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TPK 21 LT

PRO AIR TPK 21 LT Functional Description And Operating Instructions

Pressure Dew Point Monitoring Device !
TPK 21 LT
Functional description and operating instructions
Table of contents
Scope of Delivery
1
General dangers and precautions
2
Safety instructions for electrical connection
2
Safety instructions for compressed air systems
3
Important application notes
4
Avoiding damage to the measuring probe
4
Calibration and measuring accuracy
4
Intended application
5
Humidity measurement in compressed air systems
5
Function
5
Mounting of the device
6
Safety instructions
6
Application notes
6
Procedure for installation
7
Mounting
7
Connection at the compressed air network
8
Direct stationary assembly at the compressed air line
8
Stationary assembly via hose
8
Application of a pre-filter / water separator
9
Mounting examples
9
Adjustment of measurement chamber choke
10
Connection of power supply
11
TPK Start-up
12
For the rarest of the cases…
12
Operation
13
Views of unit
13
Front view
14
Side view (from the right)
15
Connection to power supply
15
View (from below)
16
Table of contents
Display
16
Description of display
17
Description of main screen
17
Description info screen
18
Adjustment of display fields
19
Possible display variation concerning the different fields
20
Personalising Password
22
Adjustment of national languages
27
Information
30
Switching the heating(Heater) system On and Off
33
Factory settings
36
Outputs
39
Touchscreen calibration
44
Measurement value simulation
47
Statistics Reset
52
Reset Fault Memory
55
Quit Alarm
58
Quit Service
61
Filter
64
Units setting
67
Setting the Date / Time
70
Setting the Date
70
Setting the Time
74
Configuration of Relay Adjustments
78
Setting Source (Output Parameters)
80
Setting the Relay Switching Characteristics
81
Setting the Limit Values
82
Configuration of Analog Output
84
Selection of desired Source (Output Parameter)
86
Selection of the desired analog output value
87
Table of contents
Configuration of lower analog output value
88
Configuration of upper analog output value
89
Configuration of Alarm Output
90
Setting of desired alarm value 1
91
Setting of desired measurement - channel (source)
91
Setting Pre-alarm
93
Setting Main-alarm
98
Setting delay
103
Setting of desired alarm value 2
105
Technical Datas
107
Appendix
109
Menu structure
110
Menu item: Main
110
Menu item: Out
111
Menu item: Alarm
112
System References and Messages
113
EG-Conformance Details
114
Guarantee
114
Accessories
115
Connecting optional accessories
116
PIN - Assignment for Conctor
117
Voltage supply from an external source of supply
119
Trouble Shooting Guide
120
The measured value is flow dependent and too high (i.e. too humid)
120
The measured value is too high (i.e. too humid)
120
The measured value is too low (i.e. too dry)
121
The measured value varies significantly
121
Service and Calibration
122
1 Scope of Delivery
1
!
Please read the operating instructions before using this device. In addition to the operating instructions, important information is provided regarding installation, initial start-up and troubleshooting in each of the relevant chapters.
The pressure dew-point monitor is supplied ready to use. The scope of delivery includes the AC adaptor, stylus, stylus holder (which may be attached to the dew-point meter) and relevant operating instructions.
You may also require:
-
Mounting tools, screws and wall plugs
-
6 / 4 mm compressed - air - hose (WARNING! Use only PTFE hoses!).
-
further nipples, reducers and adapter pieces, if the device is to be integrated into a pipeline.
- Electrical accessories for connection to higher-level overriding control devices.
- Optional accessories, such as external indicator lights, terminal adapters and PC cables!
(see accessories overview).
2 General dangers and precautions
2.1 Safety instructions for electrical connection
2
Please read the following warnings prior to initial start-up! The symbols used in the operating instructions are intended to call your attention to the safety risks. It is not enough to simply observe the symbol. It is important to read the full text provided in the safety instructions!
This symbol indicates a potential risk to humans, equipment or the environment. The information provided must be strictly observed in order to prevent risks.
This symbol indicates important instructions for use and tips that are important in order to successfully complete tasks, and which must be strictly observed to ensure good results.
