GE Sensing OxyTrak 390 Operating Manual

Sensing

OxyTrak™ 390

Panametrics Flue Gas Analyzer

User’s Manual

910-264B3 September 2007

The OxyTrak™ 390 Flue Gas Analyzer is a Panametrics product. Panametrics has joined other GE hightechnology sensing businesses under a new name—GE Sensing.

September 2007

Warranty Each instrument manufactured by GE Sensing, Inc. is warranted to be

free from defects in material and workmanship. Liability under this warranty is limited to restoring the instrument to normal operation or replacing the instrument, at the sole discretion of GE. Fuses and batteries are specifically excluded from any liability. This warranty is effective from the date of delivery to the original purchaser. If GE determines that the equipment was defective, the warranty period is:

• one year for general electronic failures of the instrument

• one year for mechanical failures of the sensor

If GE determines that the equipment was damaged by misuse, improper installation, the use of unauthorized replacement parts, or operating conditions outside the guidelines specified by GE, the repairs are not covered under this warranty.

The warranties set forth herein are exclusive and are in lieu of all other warranties whether statutory, express or implied (including warranties of merchantability and fitness for a particular purpose, and warranties arising from course of dealing or usage or trade).

Return Policy If a GE Sensing, Inc. instrument malfunctions within the warranty

period, the following procedure must be completed:

1. Notify GE, giving full details of the problem, and provide the model

number and serial number of the instrument. If the nature of the problem indicates the need for factory service, GE will issue a RETURN AUTHORIZATION number (RA), and shipping instructions for the return of the instrument to a service center will be provided.

2. If GE instructs you to send your instrument to a service center, it

must be shipped prepaid to the authorized repair station indicated in the shipping instructions.

3. Upon receipt, GE will evaluate the instrument to determine the

cause of the malfunction.

Then, one of the following courses of action will then be taken:

• If the damage is covered under the terms of the warranty, the

instrument will be repaired at no cost to the owner and returned.

• If GE determines that the damage is not covered under the terms

of the warranty, or if the warranty has expired, an estimate for the cost of the repairs at standard rates will be provided. Upon receipt of the owner’s approval to proceed, the instrument will be repaired and returned.

iii

September 2007

Table of Contents

Chapter 1: General Information

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Physical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Sample System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Display Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Zirconium Oxide Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Platinum-Catalyst Combustibles Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Heater Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11

Chapter 2: Installation

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Installation Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Selecting the Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Preparing the Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

CE Mark Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Wiring the Analog Outputs (A-C). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Wiring the Alarm Relays (A-D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Wiring the Calibration Relays (E-H) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Wiring the RS232 Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Wiring the RS485 Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Remote Display Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Wiring the Line Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Chapter 3: Operation

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Preventing Common Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Cleaning the Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Powering Up the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

The Display and Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Entering Programming Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Exiting Programming Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Temporary Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Locking Programming Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Powering Down the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Taking Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

September 2007

Table of Contents (cont.)

Chapter 4: Setting Up the Display

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Selecting the Number of Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Adjusting the Display Contrast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Selecting the Measurement Mode and Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Measurement Units Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Chapter 5: General Programming

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Setup Menu (Real Time Clock). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Calibrate Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Manual, One-Gas Oxygen Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Manual, Two-Gas Combustibles Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Automatic, One-Gas Oxygen Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Output Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

Cal Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

Relays Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Relays A-D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Relays E-H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

Communications Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

RS232/RS485 Port. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

Ethernet Port. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

Chapter 6: Advanced Programming

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Display, Relays, and Communications Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Output Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Calibrate Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

O2 Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Combustibles Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Setup Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

O2 Sensor Temp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Heater Block Temp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Auto Cal Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Blow Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

Factory Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

Upgrade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

Default Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

Additional Menu Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

September 2007

Table of Contents (cont.)

Chapter 7: Specifications

Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Functional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Physical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Appendix A: The Nernst Equation

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Equilibrium Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

The OxyTrak™ 390 Equation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Appendix B: Menu Maps

Display and Setup Menu Map (2719 passcode). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Outputs and Relays Menu Map (2719 passcode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Calibrate and Communications Menu Map (2719 passcode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

Calibrate, Output and Factory Menu Map (2719 passcode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4

Setup Menu Map (7378 passcode). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5

Appendix C: Calibration, Standard Convection

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

Method #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

Method #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

Method #3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3

Method #4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3

Method #5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4

Method #6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4

Method #7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5

Calibration Gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5

Appendix D: Calibration, Aspirated Flow

Response Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1

Calibration Gas Flow Rate Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1

Oxygen Sensor Field Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2

Manual Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2

vii

September 2007

Table of Contents (cont.)

Appendix E: Default Settings

Calibration Sheet Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1

Display Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2

Calibrate Defaults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3

Output Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-4

Output A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-4

Output B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5

Output C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6

Relays Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-7

Communications Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-13

Setup Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-14

Factory Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-15

Appendix F: Blow Back Sample System

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1

viii

Chapter 1

General Information

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Physical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

September 2007

Introduction Process plant managers are usually looking for ways to reduce

expense and increase profitability . When combustibles are burned as part of the operation, and that combustion is incomplete (allowing unburned fuel to escape), costs go up and profits go down.

A reliable system for analyzing flue gas can provide the necessary information to:

• adjust the flow of oxygen

• increase the efficiency of the combustion

• gain significant cost savings for the overall operation

To meet these specific needs, GE Sensing provides the OxyTrak™ 390 Flue Gas Analyzer which monitors the efficiency of a furnace or

boiler by measuring excess oxygen and/or ppm combustibles in the flue gases.

To measure these two parameters, the OxyTrak™ 390 uses:

unburned

• a zirconium oxide oxygen sensor

• a platinum-catalyst combustibles sensor (optional)

The oxygen sensor measures excess oxygen or, in a fuel rich environment, equivalent combustibles. The combustibles sensor monitors partially combusted fuel, only in the presence of excess oxygen (i.e. there must be enough oxygen present to burn the fuel). Each OxyTrak™ 390 may be equipped with an oxygen sensor, a combustibles sensor, or both.

Physical Description The standard GE Sensing OxyTrak™ 390 Flue Gas Analyzer is

provided in a general-purpose weatherproof (IP52, NEMA 2) enclosure. The analyzer consists of a convection loop/analyzer package and a display controller, which may be mounted either locally or remotely . Figure 1-1 on page 1-2 shows the OxyTrak™ 390 with local and remote display controllers.

General Information 1-1

September 2007

Local Controller

ESC ENT

Remote Controller

Junction Box

Figure 1-1: Standard OxyTrak™ 390 Configurations

ESC ENT

1-2 General Information

September 2007

Sample System The convection loop/analyzer package houses the sample system,

which consists of the components shown in Figure 1-2 on page 1-4 and Figure 1-3 on page 1-5. The functions of the sample system components are as follows:

• a manifold with removable thermocouple and cartridge heaters to

prevent acid components of the flue gas from condensing in the sample system and causing corrosion

• a zirconium oxide oxygen sensor

• an optional platinum-catalyst combustibles sensor to monitor

incomplete combustion of the fuel by burning it in the presence of excess oxygen

• a temperature-controlled sensor furnace to maintain the oxygen

sensor at a stable operating temperature and to act as the engine for convective sampling

• a convection loop to circulate the sample gases through the sample

system

• an aspirator port to connect to an aspirated probe.

General Information 1-3

September 2007

Sample System (cont.)

Furnace T/C

Sensor

Furnace

Convection

Loop

Aspirator

Port

Manifold

Oxygen Sensor

Combustibles

Sensor

Aspirated

Probe

Connection

Figure 1-2: The Sample System

1-4 General Information

Sample System (cont.)

Sensor

Furnace

September 2007

Convection Loop

Combustibles Sensor

Oxygen Sensor Washer

Zirconium Oxide Oxygen Sensor

Combustibles Sensor Washers

Figure 1-3: Sensor Locations (ref. dwg #705-1088, sht 3)

General Information 1-5

September 2007

Sample System (cont.)

Figure 1-4: Combustibles Sensor

SENSOR POSITIVE

Figure 1-5: Zirconium Oxide Oxygen Sensor

1-6 General Information

September 2007

Display Controller The display controller (see Figure 1-6 below) includes the terminal

blocks for making all electrical connections and the furnace temperature control (FTC) circuit board. The FTC board maintains a

constant sensor furnace temperature to improve the accuracy of the oxygen analysis and to extend the life of the oxygen sensor.

Figure 1-6: Display Controller Interior

The display controller performs the following functions:

• amplifies the oxygen and combustibles sensor outputs

• linearizes the oxygen signal

• controls the sensor temperature

• outputs the reading on a 64 x 128 pixel graphic display

• enables programming using an integral keypad

• provides a linear 4-20 mA analog output

• provides four alarm relays

• provides four auto-calibration relays

• provides RS232/RS485 communications outputs

General Information 1-7

September 2007

Principles of Operation Ideally, every furnace/burner should mix a precise ratio of air to fuel,

and the mixture should burn efficiently to yield only heat, water vapor and carbon dioxide. However, because of burner aging, imperfect air to fuel mixtures and changing firing rates, this rarely happens. Monitoring the actual efficiency of the combustion process is easily accomplished with the OxyTrak™ 390.

A flue gas sample is drawn into the probe by gaseous diffusion and a gentle convective flow. The sample passes through the probe and into the sample system, where it is maintained at a temperature above 200°C (392°F) by the heater block. In the presence of oxygen, this sample temperature is high enough to burn any partial combustion products that reach the active (platinum-coated) element of the combustibles sensor. The resulting temperature differential between the two combustibles sensor elements is related to the concentration of partial combustion products in the test sample.

Note: The sampled gas is maintained above 200°C (392°F) to

prevent flue gas acids from condensing in the analyzer and causing corrosion.

The sample then passes into the sensor furnace, which heats the sample gas and the oxygen sensor to 700°C (1,292°F) (a temperature above 650°C (1,202°F) is required for proper operation of the oxygen sensor). The oxygen sensor is covered with a platinum catalyst that causes the burning of all remaining combustibles, enabling the sensor to measure the excess oxygen (or fuel) in the flue gas.

The sensor furnace also generates the convective flow that circulates the sample gas through the sample system. The hot sample gas in the sensor furnace rises out of the furnace and cools, as it is pushed from behind by the hot gases still in the furnace. The cooled sample gases then drop down the other branch of the convection loop and into the annular space between the probe and probe sleeve, where they are carried away by the gas flow in the flue.

1-8 General Information

September 2007

Zirconium Oxide Oxygen Sensor

The inside and outside of the zirconium oxide oxygen sensor are coated with porous platinum, forming two electrodes. The sample gas flows past the outside of the sensor, while atmospheric air circulates freely inside the sensor. This atmospheric air is used as the reference gas for making oxygen measurements. See Figure 1-7 below.

Oxygen ions migrate through the zirconium oxide along the concentration gradient.

Atmospheric O

Inside Cell

20.9%

Sample O

Outside Cell

Zirconium Oxide Ceramic with Lattice Imperfec tio n s

From O u ts ide

Electrode

When O concentration in sample gas falls, the cell voltage rises

Volts

From Ins id e Electrode

with increased oxygen migration through the zirconium oxide.

Figure 1-7: Oxygen Migration in the Zirconium Oxide Sensor

At the operating temperature of the oxygen sensor, the atmospheric reference oxygen is electrochemically reduced at the inner electrode, and the resulting oxygen ions seek to equalize with the lower oxygen concentration on the sample side of the cell by migrating through the porous ceramic toward the outer electrode. At the outer electrode they give up electrons to become oxygen molecules again, and are swept away by the sample gas flow.

