Instruction Manual RADOX analyzer

Software:V1.035 10/2014 Version:V1.35_R0

This instruction has to be stored for future working processes with the analyser at an appropriate place and has to be always accessible and available for the personnel!

Instruction Manual

RRHHAADDOOXX AAMMSS 77330000

ATEX Ex II 3G IIB+H2 T3

Analyser for Wobbe Index, Air Demand,

Specific Gravity (SG), and Calorific Value

*Options

Technical Description

General information for installation, start-up, and measuring mode

Warning: Please wait 60 minutes after disconnecting power supply before open the housing.

AMS Analysen-, Mess- und Systemtechnik GmbH

Industriestrasse 9

D-69234 Dielheim

Tel. +49-6222-78877-0 e-mail: [email protected] Fax. +49-6222-78877-20 web-site: www.ams-dielheim.com

Instruction Manual

RHADOX AMS 7300 Page 2 ATEX Ex II 3G IIB+H2 T3

Version: V1.35_R0 10/2014

Table of Contents page 1. INTRODUCTION .......................................................................................................................................... 3

1.1 PHYSICAL PRINCIPLES OF THE ANALYSER RHADOX 7300 ......................................................................... 3 1.2 MEASURING PRINCIPLES ........................................................................................................................... 5 1.3 AS BUILT .................................................................................................................................................. 7 1.4 TECHNICAL DATA RHADOX 7300 ............................................................................................................. 8

2. INFORMATION FOR THE OPERATOR .................................................................................................... 10 2.1 HOW TO USE THE INSTRUCTION MANUAL.................................................................................................. 10 2.2 APPROVED USE ...................................................................................................................................... 11 2.3 SAFETY INFORMATION ............................................................................................................................. 12

3. RELEVANT INFORMATION FOR INSTRUMENTS PROTECTED AGAINST EXPLOSIONS ................. 13 3.1 IGNITION PROTECTION TYPE EEX-P (PRESSURISED ENCLOSURE) .............................................................. 13 3.2 GENERAL INFORMATION .......................................................................................................................... 15 3.3 PURGE UNIT F840 / BY GNNHEIMER .................................................................................................. 15 3.4 CATALYTIC COMBUSTION OF BYPASS-GAS ................................................................................................ 16 3.5 IN CASE OF PURGE AIR FAILURE .............................................................................................................. 16

4. INSTALLATION AND START-UP ............................................................................................................. 17 4.1 TECHNICAL DRAWINGS RHADOX 7300 .................................................................................................. 17 4.2 ELECTRIC CONNECTIONS ........................................................................................................................ 17

4.2.1 Supply Voltage ............................................................................................................................ 17 4.2.2 Signal Outputs ............................................................................................................................ 18

4.3 PNEUMATIC CONNECTIONS ..................................................................................................................... 19 4.3.1 Gas Inlets .................................................................................................................................... 19 4.3.2 Gas Outlets ................................................................................................................................. 20

5. START-UP ................................................................................................................................................. 21 5.1 GENERAL OPERATION AND OPERATION/SERVICE CODES .......................................................................... 21 5.2 STARTING THE ANALYSER ....................................................................................................................... 23 5.3 TEMPERATURE MONITORING OF THE PNEUMATIC UNIT (*OPTION) ............................................................. 24

5.3.1 Setting the Cabinet Temperature.................................................................................................. 24 5.4 MEASURING MODE ................................................................................................................................. 24

6. SETTING THE USER PARAMETERS ...................................................................................................... 25 6.1 ANALYSER OPERATION ........................................................................................................................... 25 6.2 SETTING THE SECOND LINE ..................................................................................................................... 26 6.3 SUBMENU DIAGNOSIS ............................................................................................................................. 27 6.4 SUBMENU PARAMETER ........................................................................................................................... 27 6.5 SUBMENU ANALOGUE OUT ...................................................................................................................... 28 6.6 SUBMENU CALIBRATION .......................................................................................................................... 29

6.6.1 Adjusting of Auto-calibration ......................................................................................................... 33 6.6.2 Start of Auto-calibration ................................................................................................................ 33 6.6.3 Calibration Errors .......................................................................................................................... 33

6.7 SUBMENU SERVICE ................................................................................................................................. 34 6.7.1 Fixed Density (*Option) ................................................................................................................ 37 6.7.2 Service Request .......................................................................................................................... 37 6.7.3 Cabinet Temperature (*Option) .................................................................................................... 38 6.7.4 Expert Mode.................................................................................................................................. 38

7. SERIAL INTERFACE ................................................................................................................................. 39 8. ERROR MESSAGES ................................................................................................................................. 40 I. GAS ALARM (*OPTION) ............................................................................................................................ 41 II. MEASURING CABINET COOLER (*OPTION) ......................................................................................... 42 III. SERVICE SOCKET (*OPTION) ................................................................................................................ 42 IV. EXTERNAL CATALYTIC COMBUSTION OF BY-PASS GASES (*OPTION) ........................................ 43 V. INSIDE CATALYTIC COMBUSTION OF BY-PASS GASES (*OPTION) ................................................ 44

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1. Introduction

1.1 Physical Principles of the Analyser RHADOX 7300

Due to environmental protection and as a cost-saving alternative to natural gas fuelling, more and more gases used in industrial combustion processes that produced in other operations, such as in coking plants. However, the composition of these exhaust gases is often subject to strong variations due to their generating process.