!
!
!
The device must only be supplied with extra-low voltage. The device's other electrical connections must also only be connected with electronic components that are operated via an extra-low voltage supply.
Contact with live parts may result in death. Installation of the controller and maintenance work must therefore only be carried out by trained personnel. The power supply must be turned off for installation and servicing.
Also avoid touching the plug or any other electronic components when the power is switched off. Electrostatic phenomena may damage electronic components.
The product is not intended to control systems with safety-related functions. Even during normal operation there is a risk of unexpected malfunction, for example due to a surge or the failure of a component. The user must make sure that no damage can occur as a result of a malfunction or undefined device status. This can be achieved, for instance, through the use of redundant components or safety circuits.
Incorrect screw tightening torques at the connecting terminals or the use of unsuitable tools can damage the terminal, resulting in damage to insulation or the contacts. Poorly connected cables can come loose during operation, posing a considerable risk to safety. Contact resistance at clamp connections results in increased heat production that can cause a fire to start. Incorrectly wired connections can destroy electrical components and result in other damage.
!
2.2 Safety instructions for compressed air systems
3
In the case of unforeseen events, the energy stored in compressed air can cause material damage or result in injury. The risk increases with the operating pressure of the system. All work must therefore be performed by appropriately trained personnel. Appropriate care is necessary when performing any work on the compressed-air system in order to avoid damage!
The loud venting noise produced upon uncontrolled opening of pressurised lines can damage hearing or startle other people in the vicinity.
At high flow rates, foreign bodies in the air stream can behave like projectiles and cause injury to the skin or eyes.
The built-in measuring chamber with sensor is designed to handle pressures of up to 17 bar. This maximum permissible operating pressure must not be exceeded. Upstream components must be dimensioned according to the system's operating pressure and temperature.
The warranty will become null and void if the sensor housing is opened, the sintered cap removed or in the event of improper handling or the use of force.
!
3 Important application notes
3.1 Avoiding damage to the measuring probe
3.2 Calibration and measuring accuracy
4
Measuring devices are sensitive and must be handled with care:! Avoid shocks, impacts and vibrations.
The sintered filter protects the sensor against mechanical stress and contamination.
Do not remove the filter. Only use the probe if the sintered filter is undamaged!
Prior to installation, check that there is no condensation, oil or dirt at the measuring point! Should this be the case, repair and dry out the system!
The measuring system is not suitable for use with compressed air with a high oil content, as directly covering the sensor with a film of oil impairs its response, blocks the pores of the filter and damages the filter choke.
As a rule of thumb: If you have any questions, contact the manufacturer. Do not attempt to experiment with the device as you may cause faults and damage to occur!
!
Prior to delivery, the pressure dew-point sensor is adjusted and tested by means of a complex calibration procedure involving several temperatures and humidity points. It is not possible for the end user to calibrate the device.
Please observe the permissible temperature range for use. Excessive temperatures reduce the measuring accuracy. The probe will be damaged if the temperature limit is exceeded.
The specified data, in particular the desired measuring accuracy, are valid at a temperature of 20°C. In principle, the lower the temperature at the sensor, the more accurate the measurement result. If possible, measurements should be taken in a cool area, or the gas should be cooled to ambient temperature.
With proper use, the probe will have a lifespan of many years. Nevertheless, to prevent errors, it is important that the sensor be calibrated once a year, according to the manufacturer's specifications. This particularly applies when the probe is used in critical applications within the
lower dew-point measuring range.
3.3 Intended application
4 Humidity measurement in compressed air systems
5 Function
5
The new TPK 21 LT is intended to be used to measure the pressure dew points, pressure and temperature of clean, oil-free compressed air, which is free of any abrasive, corrosive, caustic, toxic, flammable and combustible components. For the scope of application and the calibrated measuring range, please refer to the technical data.
!
In the industrial sector, quality requirements for compressed air are becoming ever stricter. Humidity and condensation are not permitted in compressed air and often cause damage to machines and lead to reduced production quality. Compressed-air dryers are commonly used. When used correctly, these reduce the moisture content of the air and ensure the production of high-quality compressed air.