The lower the concentration of oxygen in the flue gas sample, the greater the rate of ion migration through the ceramic, and the higher the cell voltage due to electron exchange at the electrodes. The cell voltage rises logarithmically as the amount of oxygen in the flue gas falls, allowing the accurate measurement of very low levels of excess oxygen in the flue gas.

General Information 1-9

September 2007

Platinum-Catalyst Combustibles Sensor

The combustibles sensor consists of two platinum thermistors mounted side by side in the sample stream. One thermistor, the active element, is used to detect/react partial combustion products, while the other thermistor, the reference element, provides a baseline. The active element is coated with a black platinum catalyst and the reference element has a white inert surface. As the sample gas passes over the active element, the platinum catalyst causes any combustibles to burn (in the presence of excess oxygen), thereby raising the temperature of the active element above that of the reference element (see Figure 1-8 below).

Flue Gas Flow

Reference

Element

(Inert Coating)

Active

Element

(Platinum C ata ly st)

Combustibles Sensor

Figure 1-8: Combustibles Sensor Elements

The resulting temperature differential between the active and reference elements is proportional to the concentration of combustibles in the sample, and a corresponding resistance change is then converted into a reading of parts per million by volume (ppm

of combustibles.

)

1-10 General Information

September 2007

Heater Control Circuit The oxygen sensor temperature in the OxyTrak™ 390 is maintained

by a heater, which is part of a complex temperature control loop. This circuit constantly monitors the oxygen sensor temperature, compares it to the set point temperature (700°C), and turns the heater ON or OFF accordingly. The specific type of control circuit used is called a Proportional Integral Derivative (PID) loop, because of the three adjustable parameters involved:

• Proportional Band: Because the system cannot respond

instantaneously to temperature changes, the actual temperature of the oxygen sensor oscillates about the set point. In general, increasing the proportional band reduces the magnitude of these temperature oscillations.

• Integral Action: A consequence of increasing the proportional

band is the introduction of an offset between the set point and the control point. The integral portion of the control loop acts to move the control point back toward the set point within a specified period of time. Thus, decreasing this integration time reduces the offset more quickly.

• Derivative Action: The derivative portion of the control loop

applies a corrective signal based on the rate at which the actual temperature is approaching the set point. In effect, the derivative action reduces overshoot by counteracting the control signal produced by the proportional and integral parameters.

The heater control circuit is configured at the factory for optimum performance. Because of the strong interaction between the three parameters involved, properly setting up the PID loop is a very complex matter. As a result, randomly changing the P, I and/or D parameters can seriously degrade the performance of the OxyTrak™

390.

IMPORTANT: Always contact the factory before attempting to

change the default P, I and/or D values.

General Information 1-11

Chapter 2

Installation

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Installation Site. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

September 2007

Introduction This chapter provides instructions on how to properly install and wire

the OxyTrak™ 390. Be sure to observe all installation limits and precautions described in this chapter. Pay particular attention to the specified ambient temperature range of –30 to +70°C (-22 to +158°F) for the analyzer and –30 to +60°C (-22 to +140°F) for the controller.

!WARNING!

To ensure safe operation, the OxyTrak™ 390 must be

installed and operated as described in this manual. Also, be

sure to follow all applicable local safety codes and

regulations for installing electrical equipment. All

procedures should be performed by trained service

personnel only.

Unpacking Remove the analyzer (see Figure 2-1 below) from its shipping

container, and make sure that all items on the packing slip have been received. If anything is missing, contact the factory immediately.

Note: See Figure 2-6 on page 2-17 (local controller) or Figure 2-7

on page 2-18 (remote controller) for a complete outline and installation drawing of the OxyTrak™ 390.

Figure 2-1: Typical OxyTrak™ 390 with Local Controller

Installation 2-1

September 2007

Installation Site Environmental and installation factors should already have been

discussed with a GE Sensing applications engineer or field sales person before the OxyTrak™ 390 arrives.

Selecting the Site The tip of the probe is typically inserted into the stack to a distance of

1/3 of the stack diameter. Also, the flue gas flow direction should be either perpendicular to the probe or angled away from the open end of the probe (see Figure 2-2 below).

IMPORTANT: Never allow the flue gas flow to be angled directly into

the end of the probe.

• For furnaces, locate the analyzer close to the combustion zone,

typically within the radiant section and always before the convection section. Make sure that the probe’s maximum operating temperature is not exceeded and that the probe is not situated in a non-homogeneous flue gas mixture.

• For boilers, locate the analyzer downstream of the heat exchanger

and just before the economizer air heater, if one is installed. The analyzer should not be placed downstream of any air heater, because of possible air leaks that can cause inaccurate readings.

In general, the sample point should be an area of high turbulence, which will ensure a good homogeneous mixture of the flue gases. Conditions to be avoided would include air leaks upstream of the sample point and dead spaces in the vicinity of the sample point.

Mounting Flange

Shroud

90°

Probe

Probe Sleeve

Figure 2-2: Permitted Flue Gas Flow Angles

2-2 Installation

September 2007

Selecting the Site (cont.) Finally, the following installation requirements should be observed:

• Install the OxyTrak™ 390 in a location that provides ready access

for programming, testing, and servicing the unit.

• Protect all cables from excessive physical strain (bending, pulling,

twisting, etc.).

• Be sure that the input voltage at the planned installation site is

within the limits specified for the OxyTrak™ 390.

Preparing the Site Preparation of the installation site should include the following steps

(see Figure 2-8 on page 2-19 and Figure 2-3 below):

Note: Although a horizontal installation is shown in this manual,

other mounting angles are permissible.

FRONT VIEW

GAS FLOW

SIDE VIEW

3" min

Welds

2" Sch 80 Pipe

Mounting Plate

1 7/8"

min.

90°

Masonry

Wall

Mating Flange

Figure 2-3: A Typical Installation Setup

Installation 2-3

September 2007

Preparing the Site (cont.) 1. At the chosen analyzer location on the furnace or boiler wall or on

the side of a horizontal or vertical flue duct, drill a hole of the proper diameter to accommodate a short length of pipe having at least a 1 7/8 in. 48 mm) inside diameter. A length of 2” Schedule 80 pipe is suitable for this purpose.

2. Weld the short pipe into a mounting plate, with welds on both sides of the plate. The pipe length must be sufficient to meet the following requirements:

• One end of the pipe should extend through the rear of the

mounting plate sufficiently to enter the wall. For installation in a masonry wall, the pipe should extend entirely through the wall to prevent the probe from becoming trapped, if the wall should crumble.

• To provide clearance for installing the flange bolts, the pipe

must be long enough to provide 4 in. (100 mm) of clearance between the front surface of the mounting plate and the back surface of the mating flange.

3. Weld the mating flange onto the end of the short pipe so that the raised face of the flange faces away from the mounting plate. Be sure that the following requirements are met:

• One end of the short pipe should be flush with the raised face of

the flange.

• The mating flange should be oriented so that its bolt holes

straddle the vertical and horizontal center lines of the mounting plate.

Note: The OxyTrak™ 390 can be supplied with an optional flange. If

a flange is desired, it must be specified (e.g. 3”-150# flange) at the time of purchase

4. Attach the mounting plate to the wall with the pipe extending into the drilled hole.

For probe lengths greater than 2 meters (6 feet), a support sleeve is recommended. Refer to Figure E-3 on page E-3.

2-4 Installation

September 2007

Mounting This section explains how to mount OxyTrak™ 390 analyzer at the

site that was prepared in the previous section. The OxyTrak™ 390 has integral male 1-1/2” NPT mounting threads. This permits a flange to be threaded onto the analyzer, and the resulting assembly is then bolted to the mating flange on the furnace/boiler wall or flue duct.

Caution!

Flue gas condensate is extremely corrosive. The OxyTrak™

390 must be wired and powered up immediately after

mounting to prevent damage to the unit. If a blowback

(purge) system is to be used, install this system and turn it on

right away also.

IMPORTANT: Direct mounting of the OxyTrak™ 390 into a threaded

hole using its mounting thr e ads is not Always use a mounting flange.

Note: Rather than the use of a thread sealant, a high temperature

lubricant such as Molykote 1000 is recommended.

recommended.

Refer to Figure 2-8 on page 2-19, and complete the following steps to mount the OxyTrak™ 390 convection loop/analyzer package:

1. Slide a suitable flange gasket over the probe and up against the mounting flange on the analyzer.

Note: Be sure to use a suitable high temperature gasket for this

application.

2. Orient the analyzer so that the convection loop/ana lyzer package is vertical, and slide the probe through the hole in the mounting wall until the two flanges meet.

3. Using suitable hardware, make sure the gasket is properly positioned between them, and bolt the two flanges together.

4. Continue as follows: a. If you have a local display controller, the physical installation

is complete. Proceed to the wiring section on the next page.

b. If you have a remo te display controller, proceed to Step 5.

5. Refer to Figure 2-7 on page 2-18 and mount the remote display

controller in a convenient location. Be sure to allow sufficient clearance for programming and operation of the unit.

6. Install suitable cable glands and conduit for the environment, to connect the junction box on the bottom of the convection loop/ analyzer package to the display controller (2 places).

Installation 2-5

September 2007

Wiring !Attention European Customers!

To meet CE Mark requirements, install all cables as

described on the next page.

IMPORTANT: For compliance with the European Union’s Low

Voltage Directive (73/23/EEC), the OxyTrak™ 390 requir es an external power disconnect device such as a switch or circuit breaker. The disconnect device must be marked as such, clearly visible, directly accessible, and located within 1.8 m (6 ft) of the unit.

!WARNING!

To ensure safe operation, the OxyTrak™ 390 must be

installed and operated as described in this manual. Be sure

to follow all applicable local safety codes and regulations

for installing electrical equipment. All procedures should

be performed by trained service personnel only.

To wire the OxyTrak™ 390, see Figure 2-9 on page 2-20 for a local assembly or Figure 2-10 on page 2-21 for a remote assembly, and connect the following items to the display controller (do not

line power through the same conduit as the other connections):

run the

• alarm relays A-D

• calibration relays E-H

• 4-20 mA analog output

• RS232 or RS485 output

• line power (connect through the right-hand port)

If you have a remote display controller, you must also make the following connections between the controller and the junction box:

• oxygen and combustibles sensors

• furnace and manifold thermocouples

• thermocouple cold junction compensation

• furnace and manifold heaters

IMPORTANT: Do not alter any of the factory-installed wiring.

To access the terminal blocks for wiring, unthread the four screws on the front of the display controller and swing the cover open. If you have a system with a remote display controller, you must also unthread the three screws on the junction box and swing the cover open.

2-6 Installation

September 2007

CE Mark Compliance For CE Mark compliance, the OxyTrak™ 390 must meet both the

EMC and LVD directives.

IMPORTANT: CE Mark compliance is required for all units used in

EEC countries.

EMC Compliance For EMC compliance, the electrical connections must be shielded and

grounded as shown in Table 2-1 below. After all the necessary electrical connections have been made, seal any unused cable entry holes with standard conduit plugs or equivalent.

Note: If the instructions in this section are followed, the unit will

comply with the EMC Directive 89/336/EEC.

Table 2-1: Wiring Modifications for EMC Compliance

Connection Wiring Modification

Power 1. When connecting the power, select the cable

entry closest to the chassis ground.

2. Use shielded cable* to connect the power to the OxyTrak™ 390 enclosure. Connect the shield to the nearest chassis ground terminal.

