Super System HP15-VR Installation Manual

HP15-VR

Self-Heated Oxygen

Measurement and Control

System

USER’S MANUAL

Super Systems Inc.

7205 Edington Drive

Cincinnati, OH 45249

Ph : 513-772-0060, 800-666-4330

Fax: [phone]

www.supersystems.com

HP15-VR Manual Rev - Page 1 of 44

Table of Contents

Table of Contents ............................................................................................................... 2

Overview ........................................................................................................................... 4

Electrical Connections ....................................................................................................... 5

Dimensional Drawing ......................................................................................................... 8

Spare Parts ......................................................................................................................12

Plumbing Connections ......................................................................................................12

HP15-VR Screens .............................................................................................................13

Main Overview Screen....................................................................................................13

Menu Screens ..................................................................................................................13

System Information .......................................................................................................15

Logs.............................................................................................................................15

Alarm Log ....................................................................................................................15

System Log ...................................................................................................................15

Shut down interface.......................................................................................................15

Burnoff ........................................................................................................................16

Slave Communications Status ........................................................................................16

Auxiliary Analog Input ....................................................................................................16

PID Loop Setup .............................................................................................................17

Burnoff Setup ...............................................................................................................19

Relay Assignments ........................................................................................................20

Redundant Probe Setup .................................................................................................20

Communications Setup ..................................................................................................21

Furnace Setup ..............................................................................................................23

Instrument Assignments ................................................................................................25

Temperature Instruments ..........................................................................................26

Event Instruments .....................................................................................................26

Analog Input Setup ........................................................................................................26

Analog Output Setup ......................................................................................................28

Alarm Setup .................................................................................................................30

Aux Analog Input Setup ..................................................................................................32

Overview ...................................................................................................................32

Equipment needed .....................................................................................................33

Calibration Procedure ................................................................................................33

Input - Zero Calibration ..............................................................................................33

Input – Span Calibration .............................................................................................34

Cold Junction ............................................................................................................34

Calibration....................................................................................................................34

Overview ...................................................................................................................34

Equipment needed .....................................................................................................35

Calibration Procedure ................................................................................................35

Input - Zero Calibration ..............................................................................................35

Input – Span Calibration .............................................................................................35

Output – Zero Calibration ...........................................................................................36

Output – Span Calibration ...........................................................................................36

Cold Junction ............................................................................................................36

HP15-VR Manual Rev - Page 2 of 44

Tuning Assistant ...........................................................................................................37

Configuration ................................................................................................................38

Edit Event Text ..........................................................................................................38

Compact Database .....................................................................................................38

Communications Setup ..............................................................................................39

Read/Write Data ........................................................................................................39

Edit Trend Charts ......................................................................................................40

Edit Datalogger .........................................................................................................41

Reset Datalogger .......................................................................................................42

Display .....................................................................................................................42

Return ......................................................................................................................42

Chart Screen ....................................................................................................................43

CO Factor .....................................................................................................................44

HP15-VR Manual Rev - Page 3 of 44

Overview

The HP15-VR system includes two main enclosures. The first contains the heater and the Gold
Probe and is painted with a heat resistant black paint. This will be referred to as the “heater
enclosure.” The second is the blue electrical control panel which includes a Super Systems
9120 controller. This will be referred to as the “electrical enclosure.” Proper operation of this
system requires that these two enclosures be wired to each other, allowing the heater to be
controlled by the electrical enclosure. For detailed information regarding the connections
between the enclosures, please refer to the Electrical Connections section of this manual on the
next page.

HP15-VR Manual Rev - Page 4 of 44

Electrical Connections

Insert the probe into the coupling at the base of the large box. It is important that the probe is
inserted at the correct depth to allow proper heating. There should be between 10.0” and 10.5”
between the bottom of the adjustable 1” NPT gland and the end of the probe (see sketch below).

Once the probe has been inserted into the heater, make the necessary electrical connections at
the head of the probe. Attach the green thermocouple wire from the electrical enclosure box to
the thermocouple connection at the head of the probe (Positive (+) = Black; Negative (-) = Red).
The sensor wire should also be attached to the probe (Positive (+) = Black; Negative (-) = White).

This unit has been pre-configured and tested prior to shipment. To maximize the accuracy and
longevity of the Heated Probe, it is recommended that the unit be operated at 1500°F. It is also
possible to configure the HP to match the temperature of your furnace.