However, problems with dryers are often detected very late on, usually when damage has already occurred. A large quantity of humidity will have already entered the compressed-air network, and considerable efforts will be required to dry the system out again. The high quality standards of the industrial sector call for continuous, reliable and stable long-term monitoring of the humidity content. This is the only way to detect problems early, before any damage has occurred.
With its large measuring range, the new TPK series is the ideal measuring system for monitoring refrigeration, adsorption and membrane dryers. The device is primarily intended for stationary applications but is also suitable for use as a portable measuring device thanks to its simple connection system.
If compressed air is not dried before being fed into the compressed-air network, significant quantities of condensate can form in the pipe network, resulting in the malfunctioning of valves and pneumatic components, ultimately leading to loss of production. The pressure dew point in compressed-air systems is therefore a key factor in determining air quality and should be measured in all systems.
The new TPK series offers the ideal device for monitoring compressed-air quality (humidity, pressure and temperature) and giving timely warning, before any damage has occurred.
The series has a built-in measuring chamber with a protection filter and filter choke, as well as a plug connection for a 7.2 mm NW compressed-air socket. Power is supplied via the mains adapter provided. Initial set-up of the measuring system therefore requires no interference with the compressed-air network, nor any electrical installation work. Alternatively, the measuring system can be installed on the compressed-air line to avoid the loss of scavenging
air.
6 Mounting of the device
6.1 Safety instructions
6.2 Application notes
6
The device must only be used for its intended purpose.
Installation of the controller and maintenance work must only be carried out by trained personnel. The power supply must be turned off for installation and servicing. The applicable safety regulations must be observed! All work on the compressed-air system must be carried out under pressure-free conditions.
The device must only be operated with extra-low voltage. This also applies to all external connections, such as the relay outputs.
!
The air quality at the site of installation must be checked prior to assembly. Repairs must be made to the system in the case of any water or oil leakages. Contact with large quantities or water or oil may damage the sensor.
The compressed air must be drawn from the upper side of the pipe. The device must be mounted above the compressed-air line so that any condensation produced in the event of failure cannot flood the measuring chamber.
Use only suitable materials. The materials used must be impermeable to water vapour. Therefore please do not use regular polyurethane hoses! The only recommended material for flexible hose connections is PTFE ("TEFLON"). All metals are suitable down to -30°Ctpd. Below this, stainless steel is the preferred choice. Avoid using excessively long sample-gas lines or unnecessary connectors.
The sensors on upstream components must not diffuse water vapour into the surrounding environment! Please use only high-quality components, e.g. ball valves with PTFE seals.
Carefully seal all points of connection with the sensor or measuring chamber. However, never use anaerobic liquid sealants, as these maydamage the sensor element!
Heavy particle loads will clog the filter or filter choke over time, resulting in a delayed response. In critical cases, an additional fine filter must be installed upstream of the measuring device.
!
6.3 Procedure for installation
6.4 Mounting
7
If using compressed air of unknown quality, use a condensate separator or particle filter. Additional components must be suitable for the intended use!
In EMC-critical environments the measuring chamber should be electrically isolated from the metal pipes of the compressed-air network. The use of a PTFE or Polypropylene double nipple is an example of a suitable solution.
Installation involves the following steps:
- Mounting of the device, if necessary.
- Connection to the compressed-air network
- Adjustment of the filter choke, if necessary
- Connection to the power supply
- Initial start-up
- Setting of the switching points
- Testing and function control
If the device is operated as a portable device or is connected using a standard coupling, as described below, no further mounting is required.
When mounting onto a machine, the device can be kept level by using mounting brackets. A drilling template can be found in the appendix of this manual.
7 Connection at the compressed air network
7.1 Direct stationary assembly at the compressed air line
7.2 Stationery assembly via hose
8
In the case of stationary use, the device is usually installed downstream of the dryer/filter, enabling the entire system to be monitored. It may also be installed at any point further downstream in the distribution system in order to monitor subsegments or the air supply entering a particular machine.
