Rosemount Manual: CH88 In-Situ Combustion Oxygen Analyzer System | Rosemount Manuals & Guides
Installation/Start-up Manual
CMB_MAN_ABR_CH88
September 2017
CH88 In-Situ Combustion O2 Analyzer System
Section 1:
General Information
Essential Instructions..........................................................................................
2
Symbols used......................................................................................................
3 Overview………………………………………………………………………….................................
4
System Configurations........................................................ ...............................
5
Technical Support Hotline.................................................. .................................
5
Section 2:
Typical System Package
CH88 In-Situ Combustion O2 Analyzer System Ordering Information................
6
Section 3:
Specifications
System Specifications..........................................................................................
7
CH88 Flue Gas O2 Probe Specifications...............................................................
7
1056 Combustion Electronics Specifications....................................................
7
Section 4:
Installation
Mechanical installation.......................................................................................
9
Installation of1056 Combustion Electronics………...................................
9
Installation Specifications - Cable Connecting Probe to
9
Probe Installation.................................................. .................................
9
Electrical Installation...........................................................................................
15
Cable Connections.................................................................................
15
Probe Connections.................................................................................
16
Power Up Procedure...........................................................................................
16
Calibration.......................................................................... .................................
19
Manual/Semi-automatic Calibration…………………...................................
19
Calibration Record.................................................................................
20
Section 5:
Menu Trees
System Menu Tree (English and Chinese)……………………….. .................................
21 Probe Menu Tree (English and Chinese) ………………………...................................
22
Probe Menu Tree (English and Chinese) ………………………...................................
23
Section 6:
Parameters
System Parameters............................................................................................
24
Probe Parameters..............................................................................................
25
CH88 In-Situ Combustion O Analyzer System Alarms........................................
26
System Alarms.............................................................................................
29
Probe Alarms........................................................ ......................................
30
Contents
Electronics…………………………………………………………....................................
Table of Contents
Essential Instructions
September 2017
Installation/Start-up Manual
CMB_MAN_ABR_CH88
Section 1: General Infor m ati on
Essential Instructions
Read this page before proceedi ng
Emerson Process Management designs, manufactures and tests its Rosemount Analytical to meet many national and
international standards. Because these instruments are sophisticated technical products, you MUST properly install, use, and
maintain them to ensure they continue to operate with-in their normal specifications. The following instructions MUST be
adhered to and integrated into your safety program when installing, using, and maintaining Rosemount Analytical products.
Failure to follow the proper instructions may cause any one of the following situations to occur: Loss of life; personal injury;
property damage; damage to this instrument; and warranty invalidation.
•
Read all instructions prior to installing, operating, and servicing the product.
•
If you do not understand any of the instructions, contact your Emerson Process Management representative for
clarification.
•
Follow all warnings, cautions, and instructions marked on and supplied with the product, including this manual
•
Install your equipment as specified in the Installation Instructions and per applicable local and national codes. Connect all
products to the proper electrical and pressure sources.
•
To ensure proper performance; inform, educate and only use qualified personnel to install, operate, update, program, and
maintain the product.
•
Use only factory documented components for repair. Tampering or unauthorized substitution of parts and procedures can
affect the performance and cause unsafe operation of your process.
•
All equipment doors must be closed and protective covers must be in place unless qualified personnel are performing
maintenance.
WARNING: RISK OF ELECTRICAL SHOCK
1)
Main power wired to separate power source must be disconnected before servicing.
2)
Do not operate or energize instrument with case open!
3)
Wiring connected in this box must be at least rated 240 VAC and 14 gauge.
4)
Non-metallic cable strain reliefs do not provide grounding between conduit connections! Use grounding type bushings and
jumper wires.
5)
Unused cable conduit entries must be securely sealed by non-flammable closures to provide transmitter's enclosure
integrity in compliance with personal safety and environmental protection requirements.
6)
Operate only with front panel fastened and in place.
7)
Safety and performance require that this system be connected and properly grounded through a three wire power source.
8)
Proper use and configuration is the responsibility of the user.
9)
Before installing this equipment read the "Safety instructions for the wiring and installation of this apparatus". Failure to
follow safety instructions could result in serious injury or death.
10)
Install all protective equipment covers and safety ground leads after installation. Failure to install covers and ground leads
could result in serious injury or death.
11)
Local Ground connection shall be provided to CH88 Flue gas O Probe in order to avoid electric shock. The ground
conductor should be equal or greater than 16 AWG for a copper conductor in free air or 12 AWG for an enclosed copper
conductor.
12)
Disconnect and lock out power before connecting the power supply.
