ENOTEC COMTEC ® Installation and Operation Instructions for 6000 ATEX GasEx Explosion proof O ₂/COE Analyzer System

ENOTEC COMTEC ® Installation and Operation Instructions for 6000 ATEX GasEx Explosion proof O ₂/COE Analyzer System

Preface and Safety Fundamentals

Product background: ENOTEC has been producing analyzers since 1980. This system consists of SME5 series electronic units and KEX600x in-situ probes; The oxygen sensor uses zirconia and adopts a special airtight packaging process, which has a longer lifespan compared to adhesive sensors; The entire product is subject to ISO9001 quality control.

Manual identification symbols: including warning (operating instructions), high temperature warning (burn risk), caution (equipment damage risk), prompt, information supplement, grounding, a total of 6 types of identification. The document content is protected by copyright.

Core security requirements

Only trained and authorized personnel are allowed to operate; The equipment comes with mains power, and there is a risk of electric shock when the cover is opened.

The operating temperature of the probe filter head and the components in contact with the flue gas is 150-500 ℃. When disassembling, insulated gloves must be worn, and the power supply to the electronic unit must be cut off before disassembling the probe.

It is strictly prohibited to directly connect the probe to 230V mains power, as it may directly burn out the probe heater.

Try to keep the analyzer powered on even when the process is shut down; Repeated cold and hot cycles of the probe can cause thermal stress, shortening the lifespan of the heater, thermocouple, and sensor.

Storage environment: dry and ventilated, avoiding paint mist and silicone spray.

Explosion proof qualification: The electronic unit and probe are both ATEX certified and can be used in Zone 1/2 hazardous areas; Probe model KEX6001/KEX6002 Explosion proof grade II 2G Ex db IIC T3 Gb; The electronic unit casing has obtained the CESI explosion-proof certificate. Before opening the probe casing, the internal temperature must be lowered to ≤ 200 ℃ and wait for at least 1 hour.

Application: Measurement of O ₂ and COe (carbon monoxide equivalent, representing CO, H ₂, and hydrocarbons, used to determine combustion efficiency) in flue gas and other non combustible process gases; The normal smoke O ₂ should not be lower than 0.5%, and if it is consistently lower than this value, a CSP sensor surface protection option needs to be selected.

System Description 

1.1 System composition

Divided into two types of configurations:

Explosion proof shell version SME-5D: The electronic unit is an Ex d explosion-proof shell, which can be arranged in hazardous areas;

Safe zone shell SME-53/SME-54 (19 inch rack): The electronic unit is arranged in a safe zone, and the probe is still in the danger zone.

The complete system consists of an electronic processing unit, an in-situ measurement probe, a pneumatic unit (optional semi-automatic/fully automatic calibration), probe signal cables FEP-0007/0008, and pneumatic cables FEP-0002; Including electrical signals, power supply, instrument air, and standard air circuits.

Working condition limitation: The maximum temperature of the flue gas is 500 ℃, and if it exceeds this temperature, a cooling protection sleeve must be installed; Probe environmental temperature -20~+70 ℃; Electronic unit environment -20~+55 ℃.

1.2 Measurement principle

O ₂ measurement (zirconia): The probe tip sensor is heated to a constant temperature of 800 ℃; Introduce instrument air (20.95% O ₂) into the reference side and measure the side in contact with the flue gas; Based on the Nernst equation, measure the mV signal of oxygen partial pressure on both sides and convert it to oxygen concentration; It is crucial to ensure airtight isolation between reference air and process gas.

COe measurement: Catalytic electrode oxidizes combustible gas, generating voltage signal; Can detect CO, H ₂ CxHy， The reading is CO equivalent; The higher the COe, the less complete the combustion and the lower the efficiency.

1.3 Nameplate Information

Electronic unit nameplate: voltage, current, serial number, protection level IP66;

Probe nameplate: Year of manufacture, serial number, O ₂ sensor number, ordering code, explosion-proof mark.

Installation

3.1 Installation requirements for electronic units

Protection level IP66; Environmental temperature -20~+55 ℃; The vibration should not exceed 2g; a minimum installation gap should be reserved around the perimeter, and it is recommended to install it at eye height.

An external power-off switch must be configured, located near the electronic unit and clearly labeled. The terminal wire diameter is 0.08-2.5mm ². Cut off the mains power before opening the cover, install the casing and then power on.

