performing any maintenance function set out in this section of the manual. WARNING Visual exposure or skin exposure to UV light...
Page 171: Introduction
The P2000D analyser requires very little maintenance and achieves a gas as it enters the in-situ sample cell. The P2000 analyser requires very little maintenance and achieves class-beating availability of over 98% in demanding applications. The Control Unit can support multiple analysers from the protea range.
Page 172 Protea P2000 Operating Manual Appendix L Features Benefits Each P2000 can measure up to eight Multi-component gas analysis component six IR & two UV Direct in-situ measurements No requirement for high cost, high maintenance sample handling system or sample conditioning...
Page 173: Maintenance Of The P2000D
Protea P2000 Operating Manual Appendix L Maintenance of the P2000D The UV source of P2000D should be replaced annually as part of the annual maintenance schedule. The part number of the UV light emitting diode (LED) is given in the Spare Parts table below.
Page 174 Protea P2000 Operating Manual Appendix L If you wish to order a spare part, please contact Protea, or your Protea Distributor or agent. If you require a spare part that is not listed here, please contact Protea, or your Protea Distributor or agent.
Page 175: Replacing The Uv Source
Protea P2000 Operating Manual Appendix L Replacing the UV source 1. Remove the lid of the GRP cover if the P2000D is fitted with a head cover. Figure L-1 Removing the GRP cover 2. Before removing the analyser lid make sure that the power to...
Page 176 Protea P2000 Operating Manual Appendix L 3. Locate the UV source assembly and disconnect the power connector from the Peltier pcb as shown in figure L-3 below. Figure L-3 Disconnecting the power connector from the Peltier pcb 4. Disconnect the UV LED connector (PL5) from the analyser pcb...
Page 177 Protea P2000 Operating Manual Appendix L 5. Unfasten the m3 grub screw and release the fibre bundle from the mount. Then unfasten and remove the two M3 x20 socket head screws as shown in figure L-5. Figure L-5 Removing the fibre bundle 6.
Page 178 Protea P2000 Operating Manual Appendix L 7. Carefully, remove the diode from the socket as shown in figure L-7. The diode is sensitive to electro static discharge (ESD). Precautions must be taken to prevent ESD such as wearing an earthing strap and using a grounded mat.
Page 179 Protea P2000 Operating Manual Appendix L 9. Carefully, fit the new diode into the connector. Use the diode tag to align the diode with the connector. Do not bend the pins. The diode must be flush with the connector as shown in figure L-9.
Page 180: In-Service History
Protea P2000 Operating Manual Appendix M In-service history Date Action Signature Issue 8 PROTEA page 180...
Page 181 Issue 8 PROTEA page 181...
Page 182 DynOptic Systems Ltd www.dynoptic.com DSL-330 MkIII – Double Pass Particulate Monitor Measuring in mg/m³ Operators Manual V1.2 DynOptic Systems Ltd – Furlong House, Crowfield, Brackley, Northamptonshire, NN13 5TW United Kingdom © DynOptic Systems Ltd 2016 All technical details and specifications are subject to change without notice...
Page 183 DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual Contents Contents......................1 Product Overview.....................4 Installing the Utility Software and Configuring USB .........6 Minimum hardware/software specification for host PC.........6 Installing the USB Driver ................6 Installing the Utility Software ................7 Updating the Utility Software ................7 Assigning a valid COM Port................7 Using the Utility Software .................9 Connecting a PC to the DSL-330 ..............9...
Page 184 DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual Alignment Tool button ................25 Temperature ...................25 Calibration ....................26 Zero Adjust Value ...................26 Zero Adjust button ..................26 Path Length ....................26 Density Scale Value................26 Enable Opacity ..................27 Opacity....................27 Calibration Checking ..................28 Reference Cal button ................28 Cal Check button ..................28 Absolute Zero Drift..................28...
Page 185 DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual cCAL (Calibration Check) ...............41 Set-up, Calibration and Commissioning............42 Overview ....................42 Head Alignment ..................44 Automatic Gain Correction (AGC)............47 Performing a Zero Adjust ................49 Defining the Path length for Particle Density...........50 Upscale Calibration.................50 Configuring the outputs................52 Calibration Checking..................53...
Page 186: Product Overview
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual Product Overview The DSL-330 Double Pass Particulate Monitor measures open path light transmission using a transceiver (TRX) and reflector system. It is typically installed on a duct, stack, chimney or flue for the purpose of monitoring increases in particle density (mg/m ) caused by suspended particles (dust and smoke) passing through the light path.
Page 187 DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual By default the instrument is a 24VDC powered device, but it can be optionally supplied with universal input 90-260VAC PSU for AC operation. After installing on the stack set-up and basic calibration involves zeroing the instrument under clear path conditions, and performing an upscale calibration adjustment based on comparison between instrument readings and independent gravimetric sample measurements.
