ENOTEC ® Installation and Operation Instructions for 5000/5000+Oxygen Analyzer System

ENOTEC  ® Installation and Operation Instructions for 5000/5000+Oxygen Analyzer System

ENOTEC in-situ flue gas oxygen analyzer complete installation, commissioning, operation, maintenance, and troubleshooting manual, product includes OXITEC ® 5000 Basic Edition and 5000+Special Configuration Edition, SME-5 is an electronic processing unit that uses zirconia sensors for in-situ measurement of flue gas oxygen content.

System Description

2.1 System composition

The entire system is divided into SME-5 electronic unit (IP66), in-situ measurement probe (IP65), supporting pneumatic cable, probe signal cable; Divided into two probe configurations:

No cooling sleeve probe: maximum flue gas temperature of 600 ℃;

Probe with cooling sleeve: The maximum flue gas temperature can reach 1600 ℃, and installation space needs to be reserved.

It is recommended to tilt the probe horizontally downwards by -1 ° to -3 ° to ensure the fastest response; Vertical installation will significantly increase response time. When the probe length is greater than 2000mm, additional support is required in the flue to prevent the probe from bending and deforming.

2.2 Measurement principle

The zirconia sensor at the tip of the probe is heated to a constant temperature of 800 ℃; Introduce instrument air (oxygen concentration 20.95%) into the reference side, measure the side in contact with the flue gas, and generate mV potential signals based on the Nernst equation to convert the oxygen partial pressure on both sides into the flue gas oxygen concentration.

Combustible components such as CO and H ₂ in flue gas can consume oxygen on the sensor surface, resulting in low measurement values; It is recommended that the oxygen content in the flue gas under normal working conditions should not be less than 0.5%. If it is consistently lower than 0.5%, it is recommended to select CSP sensor surface protection components.

2.3 Scope of Application

Used for measuring oxygen in combustion equipment flue gas or inert gas mixtures; Prohibited for detecting oxygen concentration in combustible gases. Unauthorized modification of equipment is prohibited.

Installation chapter

3.1 Installation of Electronic Unit SME-5

Environmental conditions: ambient temperature -20~+55 ℃ (pump version -20~+50 ℃); Vibration<2g; Protection level IP66; Leave enough clearance around the installation, and it is recommended to install it at a level with the human eye.

Electrical Key Points

The device does not have an external main power switch, and local circuit breakers/fuses need to be installed on site, located near the electronic unit and clearly labeled.

The maximum length of probe cable FEP-0001 is 150m, and the minimum bending radius is 96mm. The cable shielding layer is only allowed to be grounded at the PE end of the electronic unit, and grounding is prohibited on the probe side.

Terminal adaptation wire section 0.08-2.5mm ²; The matching ferrite magnetic ring must be used, otherwise CE compliance will be invalidated.

The probe junction box terminals correspond to the oxygen sensor mV signal, thermocouple, probe heating 115VAC, and solenoid valve 115VAC.

Pneumatic pipeline preparation

It is divided into three types of air circuits: instrument air supply version, built-in pump version, and external pneumatic version.

The installation of reference air (blue tube) and test gas (green tube) pipelines must use support sleeves, clamp rings, and nuts.

Flow index: Test air flow rate of 150-180 l/h; Refer to air at 30-40 l/h.

3.2 Probe Mechanical Installation

Flanges: Butt welded flanges must be air tight welded using sealing gaskets;

Adjustment of V-shaped guide cover: Loosen the locking nut and hexagon socket screw, rotate the filter head to make the V-shaped cover face the direction of smoke flow, and then tighten the screw;

Cooling sleeve: The part of the cooling sleeve extending from the outer wall of the flue must be insulated to avoid condensation; The gas outlet cannot be blocked, and the minimum inner diameter of the nozzle is 70mm;

Before conducting process side maintenance (dust cleaning, welding, refractory removal), the probe must be completely removed from the flue to prevent mechanical and chemical damage to the probe.

Startup and Initial Operation

Pre commissioning inspection checklist

Match the probe with the electronic unit system number; The nameplate voltage is consistent with the on-site power supply;

Electrical wiring and pneumatic pipelines are correct and leak free; Tighten flange welding and complete gaskets; The on-site working conditions comply with the technical manual parameters.

Power-on sequence

Connect the main power supply, set language, system date and time, TAG tag number, ENOTEC remote password (optional); Enter the probe heating stage and enter the measurement mode after heating is completed.

After 24 hours of operation, two-point calibration must be performed.

human-machine interface

3 status LEDs: Alam orange alarm, Maint orange maintenance, Error red system fault;

Soft keys, numeric keypad; The factory system password is 0000 (without password protection). After modification, it should be kept properly. If lost, it needs to be reset by professional personnel.

Screen distinguishes between heating interface and normal measurement interface.

Software menu function

Divided into SYS-MENU system menu and CAL-MENU calibration menu.

5.1 SYS-MENU system menu

Real time measurement values: oxygen content, 4-20mA output, sensor mV, probe temperature, heater power, thermocouple, reference air flow rate, sensor lifespan, pressure (optional), lambda value.

Calibration results: Record the calibration time, method, offset, slope, test gas parameters, response time, and sensor lifespan.

System Configuration

Oxygen range: 2 independent ranges, can be switched between digital input or keyboard; Wet to dry oxygen conversion can be set; Analog output supports 0-20mA/4-20mA; Fixed mA output can be set under fault conditions.