In order to avoid unnecessary compressed-air consumption through loss of scavenging air, the measuring chamber with the sensor should preferably be directly installed into the compressed-air line.
To prevent the accumulation of condensation in the event of a fault, the measuring chamber must be screwed vertically into the line from the top.
Extremely high flowrates or sudden pressure changes should be avoided, as these may damage the sensor element.
If a spur line is required for connection, this should only be a few centimetres long, otherwise the response will be impaired, especially at low dew-point values. If longer spur lines are used, the choke must be opened onto the measuring chamber and set to approximately 60 l/h.
Long, vertical spur lines impair the response or result in incorrect measured values.
The device may be alternatively connected to the compressed-air supply via a Teflon connection line through the built-in measuring chamber with choke. To ensure correct functioning and guarantee measuring accuracy there must be a throughflow of air. The basic flow rate can be set at the choke. In order to avoid unnecessarily high loss of scavenging air, the flow at the rated pressure can be set to 60 l/h by means of a flow meter. Check from time to time that there is air flowing at the adjusting screw. If the choke is closed, the measuring device displays values that are too high or triggers an alarm
7.3 Application of a pre-filter / water separator
7.4 Mounting examples
9
Depending on the state of the compressed-air system and distribution network, it is possible for dirt, condensate or oil to leak out from the measuring point. In order to avoid damage to the probe in such critical areas of application, a water separator with a fine filter can be connected upstream of the device. The upstream components must not alter the moisture content of the air or unduly impair the response. We can provide you with a list of suitable components upon request.
The device is suitable for a variety of applications. The flexible design of the measuring chamber allows it to be easily adapted to the intended use:
Connection to a 7.27,2 mm NW quick coupler:
This connection can be quickly and easily performed within minutes, without any complex installation.
-
An NW 7.2 plug-in nipple with a 3/8" thread is connected to the underside of the device.
-
The device is connected directly to the coupling, and no further mounting is required.
-
The choke is set to approximately 60 l/h (factory setting,
as delivered).
!
Permanent connection to a compressed air line:
This type of connection is ideal when there is only a short distance to the main line because no purge air is consumed.
-
Underneath, a 3/8" double nipple is mounted and connects to the pipe.
-
In the case of direct connection to a main line, the choke is closed.
-
For greater connection distances or spur lines, the choke is
set to approximately 60 l/h.
7.5 Adjustment of measurement chamber choke
10
Connection via a compressed-air hose:
This connection variant is ideal, for example, if the device is intended for portable use or mounted onto a machine or panel.
-
Underneath, the 3/8" thread is fitted onto a 6/4 mm hose.
-
The choke is set to approximately 60 l/h for stationary applications (factory setting, as delivered). If used as a portable device for rapid measurements the setting should be changed to approximately 240 l/h.
-
NOTE: Use only PTFE hose for the connection.
The choke's factory default setting is a 60 l/h basic flow rate at a pressure of 10 bar. So long as the choke has not been adjusted, no adjustment is usually required, provided that this is the desired flow rate.
Depending on the type of connection, the choke can be closed to avoid the loss of scavenging air. This is done by fully tightening the Allen screw using the socket spanner provided.
If used as a portable device for rapid measurements the basic flow rate should be set to approximately 240 l/h. To do this, the choke is opened until the screw is in line with the top edge of the measuring chamber. The venting noise can clearly be heard in this position. The response is faster with a high basic flow rate.
To reset the choke to 60 l/h for stationary applications, a flow meter is required, which is fitted over the screw using a flat seal. The desired flow rate is achieved by repeatedly adjusting and checking the flow.
Precise adjustment of the desired flow rate is particularly important in the case of stationary applications, because too high a flow rate results in high operating costs.
7.6 Connection of power supply
11
The device is operated with extra-low voltage. A suitable mains adapter is provided.
The power supply unit is plugged into the lower M12 socket.
No complex electrical installation is necessary, and the device is immediately ready for operation
The AC adaptor with Europlug is of a high-quality design with a wide-range input. It is suitable for a 90 - 240 V power supply and is therefore suitable for Europe-wide use.
How to connect with mains adapter
Do not try to force the connector when plugging it in.