3. Connect the power line ground wire to the nearest chassis ground terminal.

Input/Output 1. Use shielded cable* to interconnect the

OxyTrak™ 390 enclosure with any external I/O devices.

2. Connect the shields to the nearest chassis ground terminal.

*Wires enclosed in a properly-grounded metal conduit do not

require additional shielding.

LVD Compl iance For compliance with the European Union’ s Low Voltag e Directive

(73/23/EEC), the analyzer requires an external power disconnect device such as a switch or circuit breaker. The disconnect device must be marked as such, clearly visible, directly accessible, and located within 1.8 m (6 ft) of the unit.

Note: If the instructions in this section are followed, the unit will

comply with the Low Voltage Directive (73/23/EEC).

Installation 2-7

September 2007

Wiring the Analog Outputs (A-C)

Wiring the Alarm Relays (A-D)

To wire an analog output device to the OxyTrak™ 390, refer to Figure 2-4 on page 2-12 and Figure 2-9 on page 2-20 or Figure 2-10 on page 2-21, and make the following connections to terminal block

J11 in the display controller:

1. Connect the positive pin to the input of the analog output device: a. Output A - J11–5 (+) b. Output B - J11–3 (+) c. Output C - J11–1 (+)

2. Connect the negative pin to the return of the analog output

device:

a. Output A - J11–6 (–) b. Output B - J11–4 (–) c. Output C - J11–2 (–)

To wire a warning device to any of the OxyTrak™ 390 ala rm relay s (A-D), refer to Figure 2-4 on page 2-12 and Figure 2-9 on page 2-20 or Figure 2-10 on page 2-21, and make the following connections to terminal blocks J7 and J8 in the display controller:

1. Connect the NC pin to the alarm device input for failsafe operation, or leave this pin unused for non-failsafe operation:

a. Relay A - J7–4 (NC) b. Relay B - J7–1 (NC) c. Relay C - J8–4 (NC) d. Relay D - J8–1 (NC)

2. Connect COM pin to the alarm device return: a. Relay A - J7–6 (COM) b. Relay B - J7–3 (COM) c. Relay C - J8–6 (COM) d. Relay D - J8–3 (COM)

3. Connect the NO pin to the alarm device input for non-failsafe

operation, or leave this pin unused for failsafe operation:

a. Relay A - J7–5 (NO) b. Relay B - J7–2 (NO) c. Relay C - J8–5 (NO) d. Relay D - J8–2 (NO)

2-8 Installation

September 2007

Wiring the Calibration Relays (E-H)

To wire a warning device to any of the OxyTrak™ 390 calibrati on relays (E-H), refer to Figure 2-4 on page 2-12 and Figure 2-9 on p age 2-20 or Figure 2-10 on page 2-21, and make the following connections to terminal blocks J9 and J10 in the display controller:

1. Connect the NC pin to the alarm device input for failsafe

operation, or leave this pin unused for non-failsafe operation:

a. Relay E - J9–3 (NC) b. Relay F - J9–6 (NC) c. Relay G - J10–3 (NC) d. Relay H - J10–6 (NC)

2. Connect the COM pin to the alarm device return:

a. Relay E - J9–1 (COM) b. Relay F - J9–4 (COM) c. Relay G - J10–1 (COM) d. Relay H - J10–4 (COM)

3. Connect the NO pin to the alarm device input for non-failsafe

operation, or leave this pin unused for failsafe operation:

a. Relay E - J9–2 (NO) b. Relay F - J9–5 (NO) c. Relay G - J10–2 (NO) d. Relay H - J10–5 (NO)

Note: The OxyTrak™ 390 relays do not provide power. To use the

Blow Back process, connect a power supply in series with Relay H and the Blow Back solenoid valve.

Installation 2-9

September 2007

Wiring the RS232 Output To wire the OxyTrak™ 390 to the RS232 serial port on a PC, refer to

Figure 2-4 on page 2-12 and Figure 2-9 on page 2-20 or Figure 2-10 on page 2-21, and make the following connections to J14 in the display controller:

IMPORTANT: You may make either an RS232 connection or an

RS485 connection, but not both at the same time.

Note: This connection may be made with a GE Sensing #704-668-xx

cable. If this cable is used, pin #1 is the white wire, pin #2 is the red wire, and pin #3 is the green wire.

1. Connect J14–1 (OUT) to the transmit pin on the computer.

2. Connect J14–2 (IN) to the receive pin on the computer.

3. Connect J14–3 (EN) to the return pin on the computer.

Note: See GE Sensing document EIA-RS Serial Communications

(916-054) for a detailed discussion of serial port connections.

Wiring the RS485 Output To wire the OxyTrak™ 390 to a remote RS485 controller, refer to

Figure 2-4 on page 2-12 and Figure 2-9 on page 2-20 or Figure 2-10 on page 2-21, and make the following connections to terminal block J13 in the display controller:

IMPORTANT: One may make either an RS232 connection or an

RS485 connection, but not both at the same time.

1. Connect J13–1 to Return on the RS485 system.

2. Connect J13–2 to 12V on the RS485 system.

3. Connect J13–3 to (+) on the RS485 system.

4. Connect J13–4 to (–) on the RS485 system.

2-10 Installation

September 2007

Remote Display Option If you have a local display controller, skip this section and proceed to

the next page to wire your line power. Otherwise, wire the remote display controller to the junction box on the convection loop/analyzer package as follows (see Figure 2-4 on page 2-12 and Figure 2-10 on page 2-21):

Wiring the Signal Cable Assembly (704-1104)

1. Wire the combustibles sensor: a. Using the RED wire from the red/black pair, connect junction

box terminal J3–1 (CO ACT / BLK) to display controller terminal J4–1 (ACT / BLK).

b. Using the BLACK wire from the red/black pair, connect

junction box terminal J3–2 (CO REF / GRN) to display controller terminal J4–2 (REF / GRN).

c. Using the GREEN wire from the green/black pair, connect

junction box J3–3 (CO ACT / RED) to display controller terminal J4–3 (ACT / RED).

d. Using the BLACK wire from the green/ black pair, connect

junction box terminal J3–4 (CO REF / YEL) to display controller terminal J4–4 (REF / YEL).

2. Wire the oxygen sensor: a. Using the WHITE wire from the white/black pair, connect

junction box terminal J2–1 (O2+) to display controller terminal J1–1 (O2+).

b. Using the BLACK wire from the white/black pair, connect

junction box terminal J2–2 (O2-) to display controller terminal J1–2 (O2-).

3. Wire the furnace thermocouple: a. Using the BLUE wire from the blue/black pair, connect junction

box terminal J1–3 (T/C FURN +) to display controller terminal J6–3 (T/C FURN +).

b. Using the BLACK wire from the blue/black pair, connect

junction box terminal J1–4 (T/C FURN –) to display controller terminal J6–4 (T/C FURN –).

4. Wire the manifold thermocouple: a. Using the BROWN wire from the brown/black pair, connect

junction box terminal J1–5 (T/C MAN +) to display controller terminal J6–5 (T/C MAN +).

b. Using the BLACK wire from the brown/black pair, connect

junction box terminal J1–6 (T/C MAN –) to display controller terminal J6–6 (T/C MAN –).

Installation 2-11

September 2007

Wiring the Signal Cable Assembly (704-1104) (cont.)

Wiring the AC Cable Assembly (704-1102)

5. Wire the cold junction compensation: a. Using the YELLOW wire from the yellow/black pair, connect

junction box terminal J1–1 (CJC +) to display controller terminal J6–1 (CJC +).

b. Using the BLACK wire from the yellow/black pair, connect

junction box terminal J1–2 (CJC –) to display controller terminal J6–2 (CJC –).

1. Wire the manifold and furnace heaters: a. Using WIRE 1, connect junction box terminal J5–1

(MANIFOLD) to display controller terminal J3–3 (MANIFOLD).

b. Using WIRE 2, connect junction box terminal J5–2 (FURNACE)

to display controller terminal J3–2 (FURNACE).

c. Using WIRE 3, connect junction box terminal J5–3

(COMMON) to display controller terminal J3–1 (COMMON).

d. Connect the ground wire from a ground standoff in the junction

box to a boss in the display controller.

Comb

Sensor

1 2 3 4

4 3 2 1

2 1

Open

Temp

Control

1 2 3 4 5 6

2 1

J15

Field-

bus

RS232

Remote

RS485

J13

1 2 3 4

3 2 1

1 2 3 4 5 6

J14

Relays

E J9 F

Relays

G J10 H

1 2 3 4 5 6

A B C

6 5 4 3 2 1

J11

4-20mA

6 5 4 3 2 1

A J7 B

Relays

6 5 4 3 2 1

C J8 D

Relays

Output

Figure 2-4: Display Controller Wiring Connections

Heaters

1 2 3

GND

2 1

AC IN

2-12 Installation

Wiring the Line Power !WARNING!

Before proceeding, verify that the line power has been

turned off at the external disconnect device.

To wire the input voltage to the OxyTrak™ 390, complete the following steps. Make these connections only with wire that meets the following specifications:

• minimum 18 AWG individual conductor gauge (max. 12A current)

• voltage rating of 600V minimum

• insulation temperature rating of 105°C minimum

!WARNING!

The wire insulation rating must be at least 15°C above the

expected ambient temperature.

September 2007

Installation 2-13

September 2007

±.50 IN

±1.0 IN

±2.0 IN

±3.0 IN

1 TO 9.99 FT

10 TO 24.9 FT

25 TO 49.9 FT

50 TO 100.0 FT

CABLE

10.8 FT

25.8 FT

50.8 FT

100.8 FT

LENGTH LENGTH TOLERANCES

PART

NUMBER

704-1102-01

704-1102-02

704-1102-03

704-1102-04

THIS END WIRED

DETAIL -A-

STEP 1: CABLE PREP

1. DIMENSIONS - INCHES

3. STRIP 4.0" OF OUTER JACKET, BRAIDED SHIELD AND INNER JACKET OF ITEM 8 (CABLE) EXPOSING 4 WIRES.

2. CUT CABLE TO LENGTH -L-.

NOTES:

7. ATTACH ITEM 5 (HEAT SHRINK) AROUND BRAIDED SHIELD, LEAVING ITEM 4 EXPOSED.

6. SOLDER ITEM 4 (DRAIN WIRE) TO BRAIDED SHIELD.

5. STRIP .25" OF ITEM 4 (DRAIN WIRE) BOTH ENDS.

4. STRIP .75" OF OUTER JACKET, EXPOSING BRAIDED SHIELD.

8. ATTACH ITEM 6 (HEAT SHRINK), EXPOSING 4.0" OF 4 WIRES.

9. STRIP .25" FROM ALL WIRES.

11. CRIMP ITEM 2 TO ITEM 4 (DRAIN WIRE) USING CRIMP TOO L AMP59824-01 (#42).

10. CRIMP ITEM 9 TO EARTH GROUND WIRE USING CRIMP TOOL AMP59824-01 (#42).

12. REPEAT STEPS 3,10 & 11 ON BOTH ENDS.

STEP 2: DRAIN WIRE & SHRINK SLEEVING

DETAIL -B-

LENGTH -L-

6.0

DRAIN WIRE

BOTH ENDS

BRAIDED SHIELD

2.5"

1.5"

.75

DRAIN WIRE

4.0

WIRE 1

THIS END WIRED

WIRE 3

WIRE 2

GROUND WIRE

TO DIGITAL DISPLAY TO JUNCTION BOX

.25

Figure 2-5: AC Cable Assembly (ref. dwg #704-1102)

2-14 Installation

September 2007

Wiring The Line Power (cont.)