Page 188: Installing The Utility Software And Configuring Usb
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual Installing the Utility Software and Configuring USB Warning: The Utility Software and the USB Driver MUST BE INSTALLED ON THE PC FIRST i.e. before connecting the DSL-330 to a PC. Connecting the PC to a DSL-330 before installing the Utility Software and the USB Driver will cause problems with installation and may even cause the installation to...
Page 189: Installing The Utility Software
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual Installing the Utility Software The DynOptic Systems DSL-330 uses the “DSL-3xx Utility Software” which can be found on the CD that was shipped with the instrument. A link to a download file can be provide by DynOptic Systems on request.
Page 190 DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual Once you can see the list of current COM Ports, connect your PC to a DSL-330 by plugging the USB cable from your PC into the USB connection on top of the TRX head (unscrew the weather-proof cap to gain access).
Page 191: Using The Utility Software
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual Using the Utility Software Warning: The Utility Software and the USB Driver MUST BE INSTALLED ON THE PC FIRST i.e. before connecting the PC to a DSL-330. Connecting the PC to a DSL-330 before installing the Utility Software and the USB Driver will cause problems with...
Page 192: The Comms Tab
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual The Comms tab On first running the Utility software you will always arrive at the Comms tab. (see below). The Comms tab allows you to establish a connection with the DSL-330. When you first run the program there will be no connection, so the status bar will be red (indicating no connection).
Page 193: Connect To Instrument
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual Connect to Instrument To establish a connection with the DSL-330 click the “Connect to Instrument” button. The following pop-up window will appear. Click the ‘Find Instruments’ button. The software will scan all available computer ports (up to COM 8) for any connected DSL-330 instruments (see below).
Page 194 DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual...
Page 195: Connect Through Oi
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual Once a comms connection is established additional settings become available on the Comms tab and you will be able to select any of the tabs. Connect Through OI If you are connected directly to the TRX Head the ‘Connect Through OI’ checkbox will be un-checked.
Page 196: Bus Comms (Rs485)
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual For use when multi-heading on an RS485 bus. The default ID is always “1”. For advanced users only, please consult DynOptic Systems if you wish to use multi-heading. Bus Comms (RS485) Checking the ‘ModBus Enable’...
Page 197: The Readings Tab
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual The Readings tab The Readings tab shows the current measurement reading (complete with units). It allows you to view and alter the damping applied to the measurement reading and to select negative clipping. It also provides checkboxes for activating and controlling automatic data logging (which saves log files directly to the PC hard drive) and shows any current error messages.
Page 198: Negative Clipping
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual When in this mode the measurement reading text box is highlighted and the text is red (see below), the user can now manually edit the reading. Typing a value into the measurement reading box and pressing enter forces the reading to the value entered.
Page 199: Damping
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual If this box is CHECKED the instrument will clip the current measurement reading and the output at zero, so positive readings will show as normal, but when the instrument calculates a negative reading it will hold the display and the outputs at zero (e.g.
Page 200: Log Reading - Interval
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual Systems, advanced users may modify the question so that the log file records additional or alternative data; for example relay thresholds or analogue output scaling values. In these circumstances it is beneficial to log both the question and the answer, so that the log file is more easily interpreted.
Page 201: Fault Messages
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual There are two ‘Y’ axis, and by clicking on the coloured text at the top ‘VIS?1’, the axis that this data is plotted against can be changed; Left = Left Y-Axis, Centre = Not displayed and Right = Right Y-Axis.
Page 202: Warning Messages
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual See the section on ‘Fault Messages and Troubleshooting’ later in this manual for more information. Warning Messages Under normal operation the message that is displayed is ‘Warnings Show Here’ in green. If the instrument detects a parameter that is close to or out of range that needs investigating, a brief warning message will be displayed describing the problem, in red.
Page 203: The Outputs Tab
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual The Outputs tab The Outputs tab allows you to configure electrical interface outputs (such as the analogue output and alarm relay contacts) and also allows you to see the effects of those settings.
Page 204: Analogue Low And Analogue High
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual Analogue Low and Analogue High These two parameters set the upper and lower scaling points of the 4-20mA analogue output. Set the Analogue Low value to the reading at which you want the analogue output should generate 4mA (usually 0.0mg/m Set the Analogue High value to the reading at which you want the analogue output should generate 20mA.
Page 205: Threshold
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual Threshold This parameter defines the measurement reading at which the alarm relay will trip. Delay This value determines the continuous length of time (in seconds) that the relay is delayed by. Delaying the activation of the relay can be used to prevent borderline level changes from “dithering”...
Page 206: The Settings Tab
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual The Settings tab Warning: The Settings tab should only be used by a trained instrument engineer who has read and understood later section “Setup, Commissioning and Calibration”, as the settings and controls on this tab determine the calibration of the instrument and the measurement reading that it generates.