13)
Install all protective covers and safety ground leads after installation. Failure to install covers and ground leads could result
in serious injury or death.
14)
Disconnect and lock out power before working on any electrical components. There is voltage up to 240 VAC. Verify the
reliability and continuity of the grounding of the probe connection before powering the equipment.
15)
To meet the Safety Requirements of IEC 61010-1 (EC requirement), and ensure safe operation of this equipment,
connection to the main electrical power supply must be made through a circuit breaker (max 10A) which will disconnect all
current-carrying conductors during a fault situation. This circuit breaker should also include a mechanically operated
isolating switch. If not, then another external means of disconnecting the supply from the equipment should be located
close by. Circuit breakers or switches must comply with a recognized standard such as IEC 60947.
CAUTION
•
If the ducts will be washed down during outage MAKE SURE to power down the probes and remove them from the wash
area. This manual concentrates on the installation, start-up, calibration, and operation of this product. There is also a more
comprehensive manual that also covers troubleshooting, maintenance, repair, and spare parts identification.
3 Essential Instructions
Essential Instructions
September 2017
Installation/Start-up Manual
CMB_MAN_ABR_CH88
4
Essential Instructions
:
:
:
:
:
:
EQUIPMENT PROTECTED THROUGHOUT BY DOUBLE INSULATION(APPLIES TO 1056
COMBUSTION ELECTRONICS HOUSING ONLY)
•
When replacement parts are required, ensure that qualified people use replacement parts specified by Emerson Process
Management. Unaut hori ze d parts a nd pr oc ed ures c an af f ec t the pr od uc t's performance; place the s af e operation of your
process at risk, and VO ID YOU R WARRANTY. Look -alike s ubs tit uti ons may r esult in fire, electric al hazards, or improper
operation.
•
Ensure that all equipment doors are closed and protective covers are in place, except when maintenance is being
performed by qualified persons, to prevent electrical shock and personal injury.
• The information contained in this document is subject to change without notice
•
Do not allow the temperature of the CH88 Flue Gas O2 Probe electronics to exceed 85°C (185°F) or damage to the unit
may result.
Symbols Used on equipment and i n instr uc ti on m a nual
EARTH (GROUND) TERMINAL
PROTECTIVE CONDUCTOR TERMINAL
WARNING, RISK OF ELECTRIC SHOCK
REFER TO INSTRUCTION MANUAL
WARNING, HOT SURFACE
Note: If the equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment
may be impaired.
Definitions
The following definitions apply to WARNINGS, CAUTIONS, and NOTES found throughout this publication.
WARNING
Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not strictly observed, could result in
injury, death, or long-term health hazards of personnel.
CAUTION
Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not strictly observed, could result in
damage to or destruction of equipment, or loss of effectiveness.
Highlights an essential operating procedure, condition, or statement.
Essential Instructions
September 2017
Installation/Start-up Manual
CMB_MAN_ABR_CH88
5
General Information
General Information
Overview
The CH88 In-Situ Combustion O2 Analyzer System is Rosemount Analytical’s latest combustion flue gas oxygen analyzer
consisting of 1056 Combustion Electronics and CH88 Flue Gas O2 Probe. This product is intended for measuring the flue
gases resulting from any combustion process. It utilizes the same heated sensing technology as the O2 sensors found in most
automobiles. Contact Rosemount Analytical’s technical support group at 800-433-6076 for any applications other than
measuring combustion flue (exhaust) gases.
This product utilizes an “in situ” sensor, i.e. the sensor is placed at the end of a probe, and the probe extends directly into the
flue gas duct or stack at a given length. The sensor is like a thermocouple, generating it’s own millivolt signal based on the
difference between a reference gas (ambient or instrument air – always 20.95% O ), and the flue gases being measured.
2
System Configuration
CH88 Flue Gas O2 Probe with 1056 Combustion Electronics
There are no electronics inside the probe head, so the raw sensor signals for the heater thermocouple and zirconium oxide O sensor
are sent to a remote 1056 Combustion electronics. The 1056 Combustion electronics will also directly apply power to the probe heater
in order to maintain the correct sensor temperature. This arrangement calls for a 9- conductor cable to carry this power and the
sensor signals. Maximum length for this cable is 500 feet. This probe will also operate on previous Westinghouse/Rosemount
electronics (World Class and Oxymitter), as well as many competitive electronics.
CH88 Flue Gas O2 Probe does not communicate via HART or FOUNDATION Fieldbus communications.
2
Technical Support Hotline
For assistance with technical problems, please call the Customer Support Center (CSC).