1. Attach a cable or conduit with the three conductors to the right cable entry port on the display controller.

Caution!

Be sure that the input voltage is within the specified limits for

your OxyTrak™ 390.

2. Connect the line power leads as follows: a. Connect the line power lead to the LIVE pin (J2, pin #2) on the

power connector.

b. Connect the neutral power lead to the NEUT pin (J2, pin #1) on

the terminal block.

c. Connect the ground power lead to the earth ground connection

in the enclosure.

IMPORTANT: Do not alter any of the factory-wired power

connections in your OxyTrak™ 390.

This completes the wiring of the OxyTrak™ 390. Proceed to Chapter 3, Operation, for instructions on using the analyzer.

Installation 2-15

September 2007

CALIBRATION FLOWMETER

(0 - 300 CC/MIN)

1/4" CALIBRATION PORT INLET

(1/4" : 6MM ADAPTER FITTING OPTIONAL)

3.35 (85)

3x 1/2" NPT ADAPTERS

9.11 (231)

14.23 (361)

7.45

(189)

22.86 (581)

DIMENSIONS ARE IN INCHES (MILLIMETERS).

6.27 (159)

9.84 (250)

2.42 (61)

.75

(19)

EXTERNAL GROUND HARDWARE

1 1/2" NPT

Figure 2-6: Outline and Installation Drawing - Local Controller (ref. dwg #712-1256, sht. 1)

Installation 2-17

4.22 (107)

19.84 (504)

8.80 (224)

7.80

(198)

September 2007

4.00 (102)

2.86 (73)

5.00

(127)

RECOMMENDED

CLEARANCE

5X 1/2" NPT ADAPTERS

REMOTE CABLES 10', 25', 50', 100'

4.49 (114)

4x Ø.37 (9)

DIMENSIONS ARE IN INCHES (MILLIMETERS).

Installation 2-18

Figure 2-7: Outline and Installation Drawing - Remote Controller (ref. dwg #712-1256, sht. 2)

GASKET

MOUNTING PLATE

2" SCH 80

MOUNTING PIPE

September 2007

MOUNTING SURFACE

SHROUD

APPROX .12"

HARDWARE

MOUNTING FLANGES

4.50" MIN

1 7/8" MIN

3/4" SLEEVE

1/4" PROBE

1/3 OF STACK DIAMETER

OR 1-2 FT

(WHICHEVER IS LESS)

Installation 2-19

Figure 2-8: Outline and Installation Drawing - Mounting Details (ref. dwg #712-1256, sht. 3)

T/C FURNACE

T/C MANIFOLD

FURNACE

September 2007

ANALYZER MECHANICALS SHOWN AS REFERENCE ONLY

COMBUSTIBLE SENSOR

O2 SENSOR INNER LEAD = (+) OUTER LEAD = (-)

LEFT HEATER CARTRIDGE (LHC)

RIGHT HEATER CARTRIDGE (RHC)

115/120 VAC 230/240 VAC

HEATERS

J3-1 OPEN

A/C IN

J2-2 LIVE

OPEN TB1-4 OPEN TB1-3 RHC TB1-2 LHC TB1-1

J3-3 OPEN

J3-2 OPEN

GND

J2-1 NEUT

TB1-8 LHC TB1-7 OPEN TB1-6 FURNACE TB1-5 FURNACE

LHC TB1-4 RHC TB1-3 RHC TB1-2 OPEN TB1-1

COMB

SENSOR

J4-1 ACT / BLK

J4-2 REF / G RN

J4-3 ACT / RED

O2 OPEN

J1-2 02(–)

J1-1 02(+)

J5-4 OPEN

FOR USE WITH

704-668-XX CABLE

TEMP

REMOTE

CONTROL

J4-4 REF / YEL

J6-1 CJC (+)

J6-2 CJC (–)

J5-3 OPEN

J5-2 OPEN

J5-1 OPEN

RS485

J6-3 T/C FURN (+)

J6-4 T/C FURN (–)

J6-5 T/C MAIN (+)

J6-6 T/C MAIN (–)

J9-1 COM

J13-1 DRTN

J13-2 12V

J13-3 (–)

J13-4 (+)

4-20mA OUTPUT RELAYS RELAYS

FIELD

ABC A B C D

BUS

(–)

(+)

J15-2 (–)

J15-1 (+)

J11-6 (–)

J7-6 COM

J11-5 (+)

J11-4

J11-3

J11-2

J11-1

RS232

J14-1 OUT

J14-2 IN

J14-3 EN

WHT

RED

GRN

RELAYS

EFGH

J9-2 NO

J7-5 NO

RELAYS

J9-3 NC

J9-4 COM

J9-5 NO

J9-6 NC

J10-1 COM

J10-2 NO

J10-3 NC

J10-4 COM

J10-5 NO

J10/6 NC

COM

J7-4 NC

J7-3

J7-2

J7-1

J8-6

J8-5

J8-4

J8-3

J8-2

J8-1

TB1-8 LHC TB1-7 RHC TB1-6 FURNACE TB1-5 FURNACE

Installation 2-20

Figure 2-9: Wiring Diagram - Horizontal, Local Electronics (ref. dwg #702-623)

T/C FURNACE

T/C MANIFOLD

FURNACE

September 2007

TWISTED PAIRS

ANALYZER MECHANICALS SHOWN FOR REFERENCE ONLY

CJC (+)YEL

J1-1

CONTROL

T/C FURN (YEL)TB1-7

TEMP

CONTROL

CJC (–)BLK

T/C FURN (+)BLU

J1-2

J1-3

TEMP

COMB

SENSOR

T/C FURN (RED)TB1-6

T/C MAIN (YEL)TB1-5

T/C MAIN (RED)TB1-4

O2 (+)TB1-3

O2 (–)TB1-2

ACT / BLKTB1-1

COMB

SENSOR

T/C MAIN (–)BLK

O2 (+)WHT

O2 (–)BLK

CO ACT / BLKRED

T/C FURN (–)BLK

T/C MAIN (+)BRN

J1-6

J2-1

J2-2

J3-1

J1-4

J1-5

REF / GRNTB2-7

ACT / REDTB2-8

REF / YELTB2-9

OPENTB2-10

OPENTB2-11

OPENTB2-12

CO REF / GRNBLK

CO ACT / REDGRN

CO REF / YELBLK

OPEN

J3-2

J3-3

J3-4

J4-1

J4-2

J4-3

704-1104-XX SIGNAL CABLE ASSEMBLY

OPENTB2-13

JUNCTION

BOX

OPEN

J4-4

704-1102-XX A/C CABLE ASSEMBLY

COMBUSTIBLE SENSOR

O2 SENSOR INNER LEAD = (+) OUTER LEAD = (-)

LEFT HEATER CARTRIDGE (LHC)

RIGHT HEATER CARTRIDGE (RHC)

HEATERS

115/120

TB3-4 OPEN

TB3-3 OPEN

TB3-2 RHC

HEATERS

TB3-4 LHC

TB3-3 RHC

TB3-2 RHC

INSTALL JUMPER BETWEEN TB3-3 & TB3-4

HEATERS

WIRE 1 J5-1 MANIFOLD

WIRE 2 J5-2 FURNACE

WIRE 3 J5-3 COMMON

VAC

TB3-1 LHC

TB4-4 FURNACE

TB4-3 RHC

TB4-2 LHC

TB4-1 FURNACE

230/240

VAC

TB3-1 OPEN

TB4-4 FURNACE

TB4-3 OPEN

TB4-2 LHC

TB4-1 FURNACE

DISPLAY

CONTROLLER

TWISTED

PAIRS

704-668-XX CABLE

COMB

SENSOR

RED J4-1 ACT / BLK

BLK J4-2 REF / GRN

GRN J4-3 ACT / RED

O2 OPEN

J5-4 OPEN

BLK J1-2 02(–)

WHT J1-1 02(+)

FOR USE WITH

RS232

J14-1 OUT

J14-2 IN

J14-3 EN

WHT

RED

GRN

HEATERS

WIRE 1 J3-3 MANIFOLD

WIRE 2 J3-2 FURNACE

WIRE 3 J3-1 COMMON

A/C IN

GND

J2-1 NEUT

J2-2 LIVE

TEMP

REMOTE

CONTROL

RS485

J13-2 12V

J13-3 (–)

BLK J4-4 REF / YEL

J5-3 OPEN

J13-1 DRTN

YEL J6-1 CJC (+)

BLK J6-2 CJC (–)

BLU J6-3 T/C FURN (+)

BLK J6-4 T/C FURN (–)

BRN J6-5 T/C MAIN (+)

BLK J6-6 T/C MAIN (–)

FIELD

4-20mA OUTPUT RELAYS RELAYS ABC A B C D

BUS

(–)

(+)

J5-2 OPEN

J5-1 OPEN

J15-2 (–)

J15-1 (+)

J11-6 (–)

J11-5 (+)

J11-4

J11-3

J11-2

RELAYS

EFGH

J13-4 (+)

J9-1 COM

(+)

J11-1

J7-6 COM

RELAYS

J9-2 NO

J9-3 NC

J9-4 COM

J9-5 NO

J9-6 NC

J10-1 COM

J10-2 NO

J10-3 NC

COM

J7-5 NO

J7-4 NC

J7-3

J7-2

J7-1

J8-6

J8-5

J8-4

J10-4 COM

J10-5 NO

J10-6 NC

COM

J8-3

J8-2

J8-1

Installation 2-21

Figure 2-10: General Purpose Wiring Diagram - Remote Assembly (ref. dwg #702-625)

Chapter 3

Operation

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Preventing Common Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Cleaning the Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Powering Up the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Entering Programming Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Exiting Programming Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Powering Down the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Taking Measurements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

September 2007

Introduction The OxyTrak™ 390 Flue Gas Analyzer is a monitoring device that is

very simple to operate. Once it has been properly installed and set up, it simply begins taking readings. However, the analyzer should be allowed to warm up for at least 50 minutes prior to use. Refer to Chapter 2, Installation, if all of the required installation requirements have not yet been completed.

!WARNING!

To ensure safe operation, the OxyTrak™ 390 must be

installed and operated as described in this manual. Also, be

sure to follow all applicable local safety codes and

regulations for installing electrical equipment.

This chapter includes discussions of the following topics:

• preventing common problems

• powering up the system

Preventing Common Problems

• programming the analyzer

• taking measurements

Due to the extreme conditions in monitoring flue gases and the complexity of the OxyTrak™ 390’s measurement techniques, some simple precautions should be taken. Failure to observe these basic procedures can lead to operational difficulties. Compliance with the following instructions will help to eliminate such common problems:

• Do not use pipe thread compounds on any part of the OxyTrak™

390. Many pipe thread compounds emit combustible vapors that

may cause inaccurate readings.

• Do not handle the oxygen sensor any more than is absolutely

necessary. Scratches on the platinum electrode or the transfer of skin oils to the electrode can cause erroneous readings.

• Installing a cold probe assembly into a hot flue gas stream can

cause damage to the sensor. Always allow the probe assembly to gradually heat up to normal operating temperature, before subjecting it to hot flue gases.

• Be sure the unit has exited “Warm-up” mode prior to use.

If any problems not covered in this manual are encountered, contact a GE Sensing representative for assistance.