Oxygen limit alarm: high and low limits+hysteresis setting. If the hysteresis is 0, the alarm needs to be manually reset.

Calibration configuration: single/double point automatic calibration; Set ventilation duration, process delay, and maintain measurement values during calibration; Automatic calibration supports timed and external digital contact triggering.

Pressure compensation, system clock, TAG number, ENOTEC remote (Bluetooth type, up to 16 devices can be connected simultaneously, with three transmission distances of 1m/10m/100m).

Unit switching (℃/℉; mbar/psi), multilingual, changing system password, restoring factory settings (clearing all calibration data); The factory service menu is protected with advanced passwords.

5.2 CAL MENU Calibration Menu

Single point calibration (manual): Introduce 20.95% test air and calculate the sensor offset.

Two point calibration (manual): sequentially introduce test air (20.95% O ₂) and calibration test air, while calculating the sensor offset and slope.

Calibration has stability criteria: the calculation is completed only when the signal is stable for 2 consecutive minutes; Ventilation timeout will report a fault of "unstable sensor signal". It is recommended to recheck within 24 hours after calibration is completed.

System self-test: Sensor mV verification, mA output verification, relay output verification, digital input verification, analog input verification.

Maintenance and Service

The maintenance cycle is affected by the smoke medium (SO ₂ HCl、 Reducing gases and dust have a significant impact. Recommend using standard gas for calibration every six months; Perform a visual inspection of the probe at least once a year.

Fuse replacement: power-off operation, F1-F5 different specifications 5 × 20mm fuses.

flow regulation

Instrument air version: Both reference air and test air can be adjusted;

Built in pump version: only adjustable for testing air flow;

The regulating valve positions of SME-53 wall mounted and SME-54 19 inch rack models are different; The reference air flow rate can be read in the system menu.

Filter replacement: Only ceramic, basalt, and sintered metal filter heads can be replaced; Remove the probe for cooling, remove the old filter, mix and bond the new filter with specialized adhesive and water, and cure at room temperature for 24 hours.

Whole probe replacement: Power off, wear insulated gloves; Disconnect the wiring, loosen the flange, replace the gasket with a new one, and adjust the V-shield; After powering on and heating up, perform two-point calibration.

O ₂ Zirconia sensor replacement: Remove the internal components of the probe, replace the sensor and metal sealing gasket, assemble and reinstall; Perform two-point calibration after 24 hours of operation.

Replacement of internal components of the probe: complete extraction and maintenance of the heater, thermocouple, ceramic rod, and reference air hose; Thermocouples can be replaced separately.

Definition of Relay Output (Passive Contact)

Relay contact type function

System malfunction normally closed critical fault alarm, also effective during heating phase

Maintain normally open and enter maintenance mode

Range 1 normally open Range 1 activated

Limit alarm 1/2 normally closed oxygen over limit alarm

The probe solenoid valve is normally open and drives the probe solenoid valve, with a maximum voltage of 230VAC 1A

Digital input: 12-24VDC high level effective; Used for calibration release and second range switching.

Expansion module: Optional RS232, RS485, HART, fieldbus interfaces, with separate manual.

Status Messages

Divided into three types of messages: error messages, alarm messages, and maintenance messages

Error message (red Error light): Hardware failure, thermocouple open circuit, probe temperature not reaching set, oxygen sensor open circuit, calibration failure, abnormal test gas flow rate, sensor offset/slope abnormality, unstable signal, pressure input failure, remote module hardware failure; Most faulty relay contacts are open, and the default mA output is 2mA.

Alarm message (orange alarm light): refers to abnormal air flow, oxygen high and low limit alarm, electronic unit temperature exceeding limit, low clock battery voltage (battery model CR2032).

Maintenance message (orange Maint light): Measurement value held (output locked during calibration).

Troubleshooting 

Large fluctuations in oxygen measurement values: intermittent contact in wiring, poor contact in the internal mV circuit of the probe; Filter damage; The installation direction of V-shield is incorrect; Lack of filter head.

The reading is fixed at the upper limit/high of the range: there is a leak in the probe or sensor flange; The anti flange welding is not airtight, and the gasket fails.

The local display is normal, but the external output is incorrect: check the set range, measure the actual output of mA directly at the terminal, and evaluate whether the electronic unit is damaged.

Displaying 0% oxygen, but the process flue gas should have oxygen: probe heater damaged (heater resistance 37.5-47.5 Ω), thermocouple damaged; The fuse is burnt out; Cable short circuit and disconnection; Smoke contains a large amount of combustible reducing components; The sensor is damaged.

Technical Parameters

9.1 Electronic Unit SME-5

Protection: Wall mounted IP66; 19 inch rack version IP20; Dot matrix backlit LCD;

Oxygen measurement range: two sets of ranges, configurable from 0-2% O ₂ to 0-25% O ₂;

Accuracy: better than the measured value by 0.5% or 0.02% vol O ₂ (whichever is greater);

Power supply: 115/230VAC; Power consumption heating stage 400VA, measurement mode 200VA;

Output: Active isolation 0-4/20mA, maximum load 500 Ω; Relay contact 24VAC/DC, 1A.

9.2 Probe Parameters

Process temperature: KES-132X up to 400-600 ℃, KES-500X with cooling sleeve up to 1600 ℃;

Process pressure: ± 50mbar; Smoke flow rate 0-10m/s;

Response: T90<5 seconds; IP65 protection, made of 316 stainless steel.

9.3 Requirements for Instrument Air Source