!
Connection Diagram FGPx remote probe
Follow the guidelines for plugs and sockets!!
DC 24 V
7.7 TPK Start-up
7.8 For the rarest of the cases…
12
The device immediately starts up when plugged into the power supply. There are no other switches. The first measured values are displayed immediately after turning on the device. The measured values are likely to fall immediately following connection to the compressed-air network. The values will stabilise after a short time. Depending on the system, the following values should be set:
- For refrigeration dryers: approx. 0 to 7°Ctdp
- For an additional membrane dryer: approx. -20 to -10°C
If the device does not start up, please check the following points:
- Is power arriving at the mains socket ?
- Is the mains plug correctly plugged in ?
- Is the M12 socket of the power supply correctly connected to the device ?
- Does the power supply unit deliver 24 V DC voltage (external power supply units ?
If you have examined all the possible causes and still have not managed to rectify the malfunction, please immediately contact our customer service department. Do not open the device, as this will invalidate the warranty claim !
!
8 Operation
8.1 Views of unit
13
General information on the description of the operating procedures
All images of the displays, numerical values and configurations are used by way of example to explain and clarify the information provided. The actual display on your device may differ according to the selected settings or ambient conditions.
!
Side view
(from the right)
Front view
View
(from below)
View
Isometric
DC 24 V
8.1.1 Front view
14
Warning- / Signal LED
LCD touch-display
Choke-adjustment screw
Built-in measuring chamber
Standard NW 7,2 plug-in nipple
(suitable for direct connection to the compressed-air coupling)
Alarm LED
1
2
3
4
Assignment of the M-12 connection sockets:
Alarm output connection
Relay output connection
Analog output connection
Connection for external mains adapter
1
2
3
4
8.1.2 Side View (from the right)
8.1.2.1 Connection to power supply
15
Assignment of the M-12 connection sockets:
Connection for external mains adapter
Analog output connection Relay output connection
Alarm output connection
1
2
3
4
The external mains adapter can be connected to the lower M-12 connection socket.
4
DC 24 V
8.1.3 View (from below)
8.2 Display
16
Connection to the compressed-air network
The built-in touch display is a monochrome FSTN dot-matrix display with white backlight and a resolution of 160 x 110.
All values may be set or changed accordingly via the screen using the stylus provided or with careful finger movements.
Caution: The use of pointed objects, such as ballpoint pens or pencils, can destroy the display and invalidate the warranty!
!
8.2.1 Description of Display
8.2.1.1 Description of the Main Screen
17
Once the device is connected to the power supply, a welcome screen with the logo and company name briefly appears and then the main screen is displayed.
The screen is divided into 3 fields (a main field and 2 smaller fields).
All fields can be individually adjusted.
Main Screen
Info Screen
Field 1
Field 2
displays the physical measuring value
Info Screen (temporary), please notice next page
Unit actual measuring value
Currently measured value
This field shows a further current measured value with physical unit. (individually adaptable)
This field shows for example the actual humidity class acc. to ISO 8573-1 or a further measured value with physical unit. (individually adaptable)
Class
4
ISO 8573-1
Temperature
22.1
o
C
o
C
Dew-/Frostpoint
- 7.0
H HOLD
Class
4
ISO 8573-1
Temperature
22.1
o
C
o
C
Dew-/Frostpoint
- 7.0
H HOLD
8.2.1.1 Description Info Screen
18
After restarting the device or during bake-out of the sensor an "Information Screen" is displayed in the upper right-hand corner of the display with the following background.
Dew points in the range of -60 to -20°C at room temperature correspond to relative humidity values of 0.08 to 5.37% RH. To ensure accurate measurement at the lowest humidity values, the slightest drift effect of the humidity sensor element must be compensated for.
Moreover, in order to guarantee the long-term stability of the dew-point sensor the sensor element is periodically baked out. The sensor is heated every 13 h for approximately 5 minutes and then allowed to cool down to ambient temperature.