Operation 3-1

September 2007

Cleaning the Enclosure If the display window or the case of the OxyTrak™ 390 becomes

soiled, use a soft cloth dampened with water for cleaning. Never use solvents or detergents to clean the OxyTrak™ 390.

Powering Up the System Check the wiring connections and make sure all the OxyTrak™ 390

covers are closed and secured before applying power. Then, energize the external disconnect device to power up the OxyTrak™ 390 and allow the analyzer to warm up for at least 50 minutes before taking measurements.

IMPORTANT: For compliance with the European Union’s Low

The Display and Keypad The front panel of the digital controller supplied with the OxyTrak™

390, whether located locally or remotely, includes the components

shown in Figure 3-1 below.

Mode

Value

Units

Lock Indicator

Arrow Keys

ESC ENT

Enter KeyEscape Key

Figure 3-1: Digital Controller Display and Keypad

Note: The OxyTrak™ 390 digital controller has an integral keypad,

which permits programming of the instrument without opening the cover. Thus, all programming procedures may be performed while the unit is installed in a hazardous environment.

3-2 Operation

September 2007

Entering Programming Mode

The OxyTrak™ 390 software enables the operator to configure the meter for his specific requirements. T o accomplish this, it is necessary to leave normal run mode and enter Programming Mode as follows:

Make sure you are at the normal run mode screen. The closed black padlock indicates that the user program is currently locked.

While in normal run mode, press

[ESC], [ENTER], and [ESC] keys in

the sequence. Notice that the black padlock is now open.

Use the arrow keys to select the padlock (it will change to white on a black background). Then, press

[ENTER] key.

the

Use the arrow keys to select the

[Passcode] option. Then, press the [ENTER] key.

There are two different passcodes that can be used at the next screen:

• User-Level: passcode = 2719

(see Chapter 4, Setting Up the Display, and Chapter 5, General Programming, for instructions)

• Service- Level Access: passcode = 7378

(see Chapter 6, Advanced Programming, for instructions)

Use the arrow keys as indicated to enter the desired press the

[ENTER] key.

[Passcode]. Then,

Operation 3-3

September 2007

Entering Programming Mode (cont.)

Regardless of the password that was entered at the previous screen, this will be the first programming screen.

Exiting Programming Mode

The are two different ways to leave the OxyTrak™ 390 programming mode. These are described in the following sections.

Temporary Exit To temporarily leave Programming Mode, proceed as follows:

From any point in the user program, press the repeatedly until the run mode screen appears.

Notice that the padlock is open to indicate that programming mode is unlocked. Also, the current programm ing level is indicated just below the padlock:

[ESC] key

• M1 - indicates that the 2719 passcode is in effect.

• M2 - indicates that the 7378 passcode is in effect.

T o reenter programming mode, use the arrow keys to select the M1 or M2 symbol and press the

[ENTER] key.

Locking Programming Mode

3-4 Operation

To lock programming mode, use the arrow keys to select the padlock symbol and press the

[Lock Menus] option will permit reentry to programming mode for

The programming the display only. All other programming functions will be locked out. The programming mode and restore the black, closed padlock.

Note: If the unit is powered down, Programming Mode will be

locked when the unit is powered up again.

[ENTER] key. Then, proceed as follows:

Use the arrow keys to select either

[Lock Keypad] option or the

the

[Lock Menus] option. Then, press

[ENTER] key.

the

[Lock Keypad] option will completely lock out

September 2007

Powering Down the System

Powering down the OxyTrak™ 390 system is as simple as cutting the power to the system at the main disconnect device. However, be sure to heed the warning below.

!WARNING!

If the analyzer is left installed without power, the unit’s

components become susceptible to acid condensation that

will cause corrosion.

If the power must be removed for more than thirty

minutes, purge the analyzer through the calibration port

with a continuous flow of instrument air at a minimum rate

of 150 cc/min (0.3 SCFH).

Taking Measurements Allow the OxyTrak™ 390 to warm up sufficiently before taking any

measurements. Readings are output to the LCD Display in the format programmed into the system.

If the LCD Display is not included in the system, you may use Equation 3-1 below to convert the OxyTrak™ 390 analog output reading into percent oxygen.

(mV) 48.273

700

⎧⎫

------------------------------------------------- -

log×=

⎨⎬

% O2 in Sample Gas

⎩⎭

20.9

(3-1)

Note: See Appendix A, The Nernst Equation, for more details on how

to perform similar calculations at other operating temperatures.

Although percent oxygen can still be measured without the LCD Display , the measurement of combustibles can NOT be accomplished without the LCD Display.

Operation 3-5

Chapter 4

Setting Up the Display

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Selecting the Number of Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Adjusting the Display Contrast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Selecting the Measurement Mode and Units . . . . . . . . . . . . . . . . . . . . . . . 4-4

Measurement Units Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

September 2007

Introduction Although the OxyTrak™ 390 is set up at the factory with default

values that are suitable for many applications, the User Program provides a means for customizing many of the meter parameters.

IMPORTANT: This chapter discusses only those programming

options available at the 2719 passcode access level. For additional options available at the 7378 passcode level, see Chapter 6, Advanced Programming.

The following procedures for configuring the LCD Display are described in this chapter:

• selecting the number of display views

• adjusting the display contrast

• selecting the measurement mode/display parameter

• selecting the measurement units

Note: While in the User Program, press

current operation and return to the previous menu level.

Access the User Program as described on page 3-3, and refer to the menu map in Figure B-1 on page B-1 while programming the OxyTrak™ 390 display.

This is the initial programming screen.

From the Main Menu screen above, proceed directly to the appropriate section to perform the desired programming task.

[ESC] at any time to abort the

Setting Up the Display 4-1

September 2007

Selecting the Number of Views

The OxyTrak™ 390 can be easily configured to display 1, 2, or 3 views. To do so, proceed as follows:

Use the arrow keys to select the

[# of Views] option and press [ENTER].

Use the arrow keys to select the desired option and press

[ENTER].

You will then be returned to the

[Display] main menu.

After your selection, press

[ESC] to return to the standard run mode

screen, and depending on the option selected above, your display will look like one of the following:

This is a display configured to show 1 view.

This is a display configured to show 2 views.

This is a display configured to show 3 views.

Note: Any of the measurement modes or measurement units in any

of the displayed views may be programmed by selecting it with the arrow keys and pressing

[ENTER]

4-2 Setting Up the Display

September 2007

Adjusting the Display Contrast

After entering the User Program, as described on page 3-3, the Main Menu appears. To adjust the contrast of the LCD display, proceed as

follows:

Use the arrow keys to select the

[Display] option and press [ENTER].

Use the arrow keys to select the

[Contrast] option and press [ENTER].

Note: The

[Normal] and [Reverse] options in the above menu are used

to toggle the display between the normal (black text on a white background) display and a reverse (white text on a black background) display.

Use the keypad, as indicated, to set the desired contrast percentage and

[ENTER]. You will be returned

press to the previous menu.

[ESC] twice to exit the User Program, and return to the normal

Press run mode screen.

Setting Up the Display 4-3

September 2007

Selecting the Measurement Mode and Units

T o select the measuremen t mode/display parameter and measurement units, from the run mode screen proceed as follows:

Use the arrow keys to highlight the measurement mode/display parameter and press

[ENTER].

Use the arrow keys to select the desired parameter to be displayed and press

[ENTER].

Use the arrow keys to select the desired units for the selected measurement mode (see Table 4-1 below) and press

[ENTER] to return

to run mode.

Table 4-1: Available Measurement Units

Measurement Mode Measurement Units

Oxygen

Combustibles

Sens. mV

ppm

Furnace Temp

°C

°F

Note: If you only wish to change the measurement units, you may

use the arrows to highlight the units on the run mode screen to go directly to the

[Units] menu for the current measurement

mode.

4-4 Setting Up the Display

September 2007

Measurement Units Description

As indicated in Table 4-1 on the previous page, there are several measurement units available for the various measurement modes. Although some of these options are obvious, others require a bit of explanation. The available units are as follows:

• % - this is the percentage of the specified parameter, by volume, in

the sample gas.

• Sens. mV - this is the raw oxygen sensor millivolt output, which

indicates the condition of the oxygen sensor.

• ppm - this is the parts per million of the specified parameter, by

volume, in the sample gas.

• °C or °F - this is the furnace temperature on the scale indicated.

Setting Up the Display 4-5

Chapter 5

General Programming

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Setup Menu (Real Time Clock) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Calibrate Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Output Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Relays Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Communications Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

September 2007

Introduction Although the OxyTrak™ 390 is set up at the factory with default

values that are suitable for many applications, the User Program provides a means for customizing many of the meter parameters.

Note: See the Calibration Sheet included with the OxyTrak™ 390

and Appendix F in this manual for the factory default settings. If the Calibration Sheet is lost, contact the factory.

IMPORTANT: This chapter discusses only those programming

options available at the 2719 passcode access level. For additional options available at the 7378 passcode level, see Chapter 6, Advanced Programming.

The following submenus are included in the Main Menu of the OxyTrak™ 390 User Program:

• Display (see Chapter 4 for instructions)

• Calibrate

• Output

• Relays

• Communications

• Setup

• Factory

Note: While in the User Program, press

current operation and return to the previous menu level.

Access the User Program (as described on page 3-3) at the 2719 passcode level, and refer to Figure B-1, Figure B-2 and Figure B-3 in Appendix B, while programming the OxyTrak™ 390 features described in this chapter.

Proceed to the appropriate section to program the desired meter function(s).

[ESC] at any time to abort the

General Programming 5-1

September 2007

Setup Menu (Real Time Clock)

The options available in the [Setup] menu at the 2719 passcode level are the

[Clock] submenus and [Comb_ppm Clamp]. To set the

OxyTrak™ 390 real time clock, proceed as follows:

IMPORTANT: The real time clock must

be set before programming an

automatic calibration schedule.

At the Main Menu, use the arrow keys to select the

[ENTER] to access the [Clock]

Press

[Setup] submenu.

option.

The five clock parameters are now available for programming. Use the arrow keys to select the desired parameter, and press

[ENTER].

Use the arrow keys as indicated to enter the desired value for the chosen parameter. When done, press

[ENTER].

The two screens above show the programming of the to a value of 2005. repeat the same procedure to set the

[Hour], and [Minute] parameters to the desired values.

[Year] parameter

[Month], [Day],

When you have finished programming the [Setup] menu, press [ESC] until you return to normal run mode.

5-2 General Programming

September 2007

Calibrate Menu A variety of calibration procedures may be used with the OxyTrak™

390 (see page 7-2). As all of the procedures are very similar, only the

manual and automatic procedures for performing a one-gas oxygen calibration will be described in step-by-step detail. The other procedures are presented in Appendix C, Calibration Methods. (Refer to Figure 2-6 on page 2-17 for port locations.)

Manual, One-Gas Oxygen Calibration

To perform a manual O2 calibration with one calibration gas, access the user program as described on page 3-3 and proceed as follows:

IMPORTANT: As an example, these instructions assume the factory

default settings of a 5.00% calibration gas, a ±0.02%

calibration tolerance, and a maximum allowable

furnace temperature change of 20°C. See Chapter 6, Advanced Programming, for instructions on changing

these values.

[Display] submenu of the

At the Main Menu, press the [

At the

[Calibrate] submenu of the

X] key.

Main Menu, use the arrow keys to select the

[ENTER].

[Manual] option and press

Use the arrow keys to select the

[Oxygen] option and press [ENTER].