Page 207: Signal Strength
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual Signal Strength AGC button Clicking this button will perform an Automatic Gain Correction (AGC), which will adjust the instrument’s Gain value to achieve optimum signal strength. See the later section on Setup, Calibration and Commissioning for further details on using this feature.
Page 208: Calibration
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual Calibration Zero Adjust Value The Zero Adjust Value allows you to define the particle density reading to which the instrument will be forced to when using the Zero Adjust button. As the name implies, this value should normally be zero (0.0) as the purpose of the Zero Adjust button is to adjust the instrument to a particle density reading of 0.0mg/m...
Page 209: Enable Opacity
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual Enable Opacity When this tick box is selected the Utility will display the measured opacity as well as the particle density. Selecting the tick box changes the settings tab as shown below.
Page 210: Calibration Checking
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual Calibration Checking The section provides the functions for the manual calibration checking procedure, which is described later in this manual. Note; although the DSL-330 displays its readings in mg/m³, the reference calibration and calibration check routines are always performed in units of opacity (0-100%).
Page 211 DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual Absolute Span Drift is defined as the difference between the span Opacity reading measured during the last Reference Calibration routine, and the uncorrected span Opacity reading measured during the last Calibration Check routine, using the same span filter.
Page 212: The Diagnostics Tab
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual The Diagnostics tab The Diagnostics tab has a number of information only boxes and some features for backup and restore. See the following screen shot. If the Utility software was communicating through an OI then information on the OI firmware and PCB board will also be shown.
Page 213: Backup To Pc
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual Backup to PC Clicking this button will cause the current instrument settings to be saved in a backup file in the location ‘C\DynOptic\DSL-330 Utility\BACKUP’. The filename of the backup file will incorporate the date, time and electronic serial number of the instrument at time of backup.
Page 214: Folder Location
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual Folder Location This box shows the location on the PC of the folder that contains all of the data stored by the Utility. Left clicking on this filename opens the folder to show three subfolder.
Page 215: Using The Oi
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual Using the OI Keypad / Display Fundamentals The OI has a 4 digit LED display, four laminated push-buttons, and two LED alarm indicators. The Cycle button cycles you through the available parameters on the Page.
Page 216 DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual = parameter name Once cycling is ended, and the display has settled on one parameter for more than one second, the display will switch to show the “value” of that parameter. = parameter value The value of a parameter can be altered by initiating data entry mode, which is achieved by pressing the Next button.
Page 217: Moving Between Pages
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual The decimal point can also be selected (if present) by using the Next button also. The position of the decimal point can be changed using the increase button. Once the desired value has been achieved in data entry mode, the Enter button can be used to accept that new value and store it in memory.
Page 218: Page 0 Parameters
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual the user will then be prompted to enter a 4 digit number (the password) using the usual data entry method. The default password is 0000. If the correct number is entered, the message yES will appear and the display will move to Page 1.
Page 219: Anlo & Anhi (Analogue Low & Analogue High)
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual AnLo & AnHi (Analogue Low & Analogue High) These two parameters set the upper and lower scaling points of the 4-20mA output. Set the analogue Low value to the reading at which the analogue output should generate 4mA (usually 0.0%)..
Page 220: Rly (Relay Polarity)
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual rLy (Relay Polarity) Changing this value alters the default state of the relays in their non-alarm condition. With the value set to 0, the relays will be de-energised in a non-alarm condition.
Page 221: Dust (Reading)
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual duSt (Reading) This parameter shows the current measurement reading in mg/m³. PAgE This parameter allows you to change between “pages”. Choose between 0 and 1 (Page 0 and Page 1). Please note: on choosing Page 1 you will be prompted to enter a password (PAS?) and should enter the password using the normal data entry method.
Page 222: Tenp (Temperature)
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual tEnP (Temperature) This parameter displays current circuit board temperature inside the TRX Head and is a diagnostic tool to determine operating conditions. gAIn (Gain) This parameter displays the Gain value as determined by the AGC function (below).
Page 223: Negative Clipping
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual instrument to a particulate reading of 0.0mg/m³ under clear path conditions i.e. to “zero” the reading. Whilst this function does allow the instrument to be adjusted to values other than zero, this is not a recommended action, and is something that should only be done in certain specific situations by a DynOptic trained engineer who fully understands the consequences.
Page 224: Set-Up, Calibration And Commissioning
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual Set-up, Calibration and Commissioning Warning: It is essential that all components of the instrument have been properly installed, both physically and electrically, before proceeding with set-up, calibration and commissioning. See the separate DSL-330 Installation Manual for full details of installation requirements.
Page 225 DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual installation. These routines must be performed properly before the instrument can be considered operational or accurate. Note; subtle differences between apparently identical installations can produce very different signal strengths, so it is essential that the set-up, calibration and commissioning process is performed independently for each installed instrument.
Page 226: Head Alignment
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual Significant changes include: moving the position or alignment of the heads, changing the path length between TRX and Reflector, changing out any functional part of the instrument (especially the circuit boards) and changing the Gain value.