3.2 Probe signal cable FEP-0007/0008

The shielding layer is only grounded at the PE grounding terminal of the electronic unit, and the probe end must never be grounded;

The maximum cable length is 50m, and the minimum bending radius is specified; Operating temperature -40~+90 ℃;

The cable includes: oxygen measurement unit, 2-channel thermocouple, probe heater, probe solenoid valve, COe sensor heating and signal line;

The cable must be laid vertically intersecting with the power cable; The accompanying ferrite magnetic ring must be assembled, and CE certification will be invalidated without installing the magnetic ring.

3.3 Probe body installation

Weld the flange to the flue, tilt the flange downwards by 1-3 °, and allow the condensate to flow back into the flue;

The probe should be installed horizontally as much as possible to achieve the fastest response; Probe length>2m, additional support is required inside the flue to prevent probe bending;

Adjust the V-shaped hood to face the direction of the incoming smoke flow;

Cooling protection sleeve: The protruding part of the flue needs to be insulated to avoid being below the dew point; The air outlet cannot be blocked;

The protection level remains IP66; Avoid vibrations greater than 2g.

3.4 Pneumatic Installation

The probe air ports are all 1/4 "interfaces: standard air inlet and reference air inlet/outlet; the green tube is connected to standard air, and the blue tube is connected to reference air;

FEP-0002 pneumatic cable has a specified bending radius and operates at temperatures ranging from -40 ℃ to+90 ℃; Assemble the support sleeve, snap ring, and nut of the joint, then turn the wrench 1-1/4 turns by hand;

Air distribution instrument air version and pump version; Semi automatic calibration unit SME-5000030, fully automatic calibration SME-5000060.

Flow standard: Test air at 150-180 l/h; Refer to air at 30-40 l/h.

Initial operation

4.1 Pre operation Inspection Checklist

The probe and electronic unit system numbers are consistent; Nameplate voltage matching power supply;

Electrical wiring and pneumatic pipelines are correct and leak free; Inspection of flange welding, gaskets, and bolt fastening; The on-site working conditions comply with the technical manual.

4.2 Power on

After turning on the power, set the language, system date and time, TAG tag number, ENOTEC REMOTE remote code, and probe cable length in sequence (parameter errors can cause measurement errors or even damage to the sensor). Power on process: O ₂ sensor heating stage → COe sensor heating stage → measurement mode. The display screen can view probe temperature, heating progress, and measurement values; Panel 3 LEDs: Alarm orange, Maint orange maintenance, Error red system fault. System factory password: 0000, no password protection; Please keep your password properly when changing it.

Menu Description

The menu is divided into SYS-MENU system menu, system check menu CAL MENU calibration menu.

5.1 SYS-MENU system menu

System information: real-time measurement values, mA output, sensor raw mV, reference air flow rate, probe temperature, heater power, sensor lifespan, complete calibration history, equipment operating time, software version;

System Configuration

O ₂, COe measurement range: linear mapping 0-20mA/4-20mA output; Output 3.6mA below the lower range limit and 20.4mA above the upper range limit; customizable fault mA output for system faults;

Limit alarm (min/max alarm+hysteresis); Average filtering time for measured values; Wet to dry basis conversion;

Sensor calibration parameters (offset, slope, alpha/beta/gamma/delta/SO ₂ correction, etc.);

Calibration parameters: pre blowing time, duration of standard gas injection, process delay time; ACAL automatic calibration (triggered by timing/digital input, supports 1-point and 2-point calibration; 2-point calibration must be permanently connected to the calibration gas cylinder);

ENOTEC REMOTE Bluetooth remote: up to 16 devices can be connected simultaneously, and the transmission distance can be set to short/medium/maximum;

Unit settings, language, system password modification, factory reset, COe measurement switch;

Before replacing the COe sensor, the software must set the COe measurement to OFF; After replacement, enter all the parameters of the sensor certificate, and the incorrect parameters will directly burn the COe sensor.

System check menu: O ₂ sensor check, mA output verification, relay output, digital input status.

CAL MENU calibration menu

Support manual 1-point and 2-point calibration, capable of separately calibrating O ₂, COe, or O ₂+COe simultaneously;

1-point calibration: Calculate offset; 2-point calibration: Simultaneously calculate offset and slope; Standard air fixed at 20.95% O ₂ without input;

The calibration interface displays trend curves, traffic, and progress bars; It is recommended to perform 2-point calibration under 24-hour process conditions after calibration is completed.