The current calibration data is displayed. Start the calibration (span) gas flow. When mV and % have settled, press [ENTER].

General Programming 5-3

September 2007

Manual, One-Gas Oxygen Calibration (cont.)

Turn off the calibration gas flow. Allow the reading to return to process, then press

[ENTER].

After the calibration is completed, press [ESC] twice to return to normal run mode. If O

, refer to Appendix G for thermal calibration.

Manual, Two-Gas Combustibles Calibration

To perform a manual combustibles calibration with two calibration gases:

1. Enter the oxygen sensor’s calibration menu from the main menu as in the previous section.

2. Supply zero gas at the flow rate ente red in the analyzer.

Note: The flow rate is entered in the analyzer by using the Factory

Menu, Comb Cal / Setup / Q Cal).

3. After ten minutes, press [ENTER].

4. Supply span gas at the same flow rate.

5. After ten minutes, press [ENTER].

6. Press [ENTER] again to save calibration data.

7. Shut off the span gas.

8. Press [ESC] as required to return to the main menu.

5-4 General Programming

September 2007

Automatic, One-Gas Oxygen Calibration

To perform an automatic one-gas O2 calibration, access the user program as described on page 3-3 and proceed as follows:

IMPORTANT: As an example, these instructions assume the factory

default settings of a 5.00% calibration gas, a ±0.02%

calibration tolerance, and a maximum allowable

furnace temperature change of 20°C. See Chapter 6, Advanced Programming, for instructions on changing

these values.

[Display] submenu of the

At the Main Menu, press the [

At the

[Calibrate] submenu of the

X] key.

Main Menu, use the arrow keys to select the

[ENTER].

[Autocal] option and press

Seven options are now available for programming. Proceed to the appropriate section to program the desired option.

After you have completed the programming of the OxyTrak™ 390 Autocal process. Press

[ESC] until you return to normal run mode and

the meter will perform automatic calibrations according the settings programmed in this section.

General Programming 5-5

September 2007

Autocal Interval Program the time interval between Autocals as follows:

Use the arrow keys to select the

[Interval] option, and press [ENTER].

Use the arrow keys to select the

[Hours] option (or see below for the [Days] option), and press [ENTER].

Use the arrow keys to select the desired number of hours between Autocals, and press

[ENTER].

Use the arrow keys to select the

[Days] option (or see above for the [Hours] option), and press [ENTER].

Use the arrow keys to select the

[Days] option, and press [ENTER].

Use the arrow keys as indicated to enter the desired value. When done, press

[ENTER].

5-6 General Programming

Autocal Interval (cont.)

September 2007

Use the arrow keys to select the

[Start Time] option, and press [ENTER].

Use the arrow keys to select the

[Hour] option, and press [ENTER].

Use the arrow keys as indicated to enter the desired value. When done, press

[ENTER].

Use the arrow keys to select the

[Minute] option, and press [ENTER].

Use the arrow keys as indicated to enter the desired value. When done, press

[ENTER].

The OxyTrak™ 390 is now programmed to automatically perform calibrations at the interval programmed in this section. Press until you return to the initial

[Autocal] menu.

[ESC]

General Programming 5-7

September 2007

Gas Supply Time Program the length of time that the calibration gas will flow during an

Autocal as follows:

Use the arrow keys to select the

[Gas Supply Time] option, and press [ENTER].

Use the arrow keys as indicated to enter the desired time in minutes. When done, press

Now, whenever the OxyTrak™ 390 performs an Autocal, the calibration gas will flow for the length of time programmed above.

[ENTER].

Settling Time Program the length of time allowed for the calibration data to settle

during an Autocal as follows:

Use the arrow keys to select the

[Settling Time] option, and press [ENTER].

Use the arrow keys as indicated to enter the desired time in minutes. When done, press [ENTER].

Now, whenever the OxyTrak™ 390 performs an Autocal, the settling time allowed for the calibration data will be as programmed above.

5-8 General Programming

September 2007

Auto-Verification Failure As part of the Autocal process, the OxyTrak™ 390 periodically

verifies the current calibration. You can program the manner in which the meter responds to an Auto-Verification failure as follows:

Use the arrow keys to select the

[A/V Failure] option, and press [ENTER].

Use the arrow keys to select the desired option. The, press

[ENTER].

Oxygen Auto-Verification Tolerance

If you selected

[Alarm] above, an auto-verification failure will only

trigger the auto-verification alarm. However, if you selected

[Alarm+ReCal] above, an auto-verification failure will not only trigger

the auto-verification alarm, but it will also initiate an immediate calibration of the instrument.

In the previous section, you programmed the manner in which the OxyTrak™ 390 responds to an auto-verification failure. In this section, you define what constitutes a failure by specifying the maximum amount of variation in the oxygen calibration reading that will be tolerated. Proceed as follows:

Use the arrow keys to select the

[O2 A/V Tolerance] option, and press [ENTER].

Use the arrow keys as indicated to enter the desired tolerance value (in %O

[ENTER].

). When done, press

General Programming 5-9

September 2007

Combustibles AutoVerification Tolerance

This section is very similar to the previous section, except that it is used to program the auto-verification tolerance for the combustibles measurement. Proceed as follows:

Use the arrow keys to select the

[Comb A/V Tolerance] option, and

press

[ENTER].

Use the arrow keys as indicated to enter the desired tolerance value (in ppm combustibles). When done, press

[ENTER].

Auto Cal Now? This option may be used to force an immediate Autocal using the

currently programmed parameters. Proceed as follows:

Use the arrow keys to select the

[Yes] response of the [Auto Cal

Now?]

option (or see the next step).

Then, press

[ENTER].

Use the arrow keys to select the

[No] response of the [Auto Cal Now?]

option (or see the previous step). Then, press

[ENTER].

No matter which response you selected above, you will be returned to the main

[Calibrate] menu, press [ESC] until you return to normal run mode.

[Calibrate] menu. When you have finished programming the

5-10 General Programming

September 2007

Output Menu The [Output] menu is used to configure the OxyTrak™ 390 analog

outputs. To configure your outputs, proceed as follows:

At the Main Menu, use the arrow keys to select the Then, use the arrow keys to select the desired output to configure, and press

[ENTER].

[Output] menu.

Note: The setup of

[Output A] is shown here as an example. The other

outputs are programmed in a similar manner.

The four programmable output parameters are now available. Use the arrow keys to select the desired option, and press

[ENTER].

Proceed to the appropriate section to program the option selected at the above screen.

Measure The [Measure] option is used to specify the measured variable (%

oxygen, ppm oxygen, % combustibles, or ppm combustibles) that is sent to the output being programmed.

Use the arrow keys to select the

[Measure] option, and press [ENTER].

Use the arrow keys to select the desired output variable, and press

[ENTER].

The current OxyTrak™ 390 analog output will now display the data for the variable chosen above.

General Programming 5-11

September 2007

Type The [Type] option is used to specify the type of signal that is used for

the analog output being programmed.

Use the arrow keys to select the

[Type] option, and press [ENTER].

Use the arrow keys to select the desired output type, and press

[ENTER].

Note: The Namur NE43 specification requires a 4-20 mA output to

be clamped in specific bands to indicate out-of-range errors.

If you select

[Zero] and [Span] values of your choosing for the analog output

the

[Special] at the above prompt, you will be able to specify

range.

Range The [Range] option is used to specify the [zero] and [span] points of

the analog output range, as a percentage of the output variable range.

Use the arrow keys to select the

[Range] option, and press [ENTER].

Use the arrow keys to select the

[Zero] option, and press [ENTER].

Use the arrow keys as indicated to enter the desired output range. When done, press

[ENTER].

[Zero] point of the

5-12 General Programming

Range (cont.)

September 2007

Use the arrow keys to select the

[Span] option, and press [ENTER].

Use the arrow keys as indicated to enter the desired

[Span] point of the

output range. When done, press

[ENTER].

Trim

The [Trim] option is used to fine-tune the analog output parameters.

Use the arrow keys to select the

[Trim] option, and press [ENTER].

Use the arrow keys to select the

[Base Trim] option, and press [ENTER].

Use the arrow keys as indicated to specify the

[Zero] point of the

analog output. When done, press

[ENTER].

Use the arrow keys to select the

[Span Trim] option, and press [ENTER].

Use the arrow keys as indicated to specify the

[Span] point of the

analog output. When done, press

[ENTER].

General Programming 5-13

September 2007

Trim (cont.) The [%] option is used to output a signal at a specified percentage of

the analog output range during a

[Test] cycle.

Use the arrow keys to select the option, and press

Use the arrow keys as indicated to specify the

[Test] cycle. When done, press

[ENTER].

[Mode] option is used to test the analog output.

The

Use the arrow keys to select the

[Mode] option, and press [ENTER].

[%]

[ENTER].

[%] to be output during

Use the arrow keys to select the

[Test] option, and press [ENTER].

The analog output should now be reading a value equal to the percentage of full scale programmed into the

[%] option above (if it

does not, contact the factory for assistance). After you verify this, continue as follows:

Use the arrow keys to select the

[Normal] option, and press [ENTER].

IMPORTANT: Be sure to set the output to the

you leave the

[Trim] menu.

[Normal] mode before

5-14 General Programming

September 2007

Cal Setting The [Cal Setting] option is used to specify the manner in which the

OxyTrak™ 390 handles measurement readings during a calibration.

Use the arrow keys to select the

[Cal Setting] option, and press [ENTER].

Use the arrow keys to select the desired option (see description below). When done, press

[ENTER].

The available options at the above prompt are as follows:

• [Hold Last Value] - The last valid measurement taken prior to the

calibration is displayed while a calibration is in progress.

• [User Selectable] - The user chooses the measurement value that is

displayed while a calibration is in progress.

• [Live Output] - The instrument continues to display the actual

current measurement value while a calibration is in progress.

If you select returned to the previous menu. If you choose continue as follows:

[Hold Last Value] or [Live Output], you are immediately

[User Selectable],

At the

[Specific Value] option, press

[ENTER].

Use the arrow keys as indicated to enter a value. When done, press

[ENTER].

When you have finished programming the

[Outputs] menu, press [ESC]

until you return to normal run mode.

General Programming 5-15

September 2007

Relays Menu The [Relays] menu is used to program the OxyTrak™ 390 alarm relays

A-D and to test the system control relays E-H. T o program and/or test your relays, proceed to the appropriate section.

Relays A-D To program the alarm relays A-D, proceed as follows:

At the Main Menu, use the arrow keys to select the Then, use the arrow keys to select the desired alarm relay to configure, and press

[Relays] menu.

[ENTER].

Note: The setup of alarm

[Relay A] is shown here as an example.

Relays B, C, and D are programmed in a similar manner.

The three programmable relay options are now available. Use the arrow keys to select the desired option, and press

[ENTER].

Proceed to the appropriate section to program the option selected at the above screen.

Type The [Type] option is used to specify the general category of

parameters to which the alarm relay being programmed will respond.

Use the arrow keys to select the

[Type] option, and press [ENTER].

Highlight a type and press to select it, as indicated by a

[ENTER]

[*] to

its left. Repeat to select as many types as desired, then press

[ESC].

The current OxyTrak™ 390 alarm relay will now respond to the types of parameters chosen above.

Note: The next section provides instructions for selecting the

specific parameters to be included in each of the three categories above.

5-16 General Programming

September 2007

Setting The [Setting] option is used to choose the specific parameters that are

included in each the details for the alarm’s response may be programmed.