Page 227 DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual flange gasket provides only a small level of adjustment and cannot correct for angular errors between the flanges of more than the specified ±2 degrees. The process of adjustment is to set all four nuts to the minimum torque (10Nm) then individually tighten each one to compress the gasket and hence change the angle of the mounting.
Page 228 DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual Note: The maximum signal can be more than 80%. Always perform an AGC and re-align for maximum signal. The alignment tool window has a signal strength bar which increases in height with increases in the measured signal.
Page 229: Automatic Gain Correction (Agc)
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual Automatic Gain Correction (AGC) An AGC alters the instrument’s gain value to achieve the optimum signal strength of approximately 4V. This must be performed under clear path conditions, defined as follows: 1.
Page 230 DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual The level of gain can also be set manually (by overwriting the value in the gain box) but this is NOT recommended. Sometimes manual Gain corrections are used where the plant cannot be shut down and proper clear path conditions cannot be established.
Page 231: Performing A Zero Adjust
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual Warning; Setting a Measure Signal of ~4.0V (using either automatic or manual Gain correction) without clear path conditions can cause the Measure Signal to become saturated when the plant stops and a clear path is established.
Page 232: Defining The Path Length For Particle Density
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual Adjusting to a reading other 0.0mg/m is considered to be an imprecise method of calibrating the reading since the uncertainty in knowing the actual levels of dust in the stack has been added to the instrument reading. Defining the Path length for Particle Density Measurements for Particle Density require knowledge of the Path length for use in the calculation.
Page 233 DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual It is preferable to make coincident measurements when the particle concentration in the stack is at its highest possible, since this improves the accuracy calibration. Calibrations performed with reference measurements close to 0.0mg/m³...
Page 234: Configuring The Outputs
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual          Where: DSV = the new Density Scale Value = the original Density Scale value = the Particle Density (mg/m ) from the standard reference method = the Particle Density (mg/m ) from the DSL-330 instrument For improved accuracy this process should be repeated a number of times,...
Page 235: Calibration Checking
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual Calibration Checking Warning: When fitting or removing the heads, even for routine maintenance, there is a risk that stack gas may escape from the mounting flange, or air-purge body. Stack gas, can be hot, corrosive or otherwise damaging to health.
Page 236: Reference Calibration
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual When fitting the Calibration Head, check that the lens on the TRX is clean. After the applicable routine has been completed the Cal Head must be removed for normal operation of the instrument. The Zero Mirror and Span Filter are to be used to periodically check the calibration of the instrument.
Page 237: Reference Calibration Using The Utility Software
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual Before starting the reference calibration ensure that the instrument has been powered up for at least 1 hour. Reference Calibration using the Utility Software To start the reference calibration, go to the Settings tab of the DSL-330 Utility software and select the Reference Cal button in the Calibration Checking box.
Page 238: Step 2
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual Step 2: This window has three check boxes that must be completed before you can proceed. 1. Check the first box to confirm that the TRX lens is clean. This should be the case since the reference calibration should only take place under clean, set-up conditions.
Page 239: Step 3
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual Step 3: This step performs the reference Zero Mirror calibration. Each Zero Mirror has its own serial number and the same Zero Mirror must be used for all future calibration checking.
Page 240: Step 4
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual When this is complete select the check box. This makes the Proceed button available, click to proceed. When proceed has been selected the instrument goes through an automatic measurement routine which takes about 20 seconds.
Page 241 DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual It should be pushed down firmly into the Cal Head slot until the hole in the handle is just above the top surface of the Cal Head. When this is complete select the check box. This makes the Proceed button available, click to proceed.
Page 242: Exiting
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual Step 5: This window displays a summary of the measured reference calibration zero and span opacity values. Selecting the Store button will save these values in the instrument, along with the settings used to perform the reference calibration.
Page 243: Reference Calibration Using The Oi
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual This window has three check boxes that must be completed before you can proceed. These steps must have been completed before it is safe to return to the normal measurement mode. Note that this Exiting window is also accessed if you abort from the reference calibration at any time.
Page 244 DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual ‘ no ’ ‘YES ’ Reference calibration routine The following page details the flow of the reference calibration routine from start to finish.
Page 245 DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual...
Page 246: Calibration Check
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual Calibration Check Once an instrument has been subjected to a reference calibration, it is ready to have its calibration checked routinely. The ideal period between calibration checks will vary between installations, depending on many factors such as the process being monitored by the instrument and the air purge system used.
Page 247: Step 1
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual Step 1: The first window to appear, after selecting calibration check, has two check boxes that must be checked before you can proceed. It also contains a warning summarising what will happen if you choose to proceed. 1.
Page 248: Step 2
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual Step 2: This step performs the Zero Mirror calibration check. The window displays the serial number of the Zero Mirror that was used to perform the reference calibration and the same mirror must be used for the calibration check. If a different Zero Mirror is used the calibration check becomes invalid.