Maintenance and Repair

Maintenance General Warning: High temperature components, power off, wear insulated gloves, wait for sufficient cooling.

Fuse replacement: Replace after power failure. The manual provides all fuse specifications;

flow regulation

The SME-53 safety zone shell, SME-54 rack, and independent pneumatic unit correspond to different regulating valves respectively;

The instrument air supply pressure is 1-10 bar, and if it exceeds 6 bar, the flow rate must be readjusted.

Component replacement

Filter head: Loosen the locking ring with a hook wrench, replace the filter head with a new one, and realign it with the V-shield smoke direction;

Complete probe replacement: turn off COe measurement software → power off → disconnect wiring flange → replace probe with new one, update gasket, align with V-gear cover, turn on COe when powered on, enter sensor certificate parameters, calibrate at two points after 24 hours;

Probe internals: Disconnect all terminals, loosen the pressure plate nut, extract the ceramic internals, and reset the wiring;

O ₂ Sensor: Disassemble the probe internals, replace the sealing gasket, calibrate at two points after 24 hours of process conditions;

COe sensor: Software turns off COe measurement, power off, disconnect COe wiring from terminals 11-14; Remove the locking component and take out the sensor; New sensor assembly sealing ring; Power on and activate COe, enter RH0, Offset, Alpha, Beta, Gamma, Delta, and SO ₂ corrections. Parameter errors directly damage the sensor; Long term removal of sensors requires the use of a sealing kit to seal the conduit and prevent air from entering.

Relay output definition: system fault (normally closed), maintenance, range selection, probe valve, limit alarm 1, limit alarm 2; The probe valve relay supports up to 230VAC.

HCU heater control unit (redundant fault safety): probe heater protection, cutting off heating at 810 ℃; Trigger protection when the temperature difference between two thermocouples exceeds 10 ℃; The protection trigger must be reset after the entire machine is powered off and restarted; Observe the fault status of the panel HCU LED.

Status messages and troubleshooting

7.1 Error message

Divided into hardware failures, thermocouple open circuit, probe temperature not reaching the set value, sensor open circuit, calibration failure, abnormal flow rate, COe board communication failure, COe heating short circuit/open circuit, REMOTE module hardware failure, etc; The fault will trigger the system fault relay, and the mA output will jump to the fault set value.

7.2 Alarm Information

Reference air flow rate, O ₂ limit alarm, COe limit alarm, electronic unit temperature, and clock battery low voltage.

7.3 Typical Fault Phenomena

O ₂ reading fluctuation: poor contact, damaged filter head, inverted V-shield installation;

The O ₂ reading is high: the probe/sensor flange is leaking, and the flange is not airtightly welded;

O ₂ displays 0%: heater damage, thermocouple failure, fuse blown, cable breakage, sensor damage; Smoke contains a large amount of reducing combustible components;

O ₂ is high, COe is low: COe sensor coupling seal failure, environmental air infiltration;

No COe reading: Out of physical range, COe sensor malfunction.

For hardware failures that users cannot handle, contact ENOTEC service.

Technical specifications

electronic unit

SME-5D explosion-proof enclosure: II2G Ex d IIC T6 Gb, IP66; O ₂ range 0-25% Vol, COe 0-2000ppm; Output 0/4-20mA isolation; Power supply 115/230VAC;

SME-53 safety enclosure IP66; SME-54 is a 19 inch rack with an IP20 rating;

Probe KEX6001/KEX6002: Explosion proof II 2G Ex db IIC T3 Gb, IP66; The maximum process temperature is 500 ℃ (with cooling sleeves up to 1600 ℃); Pressure -50~+50mbar; O ₂ T90 responds for 30 seconds; material 1.4571 (316Ti);

Air source requirements (instrument air): ISO8573-1 class2; Particles ≤ 1 μ m, oil ≤ 0.1mg/m ³, pressure dew point -20 ℃; Input pressure 2-10 bar; The maximum input pressure of the standard gas cylinder is 3 bar;

Provide a complete set of external dimension drawings and pneumatic schematic diagrams (semi-automatic/fully automatic pneumatic units, SME-53 pump version/instrument air version).