HP15-VR Manual Rev - Page 5 of 44

Inside Electrical Enclosure

 6.0 AMP  6 Amp Circuit Breaker

 1000  Incoming Customer 110VAC (Line)
  Incoming Customer 110VAC (Neutral)
  110VAC (Neutral) To Heater
  110VAC (Neutral) To Heater
 GND  Incoming Customer 110VAC (Ground)

 
 

 1103  110VAC (Switched Line) to Heater Enclosure
 1601  Enriching Gas Contact #1
 1602  Enriching Gas Contact #2
 1621  Dilution Air Contact #1
 1622  Dilution Air Contact #2
 1641  Pump Terminal
 1002  110VAC (Neutral) - Spare
 1661  Burnoff Solenoid
 1681  Alarm Contact #1
 1682  Alarm Contact #2

 
 
 

 1021  RS485 Host Communications Shield
 1031  RS485 Host Communications RT- (Negative)
 1041  RS485 Host Communications RT+ (Positive)
 1101  SSR Resistor Terminal
 1102  SSR Resistor Terminal
 1320  Dry Contact for Sample Inhibit
 1330  Dry Contact for Probe Burn-Off
 1340  Dry Contact Common

 
 

 1360  Analog Output #1 (Negative)
 1380  Analog Output #2 (Negative)

Inside Heater Enclosure

 1003  Incoming 110VAC (Line) from Electrical Enclosure
 1002  Incoming 110VAC (Neutral) from Electrical Enclosure
 GND  Incoming 110VAC (Ground) from Electrical Enclosure
 1103  Incoming 110VAC (Switched Line) from Electrical Enclosure

 
 

110VAC (Line) to Heater Enclosure

1003

1002

Analog Output Common (Positive)

1350

Host Communications connect to the Host Computer.
Analog Output #1 is the 4-20mA signal for Process Variable Retransmission.
Analog Output #2 is the 4-20mA signal for Temperature Control (Optional).

HP15-VR Manual Rev - Page 6 of 44

1. Connect incoming 120VAC to the Electrical Enclosure:
110 VAC Line Terminal 1000

110 VAC Neutral Terminal 1002

110 VAC Ground Terminal GND

2. Connect Electrical Enclosure to Heater Enclosure:

Electrical Heater
Terminal 1003 Terminal 1003
Terminal 1002 Terminal 1002
Terminal 1103 Terminal 1103

3. Connect "S" Type Thermocouple wire from Probe to Model 9120 Controller in Electrical Enclosure
Probe Model 9120

+ T'CPLE (Black) Terminal 30

- T'CPLE (Red) Terminal 29

4. Connect Millivolt wire from Probe to Model 9120 Controller in Electrical Enclosure
Probe Model 9120

+ SENSOR Terminal 32

- SENSOR Terminal 31

5. (Optional) Connect Furnace Thermocouple to Model 9120 Controller in Electrical Enclosure