Page 249: Step 3
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual When this is complete select the check box. This makes the Proceed button available, click to proceed. When Proceed has been selected the instrument goes through an automatic measurement routine which takes about 20 seconds.
Page 250 DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual It should be pushed down firmly into the Cal Head slot until the hole in the handle is just above the top surface of the Cal Head. When this is complete select the check box. This makes the Proceed button available, click to proceed.
Page 251: Results
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual Results: The results window displays a summary of the measured results. The first two boxes contain the zero and span opacities recorded during the last reference calibration. The second two boxes contain the zero and span opacities measured at this calibration check.
Page 252: Exiting
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual Selecting the Correct for Drift button produces a warning message stating that proceeding will permanently change some instrument settings. Selecting Yes will save the updated calibration settings to the TRX head and will send you to the calibration mode Exiting window.
Page 253: Calibration Check Using The Oi
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual Note that the inserts may be a tight fit in the Cal Head in which case the holes in their handles can be used, with a suitable tool, to assist in removing them.
Page 254 DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual ‘ no ’ ‘RCAL’ ‘YES ’ Calibration check routine The following page details the flow of the reference calibration routine from start to finish.
Page 255 DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual...
Page 256: Relative And Absolute Drift
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual Relative and Absolute Drift The DSL-330 monitors relative drift (i.e. the change in zero and span measurements since the last drift correction) and absolute drift (i.e. change in zero and span measurements since the last reference calibration). The calibration check process in the previous section measures and (if required) corrects for the relative drift in the zero or span calibration of the instrument.
Page 257: Maintenance
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual Maintenance Warning: When fitting or removing the heads, even for routine maintenance, there is a risk that stack gas may escape from the mounting flange, or air-purge body. Stack gas, can be hot, corrosive or otherwise damaging to health.
Page 258: Checking The Reference Signal
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual lenses will be scratched and a permanent particle density drift will be introduced. Checking the Reference Signal The LED light source in the TRX head is a long life component that should maintain normal operation for at least 5 years, however eventually its light output is likely to diminish to a level where it should be replaced.
Page 259: Fault Messages And Trouble Shooting
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual Fault Messages and Trouble Shooting Fault and Warning messages can appear either on the Readings tab of the Utility software, or on the display of the OI. Important fault or warning messages that appear in the Utility Software will remain permanently displayed on the Readings tab until the fault or warning has been cleared and the operator has clicked on the message.
Page 260: Fault Messages
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual Fault Messages LO REF-VIS (“Lo r”) This fault indicates that the Reference Signal has fallen below 1.5V. The Reference Signal is a measure of the LED brightness, made by a photocell within the TRX head.
Page 261: Hi Meas-Vis ("Hi S")
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual HI MEAS-VIS (“Hi S”) This fault indicates that the Measure Signal has risen above 4.9V. The Measure Signal is the main signal used to generate the instruments measurement reading. The Measure Signal is a voltage generated by light returned from the Reflector head falling on the main photocell in the TRX Head.
Page 262: Warning Messages
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual the correct orientation. Check that the cable is intact and has not been severed or damaged. This problem can also be caused by having an incorrect combination of negative and positive bias applied to the RS485 signals in the interconnecting cable, or by missing termination links.
Page 263: Comms Crc Fault ("Crc")
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual Memory corruption is rare, but can occur in certain circumstances, for example if the instrument suffers a power loss whilst writing to its EEPROM memory. Discrepancies can also be caused by a software upgrade (in the TRX head or the OI, not the Utility software), so they can be an expected result of such actions.
Page 264: Revision Control
DSL-330 MkIII Double Pass Particulate Monitor (mg/m ) - Operators Manual Revision Control Revision Version Date Revision Details Author V1.0 11/02/2014 Original (as per V1.8 of MkII manual). Dominic Sheedy V1.1 03/03/2015 Added opacity display to the Utility settings page Colin Edge V1.2 09/02/2016...
Page 265 Technical Reference Complex Technology Made Simple Thermal Mass Flow Meter Quick Start Guide Kurz Instruments, Inc. 2411 Garden Road Monterey, CA 93940 800-424-7356 / 831-646-5911 www.kurzinstruments.com 368043B...