•
Rosemount Analytical Shangha i Serv ic e (086-21-28929294)
• 1-RAI-AND-U (1-855-724-2638)
• 1-800-433-6076
In addition to the CSC, you may also contact Field Watch. Field Watch coordinates Emerson Process Management’s field
service throughout the U.S. and abroad.
• 1-800-654-RSMT (1-800-654-7768)
Emerson Process Management, Rosemount Analytical Inc. may also be reached via the Internet through e-mail and the World
Wide Web
•
e-mail: GAS.CSC@emerson.com
•
World Wide Web: www.rosemountanalytical.com
Typical System Packag e and Ordering Information
Installation/Start-up Manual
6
Typical System Package and Ordering Information
CH88 Flue Gas O2 Probe
Length in Meters inches)
0.5 m (19.68 in)
8.6 Kgs (19 lbs)
6.1 Kgs(13.5 lbs)
6A00507G01
1056 Combustion
in Millimeter(inches)
155 x 155 x 131mm (6.10
x 6.10 x 5.15 in.)
Cal gas adaptor kit to mate to
existing tubing arrangement
September 2017
CMB_MAN_ABR_CH88
Section 2: Typical System Package
Figure 1
CH88 In-Situ Combustion O2 Anal yzer System Ordering Information
Shipping Weight Actual Weight Part Number
1 m (39.37 in) 10.43 Kgs (23 lbs) 7.6 Kgs(16.8 lbs) 6A00507G02
2m (78.74 in) 13.8 Kgs (30.5 lbs) 10.43 Kgs(23 lbs) 6A00507G03
Electronics dimensions
Accessory Part Number
Calibration Flowmeter 771B635H01
Replacement sensor board 6A00493G01
Replacement power supply board 24248-03
Shipping Weight
1.8 Kgs(4 lbs) 1.4 Kgs(3 lbs) 24490-00
1A98771H07
Actual Weight
Part Number
Replacement display board 24361-00
Specifications
Installation/Start-up Manual
7
Specifications
System Specifications
±1% of full scale for 0-10% ranges and above
Initial response in less than 3 seconds T90 in less than 8 seconds.
velocity and particulate loading of the diffuser
Presentation of calibration gases matches the bottle value to within
±0.1% O2
Reference Air
Reference air is ambient air that will passively diffuse into the probe.
2
CH88 Flue Gas O2 Probe Specifications
Process-wetted materials are 304 Stainless
-40°to 705°C (40°to 1300°F)
(1922°F)
Vertical or horizontal–2" 150# (4.75" (121mm) bolt circle) and DIN 145
Many adapter flanges are available to mate to existing flanges.
Manual/Semi-automatic Calibration
electronics.
0.4% O2 and 8% O2, balance N2 recommended. Instrument air may be
be used as the low cal gas.
Temperature: -40°to 90°C (-40°to 194°F)
Humidity: 5 to 95% RH (non-condensing)
Temperature: 0-50°C (32-122°F)
Humidity: 5 to 95% RH (non-condensing)
1056 Combustion Electronics
Overall 155 x 155 x 131mm (6.10 x 6.10 x 5.15 in.). Cutout: 1/2 DIN
Temperature: 20°C to 50°C (-4°F to 122°F)
Humidity: 5 to 95% RH (non-condensing)
Temperature: -20°C to 60°C (-4°F to 140°F
Humidity: 5 to 95% RH (non-condensing)
September 2017
Net O
2
Range
Accuracy
Lowest Detectable Limit
Process Temperature Effect
System Speed of Response to
Calibration Gas
Calibration Validity
Power
Enclosure
Process Temperature Limits
CMB_MAN_ABR_CH88
Section 3: Specificat ions
Variable 0-10% to 0-50%
0.05% O2
Less than 0.05% O2 from 100°to 700°C (212°to 1292°F)
Response to process gas changes will vary depending on process gas
240V ±10%,50/60 Hz, 150 Watts max (during initial warm up)
The ambient air at the installation location must be fresh (20.95% O ).
optional bypass and jacket accessories permit operation to 1050°C
Output/s
Probe Length
Mounting
Calibration
Calibration Gases
Calibration Gas Flow
Ambient Conditions
Storage Conditions
Enclosure
One 4-20 mA
0.5, 1, 2 m
Note: Flanges are flat-faced and for mounting only. Flanges are not
pressure-rated. A 2.5" diameter hole in the process is required.
Spool piece P/N 3D39761G02 is available to offset probe housing from
hot ductwork.