[Measure] submenu:

The

[Type] category for triggering the alarm relay. Also,

Use the arrow keys to select the

[Setting] option, and press [ENTER].

Use the arrow keys to select the

[Measure] option, and press [ENTER].

Use the arrow keys to select the

[Type] option, and press [ENTER].

Use the arrow keys to select the desired option, and press

[ENTER].

Note: The alarm setpoint is the signal value at which the relay will

be triggered. A exceeds the setpoint; a

[High] relay is triggered when the signal

[Low] relay is trigger ed when the signal

drops below the setpoint.

Use the arrow keys to select the

[Setpoint] option, and press [ENTER].

General Programming 5-17

September 2007

Setting (cont.)

Use the arrow keys as indicated to specify the value for the alarm relay setpoint. When done, press

[ENTER].

The [Deadband] option is used to specify a range of valu es around the setpoint within which the relay will not reset after it has been triggered. This is to prevent the relay from cycling on and off in response to minor fluctuations near the setpoint.

Use the arrow keys to select the

[Deadband] option, and press [ENTER].

Use the arrow keys as indicated to specify the deadband value for the alarm relay. When done, press

[ENTER].

This completes the programming of the return to the

[Measure] menu.

Use the arrow keys to select the desired measurement parameter to trigger the alarm relay ( shown as an example). Then, press

[ENTER].

[Type] submenu. Press [ESC] to

[% O2] is

5-18 General Programming

Setting (cont.) The [Diag Errors] submenu:

Note: This submenu allows you to select one or more diagnostic

error signals for triggering the alarm relay.

Note: All three oxygen and three combustibles diagnostic err ors that

are available are listed above.

September 2007

Use the arrow keys to select the

[Diag Errors] option, and press [ENTER].

Highlight a diagnostic error type and press indicated by a

[ENTER] to select it, as

[*] to its left. Repeat

to select as many types as desired, then press

[ESC].

[System Faults] submenu:

The

Use the arrow keys to select the

[System Faults] option, and press [ENTER].

Note: This submenu allows you to select one or more system fault

signals for triggering the alarm relay.

Highlight a system fault type and

[ENTER] to select it, as

press indicated by a

[*] to its left. Repeat

to select as many types as desired, then press

[ESC].

Note: In addition to the seven system faults listed above, the

[Active RTD Under Range], [Ref RTD Over Range], and [Ref RTD Under Range] options are available in the above list.

General Programming 5-19

September 2007

Normal/Failsafe The [Normal/Failsafe] option is used to choose the mode of operation

for the alarm relay being programmed.

Note: A

[Normal] relay uses the normally-open contacts and must be

energized when a fault occurs; a normally-closed contacts and is de-energized when the fault occurs.

Use the arrow keys to select the

[Normal/Failsafe] option, and press [ENTER].

Use the arrow keys to select the desired option, and press

If you have finished programming the until you return to normal run mode.

[Failsafe] relay uses the

[ENTER].

[Outputs] menu, press [ESC]

5-20 General Programming

September 2007

Relays E-H Note: The control relays are configured at the factory to perform

their designated functions. These relays may not be reprogrammed at the 2719 passcode access level. However, the relays may be tested for proper operation.

To test the control relays E-H, proceed as follows:

At the Main Menu, use the arrow keys to select the Then, use the arrow keys to select the desired relay to configure, and

[ENTER].

press

[Relays] menu.

Note: The setup of

[Relay E] is shown here as an example. Relays F,

G, and H are programmed in a similar manner.

[Test] the relay, press [ENTER].

Use the arrow keys to select the

[Trip] option, and press [ENTER].

Physically verify that the relay has in fact been tripped. If it has not been tripped, contact the factory for assistance.

Use the arrow keys to select the

[Reset] option, and press [ENTER].

IMPORTANT: Be sure to

[Reset] the relay before leaving the [Relays]

menu.

If you have finished programming the

[Relays] menu, press [ESC] until

you return to normal run mode.

General Programming 5-21

September 2007

Communications Menu The [Communications] menu is used to configure the OxyTrak™ 390

communications port. RS232, RS485, and Ethernet ports are supported. To configure your port, proceed to the appropriate section.

RS232/RS485 Port As an example, the programming of an RS232 port with the factory

default settings is illustrated here. The programming of other configurations is done in a similar manner.

At the Main Menu, use the arrow keys to select the menu. Then, use the arrow keys to select the press

[Select Port] option, and

[ENTER].

Use the arrow keys to select the desired option, and press

[Communications]

[ENTER].

IMPORTANT: The choice you make above must correspond to the

actual wiring the was made to the meter during installation (see Chapter 2).

Use the arrow keys to select the

[Node ID] option, and press [ENTER].

Use the arrow keys as indicated to specify the port. When done, press

[Node ID] value for the

[ENTER].

Use the arrow keys to select the

[Port Settings] option, and press [ENTER].

5-22 General Programming

RS232/RS485 Port (cont.)

September 2007

Use the arrow keys to select the

[Baud Rate] option, and press [ENTER].

Use the arrow keys to select the desired baud rate, and press

[ENTER].

Use the arrow keys to select the

[Parity] option, and press [ENTER].

Use the arrow keys to select the desired parity , and press

[ENTER].

Use the arrow keys to select the

[Stop Bits] option, and press [ENTER].

Use the arrow keys to select the desired number of stop bits, and press

[ENTER].

General Programming 5-23

September 2007

RS232/RS485 Port (cont.)

Use the arrow keys to select the

[Data Bits] option, and press [ENTER].

Use the arrow keys to select the desired number of data bits, and press

[ENTER].

When you have finished programming the [Communications] menu,

[ESC] until you return to normal run mode.

press

Ethernet Port To configure an Ethernet port, proceed as follows:

Note: The

passcode level.

Use the arrow keys to select the

[Ethernet Settings] option, and press [ENTER].

Use the arrow keys to select the

[Port #] option, and press [ENTER].

Use the arrow keys as indicated to enter the value for the [Port #]. When done, press

[Port #] is the only programmable parameter at the 2719

[ENTER].

When you have finished programming the

[ESC] until you return to normal run mode.

press

5-24 General Programming

[Communications] menu,

Chapter 6

Advanced Programming

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Display, Relays, and Communications Menus . . . . . . . . . . . . . . . . . . . . . . 6-1

Output Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Calibrate Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Factory Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

September 2007

Introduction Although the OxyTrak™ 390 is set up at the factory with default

values that are suitable for many applications, the User Program provides a means for customizing many of the meter parameters.

IMPORTANT: This chapter discusses only those additional

programming options available at the 7378 passcode access level. For the options available at the 2719 passcode level, see Chapter 5, General Programming.

Display, Relays, and Communications Menus

Note: While in the User Program, press

current operation and return to the previous menu level.

Access the User Program as described on page 3-3, and refer to Figures B-4 to B-5 on pages B-4 to B-5 in Appendix B, Menu Maps, while programming the OxyTrak™ 390 features discussed in this chapter.

This is the initial programming screen.

From the Main Menu screen above, proceed directly to the appropriate section to perform the desired programming task.

There are no additional options that become available in these main menus at the 7378 passcode access level. See Chapter 4, Setting Up the Display, and Chapter 5, General Programming, for a full description of how to program these menus at the 2719 passcode access level.

[ESC] at any time to abort the

Advanced Programming 6-1

September 2007

Output Menu In the [Measure] option of the [Output] menu, the following two

additional choices are available at this passcode level:

• Furnace Temp °C

• Furnace Temp °F

Note: If necessary, see Chapter 5, General Programming, for

instructions on navigating to this menu.

Use the arrow keys to select the

[Measure] option, and press [ENTER].

Use the arrow keys to select the desired output variable, and press

[ENTER].

The current OxyTrak™ 390 analog output will now display the data for the variable chosen above. When you have finished p rogramming

[Output] menu, press [ESC] until you return to normal run mode.

the

Calibrate Menu In the [Autocal] option of the [Calibrate] menu, the following two

additional choices are available at this passcode level:

• O

Tolerance

• Comb Tolerance

Note: If necessary, see Chapter 5, General Programming, for

instructions on navigating to this menu.

At the [Calibrate] submenu of the Main Menu, use the arrow keys to select the

[ENTER].

[Autocal] option and press

6-2 Advanced Programming

September 2007

O2 Tolerance This option is used to define how close the actual oxygen reading

must be to the calibration gas specification for a calibration to be considered complete. Proceed as follows:

Use the arrow keys to select the

[O2 Tolerance] option, and press [ENTER].

Use the arrow keys as indicated to enter the desired tolerance value (in %O

[ENTER].

). When done, press

When you have finished programming the

[ESC] until you return to normal run mode.

[Calibrate] menu, press

Combustibles Tolerance This section is very similar to the previous section, except that it is

used to program the tolerance for the combustibles calibration. Proceed as follows:

Use the arrow keys to select the

[Comb Tolerance] option, and press [ENTER].

Use the arrow keys as indicated to enter the desired tolerance value (in ppm combustibles). When done, press

When you have finished programming the

[ESC] until you return to normal run mode.

[ENTER].

[Calibrate] menu, press

Advanced Programming 6-3

September 2007

Setup Menu The [Setup] menu has several additional options that become available

at this passcode level. Proceed to the appropriate section to program any of these new options.

Note: If necessary, see Chapter 5, General Programming, for

instructions on navigating to this menu.

O2 Sensor Temp This option is used to specify the operating temperature of the

zirconium oxide oxygen sensor (factory default = 700°C).

At the

[Setup] submenu of the Main

Menu, use the arrow keys to select

[O2 Sensor Temp] option and

the

[ENTER].

press

Use the arrow keys to select the desired operating temperature from the list or choose the option. Then, press

[Custom]

[ENTER].

If you chose the above, press

[Custom] option

[ENTER] to program

this option.

If you chose the

[Custom] option

above, use the arrow keys as indicated to enter the desired operating temperature. When done,

[ENTER].

press

When you have finished programming the [Setup] menu, press [ESC] until you return to normal run mode.

6-4 Advanced Programming

September 2007

Heater Block Temp This option is used to specify the operating temperature of the heater

block (factory default = 220°C).

[Setup] submenu of the Main

At the Menu, use the arrow keys to select

[Heater Block Temp] option and

the press

[ENTER].

To program the

[ENTER].

press

Use the arrow keys as indicated to enter the desired heater block temperature. When done, press

[ENTER].

When you have finished programming the until you return to normal run mode.

[Custom] option,

[Setup] menu, press [ESC]

Advanced Programming 6-5

September 2007

Auto Cal Method This option is used to configure the OxyTrak™ 390 for the type of

calibration method you wish to use (see Appendix C, Calibration Methods, for details on the various choices).

[Setup] submenu of the Main

At the Menu, use the arrow keys to select the

[Cal Method] option and press

[ENTER].

Use the arrow keys to select the desired calibration method from the list. Then, press

Proceed to the appropriate subsection to complete the programming of your chosen Cal method.

[ENTER].

1-Gas Oxygen This method is used to perform an oxygen calibration with one

calibration gas.

To program the O2 span gas, press

[ENTER].

Use the arrow keys as indicated to enter the span gas oxygen percentage. When done, press

[ENTER].

When you have finished programming the

[ESC] until you return to normal run mode.

[Cal Method] menu, press

6-6 Advanced Programming

September 2007

2-Gas Oxygen This method is used to perform an oxygen calibration with two

calibration gases.

Use the arrow keys to select the

[Zero O2] option. Then, press [ENTER].