Page 266 Copyrights and Trademarks Copyright © 2013 Kurz Instruments, Inc. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system without express written permission from Kurz Instruments, Inc., 2411 Garden Road, Monterey, California 93940; Phone: 831‐646‐5911, Fax: 831‐646‐8901, or www.kurzinstruments.com The material in this manual is for information only and is subject to change without notice. Every reasonable effort has been made to ensure that the information in this manual is complete and accurate. Kurz Instruments, Inc. makes no representations or warranties of any kind concerning the contents of this publication, and therefore assumes no liability, loss, or damages resulting from use, errors, or omissions in this publication or from the use of the information contained herein. Kurz Instruments, Inc.,is not responsible for printing or clerical errors. Kurz Instruments, Inc., reserves the right to make engineering changes, product improvements, and product design changes without reservation and without notification to its users. Consult your Kurz Instruments, Inc. representative or a factory applications engineer for information regarding current specifications. Kurz Instruments, Inc. assumes no liability for damages or injuries (consequential or otherwise) caused by the improper use and/or improper installation of this product or where this product is used in any application other than what it was designed for and intended. Kurz Instruments, Inc. expressly denies any responsibility if this product has been modified without Kurz Instruments, Inc. written approval or if this product has been subjected to unusual physical or electrical stress, or if the original identification marks have been removed or altered. Equipment sold by Kurz Instruments, Inc. is not intended for use in connection with any nuclear facility or activity unless specifically sold for such applications and specific conditions for such usage are detailed. If the equipment is used in a nuclear facility or activity without supporting quotation, Kurz Instruments, Inc. disclaims all liability for any damage, injury, or contamination, and the buyer shall indemnify and hold Kurz Instruments, Inc., its officers, agents, employees, successors, assigns, and customers, whether direct or indirect, harmless from and against any and all losses, damages, or expenses of whatever form and nature (including attorneys fees and other costs of defending any action) which they, or any of them, may sustain or incur, whether as a result of breach of contract, warranty, tort (including negligence), strict liability or other theories of law, by reason of such use. The Kurz logo is a trademark of Kurz Instrument, Inc., registered in the U.S. and other countries. Use of the Kurz logo for commercial purposes without the prior written consent of Kurz Instruments, Inc. may constitute trademark infringement in violation of federal and state laws. MetalClad, Series MFTB, Series 454FTB, Series 504FTB, Series 534FTB, and KBar‐2000B are trademarks of Kurz Instruments, Inc. Other company and product names mentioned herein are trademarks of their respective owners. Mention of third‐ party products is for informational purposes only and constitutes neither an endorsement nor a recommendation. Kurz Instruments, Inc., assumes no responsibility with regard to the performance or use of these products. Kurz Instruments Inc.
Page 267 Table of Contents Preface ..................Before You Begin .................... Using this Manual ................... Manual Conventions ..................Chapter 1 Installation ................1‐1 Overview ......................1‐1 Unpacking ....................... 1‐2 Hardware Description ..................1‐2 Installation Requirements ................1‐3 Insertion Flow Meters ................1‐3 Insertion Flow Meter Guidelines ............. 1‐5 In‐Line Flow Meters ................. 1‐6 In‐Line Flow Meter Guidelines ..............1‐6 Wiring Requirements ..................1‐7 K‐BAR Flow Meter System ................1‐8 Multipoint Flow System Guidelines ............
Page 268 ii Kurz Thermal Mass Flow Meter Quick Start Guide...
Page 269: Preface
Preface Kurz Thermal Mass Flow Meter Quick Start Guide...
Page 270: Before You Begin
Before You Begin The device warranty is void if the device is not installed in accordance with the Important specified installation requirements. Read and thoroughly understand the installation requirements before attempting to install the device. If you have any questions, contact your Kurz customer service representative before attempting installation. Using this Manual Kurz Instruments, Inc., documentation includes manuals, product literature, Adobe Acrobat PDF files, and application online Help files. The Kurz Instruments CD contains all the available documentation files. To read PDF files, download the free Adobe Acrobat Reader from www.adobe.com. The Kurz Instruments Web site provides additional information: World Wide Web: www.kurzinstruments.com • Email: service@kurzinstruments.com • Documentation links to the most current manuals and literature • You can access device support in the following ways: Main: 831‐646‐5911 • Phone: 800‐424‐7356 • Fax: 831‐646‐8901 • Manual Conventions The following table lists conventions used in the Kurz Instruments, Inc., documentation, and gives an example of how each convention is applied. Table 1. Conventions used in this manual Convention For Example Text type, click, or select (for example, ...
Page 271: Installation
Chapter 1 Installation Overview Thank you for purchase one of the finest thermal mass flow meters available in the industry. Kurz Instruments has a strong reputation for designing and manufacturing highly accurate and responsive thermal mass flow meters for industrial gas flow measurement. For more than 35 years our team has successfully provided solutions to our customers most demanding and difficult applications. Kurz products are used in a wide variety of industrial applications including combustion air, aeration air flow, digester gas, nuclear power plants, flare stack monitoring, and compressed air. This guide is for the following B‐Series devices using firmware v2.x: Series 454FTB (insertion) • Series 454FTB‐WGF (insertion) • Series 504FTB (in‐line) • Series 504FTB‐CL2 (in‐line) • Series 534FTB (in‐line) • Series K‐BAR 2000B (multipoint) • This Quick Start Guide is an abbreviated version of the B‐Series Hardware Guide. Once your flow meter is correctly installed, refer to the following guides: B‐Series Operations Guide – Chapter 1, “B‐Series Flow Meter Modes & Menus,” and • “Display Mode — Basic Access” in Chapter 2. KzComm User Guide for accessing your flow meter configuration parameters using • KzComm or a terminal emulator, and configuring the USB port. All guides are available on the customer CD and online. Kurz Thermal Mass Flow Meter Quick Start Guide 1–1...