Probe Model 9120

+ T'CPLE Terminal 28

- T'CPLE Terminal 27

6. (Optional) Connect RS485 Communications to Host Computer

Electrical Host Computer
Terminal 1021 Shield
Terminal 1031 RT­Terminal 1041 RT+

7. (Optional) Connect Enriching Gas Contact

Electrical (Customer)
Terminal 1601 T.B.D
Terminal 1602 T.B.D

8. (Optional) Connect Dilution Air Contact

Electrical (Customer)
Terminal 1621 T.B.D
Terminal 1622 T.B.D

9. (Optional) Connect Alarm Contact

Electrical (Customer)
Terminal 1681 T.B.D
Terminal 1682 T.B.D

10. (Optional) Connect Dry Contact for Sample Inhibit

Electrical (Customer)
Terminal 1320 T.B.D
Terminal 1340 T.B.D

11. (Optional) Connect Dry Contact for Probe Burnoff

Electrical (Customer)
Terminal 1330 T.B.D
Terminal 1340 T.B.D

12. (Optional) 4-20mA Output for Process Variable Retransmission

Electrical (Customer)
Terminal 1350 T.B.D +
Terminal 1360 T.B.D -

13. (Optional) 4-20mA Output for Temperature Control

Electrical (Customer)
Terminal 1350 T.B.D +

HP15-VR Manual Rev - Page 7 of 44

Dimensional Drawing

Dimensional Drawing of HP15-VR Electrical Enclosure

HP15-VR Manual Rev - Page 8 of 44

Dimensional Drawing of HP15-VR Heater Enclosure with Sensor Inserted

HP15-VR Manual Rev - Page 9 of 44

Dimensional Drawing of HP15-VR Heater Enclosure with Sensor Removed

HP15-VR Manual Rev - Page 10 of 44

HP15-VR Manual Rev - Page 11 of 44

P/N

Description

20401

Ceramic Heater/Well Spacers

31080

7EK Temperature Controller

31096

Controller, Overtemp

31125

Power Supply 24V DC

32074

Heater

32122

SSR, 10A 240V Low Profile

37120

Pump - Reference Air

37138

Valve, Solenoid, 3-Way

37177

Pump - Sample / Burnoff Air

13454

Series 9120 Controller

36013

Flowmeter, 0.2 to 2 SCFH

36027

Flowmeter, 0.5 to 5 SCFH

36017

Flowmeter, 1 to 10 SCFH

31604

SD Flash Card

13498

3.5" Color Touch Screen

20059

Filter with Glass Wool Media

37037

Filter media replacement (20 grams)

Spare Parts

The following is a list of spare parts recommended for the HP15-VR.

Plumbing Connections

The sample gas is transported from the furnace to the electrical enclosure filter using silicone
tubing. The sample flow should be between 4.0 and 5.0 SCFH. Connect the ports on the side of

HP15-VR Manual Rev - Page 12 of 44

the electrical enclosure to the probe in the heater enclosure using silicone tubing. Connect

tubing from the fitting on the electrical enclosure marked “To Probe Reference” to the “Ref.
Air” port on the probe. A connection should also be made between the “To Burnoff Port” fitting
and the “B.O.” fitting on the probe. There is a barb fitting on the stainless steel well on the

heated probe. This is the vent, which needs to be routed to an appropriately safe location.

HP15-VR Screens

Main Overview Screen

The Main Overview screen will be the initial screen that is displayed when the Touchscreen is
started. The Main Overview screen will display
the following for each loop: type, setpoint, current
value, output mode, output, the
activated/deactivated inputs and outputs, any
messages, the Menu button, Chart button and CO
Factor button. Any activated inputs or outputs will
be lit up. Note on Inputs and Outputs – The
numbering on the display starts at 0 instead of 1,
so input 2 shown in the figure is actually input 3,
and output 4 is actually output 5. The red bar will
display any messages. The output mode can be
changed from auto to manual by pressing the
auto/manual button to toggle between the two
options.

The top of the screen displays the point value type (PVT) of %Carbon with Temperature control.
In the example figure, the %Carbon column shows the calculated %Carbon of 1.8% and the
setpoint of 1.00%. The Temperature column shows the measured temperature of 1502°F and
the setpoint of 1531°F. The PVT can be Oxygen, Carbon, Dewpoint, or millivolts.

There are three active buttons at the bottom of the
screen: Menu, Chart, and CO Factor.

Menu Screens

The menu screen will allow the user to configure
the 9120 unit based on the login level. When the
menu list is first displayed, the user will be
automatically logged in at the Operator-level. The
number of menus will vary based on the login level.
The default login for Supervisor is a 1. The default login for Administrator is 2.

The Operator–level will have the following menu items:

 System Information
 Logs

HP15-VR Manual Rev - Page 13 of 44

 Shut down interface
 Burnoff
 Slave Communications Status
 Auxiliary Analog Input

The Supervisor-level will have the following menu items:

 System Information
 Logs
 Shut down interface
 Burnoff
 Slave Communications Status
 Auxiliary Analog Input
 PID Loop Setup
 Burnoff Setup
 Relay Assignments
 Redundant Probe Setup

The Administrator-level will have the following items:

 System Information
 Logs
 Shut down interface
 Burnoff
 Slave Communications Status
 Auxiliary Analog Input
 PID Loop Setup
 Burnoff Setup
 Relay Assignments
 Redundant Probe Setup
 Communications Setup
 Furnace Setup
 Instrument Assignments
 Analog Input Setup
 Analog Output Setup
 Alarm Setup
 Aux Analog Input Setup
 Calibration
 Tuning Assistant
 Configuration

There is also an SSi-special-level that can only be accessed with the passcode that can be
provided by Super Systems Inc at 800-666-4330. Currently, the menu list for this level is the
same as the list for the Administrator-level. To select a menu item, highlight the item by
clicking on it and pressing the Detail button. The Login button will allow the user to login as a
different access level. The Return button will allow the user to return to the main screen.

HP15-VR Manual Rev - Page 14 of 44