Use the arrow keys as indicated to enter the zero gas oxygen percentage. When done, press

[ENTER].

Use the arrow keys to select the

[Span O2] option. Then, press [ENTER].

Use the arrow keys as indicated to enter the span gas oxygen percentage. When done, press

[ENTER].

When you have finished programming the

[ESC] until you return to normal run mode.

[Cal Method] menu, press

Advanced Programming 6-7

September 2007

1-Gas Oxygen and Combustibles

This method is used to perform both an oxygen calibration and a combustibles calibration with one calibration gas.

To program the O

[ENTER].

press

* span gas,

Use the arrow keys as indicated to enter the span gas oxygen

percentage (combustibles must be 0 ppm). When done, press

When you have finished programming the

[ESC] until you return to normal run mode.

[Cal Method] menu, press

[ENTER].

6-8 Advanced Programming

September 2007

2-Gas Oxygen and Combustibles

This method is used to perform both an oxygen calibration and a combustibles calibration with two calibration gases.

Note: This method has two variations. One of the calibration gases

is always used for one of the oxygen points and the low combustibles point. However, the second calibration gas may be used for either the high oxygen point or the high combustibles point. Only one of the variations is shown here as an example.

Use the arrow keys to select the

[1O2 2HC] option. Then, press [ENTER].

Use the arrow keys to select the

[Span O2*] option. Then, press [ENTER].

Use the arrow keys as indicated to enter the span gas oxygen

percentage (combustibles must be 0 ppm). When done, press

Use the arrow keys to select the

[Span HC] option. Then, press [ENTER].

Use the arrow keys as indicated to enter the span gas combustibles ppm. When done, press

When you have finished programming the

[ESC] until you return to normal run mode.

[ENTER].

[Cal Method] menu, press

Advanced Programming 6-9

September 2007

3-Gas Oxygen and Combustibles

This method uses three calibration gases to perform the oxygen and combustibles calibrations. One of the gases is used for both an oxygen point and the 0 ppm combustibles point.

Use the arrow keys to select the

[Zero O2] option. Then, press [ENTER].

Use the arrow keys as indicated to enter the zero gas oxygen percentage. When done, press

[ENTER].

Use the arrow keys to select the

[Span O2*] option. Then, press [ENTER].

Use the arrow keys as indicated to enter the span gas oxygen

percentage (combustibles must be 0 ppm). When done, press

Use the arrow keys to select the

[Span HC] option. Then, press [ENTER].

Use the arrow keys as indicated to enter the span gas combustibles ppm. When done, press

When you have finished programming the

[ESC] until you return to normal run mode.

[ENTER].

[Cal Method] menu, press

6-10 Advanced Programming

September 2007

4-Gas Oxygen and Combustibles

This method uses four calibration gases, 2 for oxygen and 2 for combustibles, to perform the oxygen and combustibles calibrations.

Use the arrow keys to select the

[Zero O2] option. Then, press [ENTER].

Use the arrow keys as indicated to enter the zero gas oxygen percentage. When done, press

[ENTER].

Use the arrow keys to select the

[Span O2] option. Then, press [ENTER].

Use the arrow keys as indicated to enter the span gas oxygen percentage. When done, press

[ENTER].

Use the arrow keys to select the

[Zero HC] option. Then, press [ENTER].

Use the arrow keys as indicated to enter the zero gas combustibles ppm. When done, press

[ENTER].

Advanced Programming 6-11

September 2007

4-Gas Oxygen and Combustibles (cont.)

When you have finished programming the [Auto Cal Method] menu,

[ESC] until you return to normal run mode.

press

Use the arrow keys to select the

[Span HC] option. Then, press [ENTER].

Use the arrow keys as indicated to enter the span gas combustibles ppm. When done, press

[ENTER].

Blow Back The OxyTrak™ 390 uses a process called Blow Back to purge its

sample system by initiating a temporary reversal of the sample gas flow direction. This menu option is used to configure the parameters for that process.

Note: The Blow Back programming opens and closes Relay H only.

Relay H is a switch only and does not provide power. To use the Blow Back process, connect a power supply in series with Relay H and the Blow Back solenoid valve.

At the [Setup] submenu of the Main Menu, use the arrow keys to select

[Blow Back] option and press

the

[ENTER].

Use the arrow keys to select the

[Interval] option and press [ENTER].

Use the arrow keys as indicated to enter the time in minutes between blowbacks. When done, press

[ENTER].

6-12 Advanced Programming

Blow Back (cont.)

September 2007

Use the arrow keys to select the

[Duration] option and press [ENTER].

Use the arrow keys as indicated to enter the length of time in seconds that the blowback will last. When done, press

[ENTER].

Use the arrow keys to select the

[Settling] option and press [ENTER].

Use the arrow keys as indicated to enter the length of time in seconds to allow after the blowback is complete. When done, press

[ENTER].

To force an immediate blowback, complete the next step.

Use the arrow keys to select the

[Yes] response to the [Blow Back Now] option. Then,

[ENTER] to initiate the

press blowback.

Note: If you select the

[No] option at the above prompt, the blowback

will be aborted.

When you have finished programming the

[ESC] until you return to normal run mode.

[Blow Back] menu, press

Advanced Programming 6-13

September 2007

Factory Menu All of the [Factory] menu options become available at this passcode

level. Proceed to the appropriate section to program these options.

Note: If necessary, see Chapter 5, General Programming, for

instructions on navigating to this menu.

Versions This option is used to display the versions of the instrument software

currently installed in your analyzer.

At the

[Factory] submenu of the

Main Menu, use the arrow keys to select the press

The current versions of your instrument serial number and software are displayed. When done, press

[Versions] option and

[ENTER].

[ESC].

When you have finished programming the

[Factory] menu, press [ESC]

until you return to normal run mode.

Upgrade This option is used update or restore the instrument firmware.

At the [Factory] submenu of the Main Menu, use the arrow keys to select the press

Use the arrow keys to select either

[Yes] to proceed or [No] to abort.

Then, press

When you have finished programming the until you return to normal run mode.

[Upgrade] option and

[ENTER].

[Factory] menu, press [ESC]

6-14 Advanced Programming

September 2007

Default Analyzer This option is used restore all programmable parameters to their

factory default values.

[Factory] submenu of the

At the Main Menu, use the arrow keys to select the and press

Use the arrow keys to select either

[Yes] to proceed or [No] to abort.

Then, press

[Default Analyzer] option [ENTER].

[ENTER].

When you have finished programming the until you return to normal run mode.

[Factory] menu, press [ESC]

Additional Menu Options In addition to the previously discussed options, the following menu

options are available at the 7378 passcode level:

Caution!

Improper reprogramming of the parameters in these menus will seriously degrade the performance of the

OxyTrak™ 390.

• Thermal Cal

• Air Offset

• Furnace Temp

• Comb. Cal

• Development

As the parameters programmed in these menus are critical to the proper operation of the OxyTrak™ 390, detailed instructions are not provided here. If it becomes necessary to change any of these parameters, you must contact the factory for assistance.

When you have finished programming the until you return to normal run mode.

Advanced Programming 6-15

[Factory] menu, press [ESC]

Chapter 7

Specifications

Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Functional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Physical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

GE Sensing OxyTrak 390 Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Chapter 1

General Information

Introduction Process plant managers are usually looking for ways to reduce

Physical Description The standard GE Sensing OxyTrak™ 390 Flue Gas Analyzer is

Figure 1-1: Standard OxyTrak™ 390 Configurations

Sample System The convection loop/analyzer package houses the sample system,

Figure 1-2: The Sample System

Figure 1-3: Sensor Locations (ref. dwg #705-1088, sht 3)

Figure 1-4: Combustibles Sensor

Figure 1-5: Zirconium Oxide Oxygen Sensor

Display Controller The display controller (see Figure 1-6 below) includes the terminal

Figure 1-6: Display Controller Interior

Principles of Operation Ideally, every furnace/burner should mix a precise ratio of air to fuel,

Zirconium Oxide Oxygen Sensor

Figure 1-7: Oxygen Migration in the Zirconium Oxide Sensor

Platinum-Catalyst Combustibles Sensor

Figure 1-8: Combustibles Sensor Elements

Heater Control Circuit The oxygen sensor temperature in the OxyTrak™ 390 is maintained

Chapter 2

Installation

Introduction This chapter provides instructions on how to properly install and wire

Unpacking Remove the analyzer (see Figure 2-1 below) from its shipping

Figure 2-1: Typical OxyTrak™ 390 with Local Controller

Installation Site Environmental and installation factors should already have been

Selecting the Site The tip of the probe is typically inserted into the stack to a distance of

Figure 2-2: Permitted Flue Gas Flow Angles

Preparing the Site Preparation of the installation site should include the following steps

Figure 2-3: A Typical Installation Setup

Mounting This section explains how to mount OxyTrak™ 390 analyzer at the

Wiring !Attention European Customers!

CE Mark Compliance For CE Mark compliance, the OxyTrak™ 390 must meet both the

Table 2-1: Wiring Modifications for EMC Compliance

Wiring the Analog Outputs (A-C)

Wiring the Alarm Relays (A-D)

Wiring the Calibration Relays (E-H)

Wiring the RS232 Output To wire the OxyTrak™ 390 to the RS232 serial port on a PC, refer to

Wiring the RS485 Output To wire the OxyTrak™ 390 to a remote RS485 controller, refer to

Remote Display Option If you have a local display controller, skip this section and proceed to

Figure 2-4: Display Controller Wiring Connections

Wiring the Line Power !WARNING!

Figure 2-5: AC Cable Assembly (ref. dwg #704-1102)

Figure 2-6: Outline and Installation Drawing - Local Controller (ref. dwg #712-1256, sht. 1)

Figure 2-7: Outline and Installation Drawing - Remote Controller (ref. dwg #712-1256, sht. 2)

Figure 2-8: Outline and Installation Drawing - Mounting Details (ref. dwg #712-1256, sht. 3)

Figure 2-9: Wiring Diagram - Horizontal, Local Electronics (ref. dwg #702-623)

Figure 2-10: General Purpose Wiring Diagram - Remote Assembly (ref. dwg #702-625)

Chapter 3

Operation

Introduction The OxyTrak™ 390 Flue Gas Analyzer is a monitoring device that is

Preventing Common Problems

Cleaning the Enclosure If the display window or the case of the OxyTrak™ 390 becomes

Powering Up the System Check the wiring connections and make sure all the OxyTrak™ 390

The Display and Keypad The front panel of the digital controller supplied with the OxyTrak™

Figure 3-1: Digital Controller Display and Keypad

Entering Programming Mode

Exiting Programming Mode

Temporary Exit To temporarily leave Programming Mode, proceed as follows:

Locking Programming Mode

Powering Down the System

Taking Measurements Allow the OxyTrak™ 390 to warm up sufficiently before taking any

Chapter 4

Setting Up the Display

Introduction Although the OxyTrak™ 390 is set up at the factory with default

Selecting the Number of Views

Adjusting the Display Contrast

Selecting the Measurement Mode and Units

Table 4-1: Available Measurement Units

Measurement Units Description

Chapter 5

General Programming

Introduction Although the OxyTrak™ 390 is set up at the factory with default

Setup Menu (Real Time Clock)

Calibrate Menu A variety of calibration procedures may be used with the OxyTrak™

Manual, One-Gas Oxygen Calibration

Manual, Two-Gas Combustibles Calibration

Automatic, One-Gas Oxygen Calibration