Page 272: Unpacking
Installation Unpacking Your Kurz flow meter is shipped with the following items: Flow meter • Calibration certificate • Customer CD • Quick lookup card (additional copies are available in the B‐Series Operations Guide and the • B‐Series Hardware Installation Guide) Hardware Description The Kurz flow meter electronics head has front and back covers. The front cover allows access to the display/keypad (optional), and the back cover allows access to wiring connections. The features for the B‐Series flow meter shown in the figure include: ¾‐inch FNPT signal and power conduit ports Backlit 2x16‐character display and 20‐character keypad interface (optional) ¾‐inch FNPT sensor support port (transmitter‐ attached version), conduit or cable port (transmitter‐separate version) Safety label and product ID tag AC power input — 85 to 265 VAC 50/60 Hz 1 phase Optional hardware, AI, DO, DI, Purge valve, I/O connector TB6 Power indicator green LED, right side of TB1 — Main I/O wiring terminal block for sensor, power, RS‐485 and 4‐20 mA outputs, TB1 External and internal ground lug locations and ...
Page 273: Installation Requirements
Installation Installation Requirements The flow meter must be installed and used in accordance with safe design and standard industry practices, accounting for the process pressures, corrosion, temperature, and any potentially hazardous areas. The device warranty is void if the device is not installed in accordance with the Important specified installation requirements. Read and thoroughly understand the installation requirements before attempting to install the device. If you have any questions, contact your Kurz customer service representative before attempting installation. Each flow meter has a flow arrow below the sensor electronics head. The arrow indicates the direction of the process flow, as designated in your order specifications. The electronics head on the sensor support must be accessible for wiring. Wiring requirements include electrical and communications (computer) connections. Flow arrow For transmitter‐attached (TA) devices with the display/ • keypad option, the area must allow for viewing and accessing the display/keypad. For transmitter‐separate (TS) devices, the area must provide a location for mounting the • transmitter electronics and a connection from the transmitter to the sensor electronics. Insertion Flow Meters Insertion flow meters have a sensor support connected to an electronics head. Remove the protective shipping cover from the tip of the probe support before installing the device. The probe sensors must have direct contact with the process flow. Do not bend the probe sensors. The probe Important Sensor sensors get extremely hot when the flow meter Window is powered ON. Do not touch the sensors unless the flow meter is powered OFF and there has ...
Page 274 Installation Dry gas and wet gas process flows have different probe angle requirements. For the Series 454FTB flow meter with dry gas flows, the probe can be inserted at any angle • that meets the general installation requirements. For the Series 454FTB‐WGF flow meter, the ideal location is at a 45‐degrees up angle so • that condensed water flows away from the sensor. "FLOW INTO PAPER" FLOW "THREADOLET" FITTING WELD OVER PROBE INSERTION HOLE COMPRESSION FITTING 45° "FLOW INTO PAPER" Series 454FTB MOUNT 454FTB-WGF SUCH THAT FLOW ARROW POINTS IN SAME DIRECTION AS FLOW Series 454FTB–WGF Additionally, the flow meter should be installed away from flow disruptions (such as elbows or ...
Page 275: Insertion Flow Meter Guidelines
Installation Insertion Flow Meter Guidelines Before installing and operating an insertion flow meter, confirm the following information: Mount the probe support so the probe sensors are centered in the duct/pipe. Confirm flow arrow: This location has the most stable flow reading. Note the flow arrow points in Yes ___ No___ the direction of the process flow. The upstream‐downstream distance from flow profile disruptions are 5x diameters downstream and x diameters upstream. This provides a 2% maximum error from the Disruption distance: baseline straight pipe calibration for the distance criteria. Longer straight runs Down _________ reduce this error level. Up _________ Disruption Types: Valves change the flow profile as they open and close. Branching joints change the flow profile as the percentage of flow between the branches. Elbows or direction changes disrupt long‐run pipe profiles by creating a flow profile that wobbles or moves depending on the flow rate. The distance from elbows can be reduced by using field calibrations. Multiple elbows impart a swirl that requires increasing the upstream distance, typically up to 50% more distance. A line size change can introduce instability. The distance from a line size change can be reduced by using field calibrations. The duct or pipe inside dimensions are used to determine the flow area of the meter. Dimension: An area wizard in the meter setup menu walks you through entering the data and Pipe _________ the meter will calculate the flow area. Duct _________ The Sensor Blockage Correction Factor (SBCF) is a result of the probe support Depth:_________ blocking some of the flow area and accelerating the velocity in the duct/pipe cross To wall: ________ section. By measuring from the end of the sensor window to the duct inside wall and ...