New calibration values are calc ula ted in the 10 56 Com bus tio n
used as a high cal gas but is not recommended. 100% nitrogen cannot
2.5-5 l/min. (5-10 scfh)
139mm x 139mm (5.45 x 5.45 in.),Polycarbonate Material
Note: To ensure a water- tight seal, tighten all four front panel screws to
6 in -lbs of torque.
Mounting
Conduit Openings
Pipe, wall, or panel (Refer to drawings)
Accepts 1/2” or PG13.5 conduit fittings
Ambient Conditions
Storage Conditions
Specifications
Installation/Start-up Manual
8
Specifications
4-20 mA, max. load 550 ohms
Two (2) SPDT Form C, epoxy sealed contacts rated 5A, 30VDC, 120
VAC, or 230VAC; User configurable to alarm
The high-contrast LCD provides live measurement readouts in large
meet user requirements.
September 2017
Analog Output
Alarm Relays
Display
CMB_MAN_ABR_CH88
digits and shows up to four additional process variables or diagnostic
parameters. The display is back-lit and the format can be customized to
Installation
Installation/Start-up Manual
9
Installation
September 2017
CMB_MAN_ABR_CH88
Section 4: Installation
Mechanical Installa t ion
Installation of1056 Combustion Electronics
The 1056 Combustion Electronics is available in a panel mounting, or wall/pipe mounting configuration. Refer to Figure 5 or
Figure 6 for the panel, wall, or pipe mounting details.
1.
Ensure all components are available to install the 1056 Combustion Electronics.
2.
Select a mounting location near or removed from the O2 Probe. Consider the temperature limitations of the 1056
Combustion Electronics (see "Specifications") when selecting the mounting location.
3.
Mount at a height convenient for viewing and operating the interface.
Approximately 1.5 m (5 ft) is recommended.
4.
The keypad window on the 1056 Combustion Electronics may have an exterior protective membrane. Remove the
protective membrane prior to use of the 1056 Combustion Electronics enclosure. Failure to remove the protective
membrane may cause the display to appear distorted. The membrane may be difficult or impossible to remove after
extended use at elevated temperatures.
Installation Specifications - Cable Connecting Probe to Electronics
Customer supplied, total of 9 conductors, rated for 105°C or greater, insulation rated for 250V or greater:
Heater Power
2 conductors, 12 – 18 ga. (<200ft.); use 12 ga. for lengths between 200 and 500 ft.
Probe sensing
7 conductors (3 twisted pairs plus shield) 16 to 25 ga. (<200 ft.); Use 16ga. for lengths between 200 and 500ft. Shield
connected to ground at 1056 Combustion Electronics. All wiring must be rated for 250VAC. Minimum 105°C
temperature.
CH88 Flue Gas O2 Probe Installation
A “weld plate” for welding to the flue gas duct can be supplied for new installations.
1.
Ensure all components are available to install the CH88 Flue Gas O2 probe. Refer to Figure 1.
2.
If using the standard square weld plate (Figure 1) or an optional flange mounting plate weld or bolt the plate onto the
duct. The through hole diameter in the stack or duct wall and refractory material must be at least 63.5 mm (2-1/2 in).
3.
Insert probe through the opening in the mounting flange and bolt through the probe gasket and flange.
Grounding screws
A Grounding Screw is located on the outside of the CH88 Flue Gas O
local ground. A second Grounding Screw is located inside the probe housing. It is intended to connect the grounding
conductor to the control electronics.
WARNING: RISK OF ELECTRICAL SHOCK
Local Ground connection shall be provided to CH88 Flue Gas O2 Probe in order to avoid electric shock. The ground conductor
should be equal or greater than 16 AWG for a copper conductor in free air or 12 AWG for an enclosed copper conductor.
WARNING
Before installing this equipment read the "Safety instructions for the wiring and installation of this apparatus" at the front of this Instruction Manual. Failure to follow safety instructions could result in serious injury or death. Install all protective equipment covers and safety ground leads after installation. Failure to install covers and ground leads could result in serious injury or death.
Probe enclosure. It is intended to provide a
2
Installation
Installation/Start-up Manual
10
Installation
September 2017
CMB_MAN_ABR_CH88
CAUTION
Do not allow the temperature of the CH88 Flue Gas O2 Probe electronics to exceed 85°C (185°F) or damage to the unit
may result.
CAUTION
If the ducts will be washed down during outage MAKE SURE to power down the probes and remove them from the
wash area.
Figure 2: CH88 Flue Gas O2 Probe Installation
NOTE: ALL DIMENSIONS ARE IN MILLIMETERS WITH INCHES IN PARENTHESES
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