During heating "HHOLD" appears on the display, and "CHOLD" is indicated during cooling. The operation is indicated on the display:
The „Info Screen“ displays the current auto-calibration status:
H HOLD: Heat (The sensor element is being heated) HOLD (The measured value is being saved)
C HOLD: Cold (The sensor is cooling down) HOLD (The measured value is being saved)
H HOLD
C HOLD
!
Bake-out is performed every time the device is connected to the mains supply, then every 13 h. During the entire cycle, the last measured values are retained and are qualitatively available at the outputs. No further measurements are made during the heating phase. Therefore no alarm signal will be emitted during this period of time in the event that a maximum permissible value is exceeded. Only after the heating/ cooling cycle has finished will the device resume measurement and alarm evaluation.
8.2.2 Adjustment of display fields
19
To adjust one of the fields according your specific needs, select the desired field by tapping it with the stylus provided or your finger.
The display now appears as follows (the main field has been selected as an example).
In the lower third of the display an additional menu bar appears that allows further settings to be defined.
Klasse
ISO 8573-1
1.17
bar
Tau-/Frostpunkt
- 7.0
o
C
4
Druck
Information
Settings
Scroll - up
Enter - Confirm
Scroll - down
Class
ISO 8573-1
22.1
o
C
Dew-/Frostpoint
- 7.0
o
C
4
Temperature
8.2.2.1 Possible display variation concerning the different fields
20
Each field can be adjusted on site to meet your specific needs.
The procedure is as follows:
1. Select the desired field on the display (the background turns dark and control keys appear at the bottom of the display).
2. Scroll up or down to the desired setting using the two arrow keys.
3. Confirm the setting using the "Confirm" key. The display jumps back to the home screen, where the modified field contents can be seen.
example: Changing the display value in the main field
1
2
3
Select the main field
Scroll up or down to the desired display value
Confirm the desired value
Class
ISO 8573-1
22.1
o
C
Dew-/Frostpoint
- 7.0
o
C
4
Temperature
1
21
Physical variable
Possible units
Field
Field
Field
Pressure dew point / Frostpoint
o
C, oF
X
Alarm values (settings)
Pre-alarm / Main alarm / Service
X
X
Date / Time
Various settings are possible in the main menue
X
X
Relay - settings
On/Off
X
X
Statistics
Minimum- / Maximum- / mean value
X
X
Temperature
o
C, oF
X
Relative Humidity
%
XXX
Compressed air class according to ISO 8573-1
X
123
Class
4
ISO 8573-1
Temperature
22.1
o
C
o
C
Dew-/Frostpoint
- 7.0
H HOLD
1
3
2
8.3 Personalising Password
22
The password can be personalised. The factory default is 111111.
CAUTION: Please make a note of the new password. If the password is forgotten, the device must be reset to the factory settings. This will result in the loss of all settings!
!
The procedure is as follows:
1. Select one of the three segment fields (the background turns dark and control keys appear at the bottom of the display).
2. Select „Settings“
The following display appears:
PIN
- - - - - -
123
456
789
0
X
3. Enter your personal PIN code (if it has already been changed). If the device is
still in its factory settings, key in 111111 .
1
2
3
Class
ISO 8573-1
22.1
o
C
Dew-/Frostpoint
- 7.0
o
C
4
Temperature
23
You are now in the settings menu (Level 1).
4. If the „Main“ field is not already highlighted, select the field and
confirm with .
Under the menu item „Main“ you will find all of the device settings, as well as the settings for displaying the measured values.
The following display of the settings menu appears (Level 2):
6. If the „Device“ setting field is not already highlighted, select the field and
confirm with .
Under the menu item „Device“ " you will find all of the basic settings for the device.
4
5
6
7
Main
Out
Alarm 1
Alarm 2
Device
Filter
Unit
Clock
24
The following display of the settings menu appears (Level 3):
8. If the „Password“ field is not already highlighted, select the field and
A display will appear with the following warning:
Select "Yes" to confirm and continue.
8
9
10
Password
Language
Info
Heater
No
Yes
If you forget the password, you have to send
the device to our service to reset it to the
factory default state. Are you sure ?
PIN
_ _ _ _ _ _
123
456
789
0
X
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