Page 276: In-Line Flow Meters
Installation In-Line Flow Meters In‐line flow meters provide excellent accuracy and dependability for small line sizes. Series 504FTB Valve Valve X = 40D Branch Branch X = 20D Series 534FTB Elbow Elbow X = 20D Line size Line size X = 15D (Less than two line changes) (Less than two line changes) where: D = inside diameter In-Line Flow Meter Guidelines Before installing and operating an in‐line flow meter, confirm the following information: ...
Page 277: Wiring Requirements
Installation Wiring Requirements Kurz insertion and in‐line thermal flow meters are 4‐wire devices, with two wires for power and two wires for signal. There can be four wires for signal if the feature was ordered. The 4‐20 mA analog output (AO) connections are for reading flow, temperature, or velocity. The power input is either 24VDC or 85‐265VAC. Refer to the B‐Series Hardware Guide for a complete set of wiring diagrams. Transmitter Attached (TA) Wiring Customer I/O Panel 4‐20 mA 24 VDC Transmitter and Sensor Electronics Transmitter Separate (TS) Wiring Sensor Electronics Customer I/O Panel 24 VDC 4‐20 mA 24 VDC Transmitter Electronics Kurz Thermal Mass Flow Meter Quick Start Guide ...
Page 278: K-Bar Flow Meter System
Installation K-BAR Flow Meter System The K‐BAR is a multipoint sensor array used to measure the flow in applications that: Have changing flow profiles at the same flow rate (such as near valves, dampers, or • branching duct work) Need higher system reliability due to redundant sensors • Need lower flow noise from averaging a duct cross section • Multipoint Flow System Guidelines Before installing and operating a multipoint flow system, confirm the following information: Not Stable 1 2 3 4 5 6 7 8 9 10 Very Stable How stable are the gas properties? Gas 1 ___________________________________ Gas 2 ___________________________________ Is more than one gas state being supported? Gas 3 ___________________________________ Average ___________________________________ What are the expected average velocities? Minimum ___________________________________ What is the minimum velocity? Maximum ___________________________________ What is the maximum velocity? Low Accuracy 1 2 3 4 5 6 7 8 9 10 High Accuracy What are the accuracy expectations? Yes _______ No_______ Is there a plan for field calibration?
Page 279: K-Bar Configuration
Installation K-BAR Configuration The system is composed of two components. The sensor array • The flow computer, which collects and processes the array data in to flow and • temperature outputs Each K‐BAR array is custom‐sized to measure the process velocity in equal area zones. The average total duct flow is computed based on the duct area using and field calibration factors specified at startup. The length of the K‐BAR probe support determines the mounting requirements. The probe support must be held in place with sufficient rigidity to minimize the vibrations created by the process, and there must be enough clearance for installation and maintenance. As shown in the diagram, a single‐end support installation (categories A, B, E, and F) is cantilever mounted from the flange. The size and length of the flange mounting adapter is determined by the K‐BAR specifications. For high vibration applications or when access is limited to one side, a double‐end mounting installation (categories C, D, G, and H) is recommended. The double‐end support uses a probe support cup on the side opposite the mounting flange. Round Stacks / Ducts Mounting flange External-end support (C) Internal-end support (D) Mounting flange Single-end support (B) Category A: Half span, single-end support Category B: Full span, single-end support Category C: Full span, external-end support Category D: Full span, internal-end support...
Page 280 Installation Most K‐BAR installations are flange mounted. In environments where the stack/duct pressure does not match ambient, the clearance gap between the K‐BAR probe and flange mounting adaptor can cause significant blow‐by. The K‐BAR should be installed during a planned outage to reduce safety risks and improve the ease of the installation. The electronics and wiring locations are determined by several factors such as the application environment, weather, temperatures, vibration, and maintenance requirements. The two most common installation types are: Transmitter attached • Transmitter‐attached installations send a linearized 4‐20 mA flow signal to the flow computer. Each sensor has its electronics on the end of the K‐BAR, which minimizes wiring and EMC requirements. Transmitter separate • Transmitter‐separate installations typically use a short service loop between the transmitter electronics and the sensor wire junction box on the end of the probe. The wire gage and conduit shielding determine the length you can run the sensor wires. The wire from the K‐BAR to the transmitter electronics must be shielded in solid conduit, EMT, or braided shielded cable using peripheral bonds at each end. Refer to the B‐Series Hardware Guide for a complete set of wiring diagrams. 190-4B 15 feet (max) flex conduit w/ 5-cond. 196-4B shielded cabled (customer provided) 196-4B Metal conduit & Metal conduit &...

PROTEA P2000 Operating Manual

Section 1

Section 2

Section 3

Quick Links

Chapters

Need help?

Questions and answers

Related Manuals for PROTEA P2000

Summary of Contents for PROTEA P2000