On the other hand, a constant energy supply at the combustion of the off-gases is an economic necessity and minimizing the emission desired. The reliable and continuous measuring of the air demand and the Wobbe index of the gas used is necessary in order to adjust the combustion process to the changing gas qualities and to the specific operating conditions.

Field of Application

Utilization of off-gases of furnaces, chemical plants and refineries as well as of sewage digesters and bio-gas plants: in the combustion control for gas-fired boiler plants and industrial furnaces in power production plants, the chemical and petrochemical industry

In plants producing blended gases of a given quality For the production of synthetic gases, even with a very low Wobbe index The gas flame as a tool: quality assurance in the glass industry

Systems Characteristics

RHADOX - measuring systems for air demand, Wobbe index, and calorific value, specific gravity

Customized systems Burner or catalytic reactor for adjusting to the measuring gas quality Calibrateable with the PTB certification (special model) Automatic and manual 2-point calibration ZrO2 sensor for the oxygen measurement menu-driven parametrizing Diagnostic system for the instrument functions and alarms Continuous operating mode

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RHADOX 7300

The RHADOX 7300 is a compact system for the continuous and reproducible determination of the air demand at a total combustion of a gas. The instrument built into an insulated wall cabinet.

The mixing cell consists of two separated gas chambers, i.e. the mixing chamber and the fitting chamber. This mixing cell plays a key part in the homogenous and reproducible process of the sample gas with the combustion air. Due to built-in gas jets (Venturi-jets) for the probe gas and the combustion air, the simple measuring method makes use of the law of Bernoulli (see measuring principles).

From the mixing chamber, the gas/air mixture flows to the fitting chamber, which might design as a supersonic jet or a flame barrier (depending on the application involved). Hence, a reaction from the burner on the performance of the mixing chamber has prevented and the ultimate mixing of the two gases will achieved.

Gas and air supplied to the corresponding apertures located in the mixing cell.

The electronic controller ensures that the pressure of both gases in the two separated gas volumes is equal and constant (controller accuracy + 0,01 mbar). For this purpose, a pressure controller for the combustion air as well as a differential pressure transmitter is used in the instrument.

The front panel features two pressure meters: the controller to adjust the correct pressure of the combustion air and a meter for the sample gas pressure. The latter will adjust to the correct air pressure via the electronic controller.

Programming and operating the instrument needs only three push buttons: one for the operation mode (measurement, calibration, and signal outputs), two for the cursor. A display with two LCD rows indicates the corresponding values and user fed data (alarms, residual Oxygen). A key operated switch locks the programming level if required.

Figure 1.1: RHADOX 7300 Basic Gas Flow Diagram

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Fig. 1.2

Using the semi-automatic calibration mode a given and correct value compared to the corresponding measuring value of the test gas via the electronic controller. Deviations show on the display.

If a two-point calibration is need, a second calibration point can obtain via an auxiliary airflow to dilute the reference gas properly. Of course, also two different reference gases can use to cover the measuring ranges. The actual calibration mode depends on the specific AMS application.

1.2 Measuring Principles

The combustion gas to analyze via the RHADOX measuring system will completely oxidize with air in surplus (approx. 3-10 fold). The mixture of the measuring gas with the burner air has to be constant and reproducible. Hence, the residual Oxygen is a reliable measure for the Air Demand of the oxidized gas. Once the instrument has been calibrated the corresponding Wobbe Index can be determined. Design and construction of the mixing cell for combustion gas and air meet Bernoullis law, taking into account the viscosity of the compound (Reynolds Number Re):

ppAvA /*2** == = Const. ( 1 )

2/*(Re)]1[ 2vfp ++= ( 2 )

D/ v Re ..= ( 3 )

With: p pressure loss in the reduction D diameter of the restriction Density V flow speed in the restriction Volume flow A restriction area Dynamic viscosity

Apart from temperature and pressure, the volume flow depends only on the density and the viscosity of the gas considered. For Re < 2000 a laminar gas flow can be assumed, the function f(Re) tends to zero. This prescription will met through the corresponding layout of the gas jets for measuring gas and air as well as by maintaining pressure and temperature of both the components sufficiently constant and equal:

p ~ 0.2 mbar T ~ 0.25 C p ~ 100 mbar T ~ 2 C

The dimensions of the aperture(s) in the mixing chamber in order to achieve Reynolds number following eq. (3) are set during the application at AMS GmbH.

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The stoichiometric Air Demand l at the combustion process has defined as

lstoichio. = [air supplied - res. O2] / gas (4)

and the corrected stoichiometric air demand as

lcorrr. = stoichio. / d rel. (5) with the specific gravity defined as drel. = gas / air

Values for the relative density may take from the literature, or more precisely determined via a specific measurement of the actual gas mixture. The measuring procedure featured by the RHADOX reduces the determination of l

corr.to a single

measurement, i.e. to the residual Oxygen concentration or Air Demand. The residual Oxygen concentration will display.

Within reasonable concentration ranges, a linear relationship exists between the (corrected) stoichiometric Air Demand and the Wobbe Index, the latter of major importance for burner control units. To determine this relationship for a given gas matrix is a further major task of the AMS application lab. The corresponding calibration enables the determination of the Wobbe Index WI via the built-in computer:

WI = f(lkorr.) (6)

The Wobbe-Index WI has related to the Calorific Value H as

WI = H / d (7)

The instrument computer can determine the calorific value of a gas with the help of an additional, separately installed density measurement. There are two systems for the oxidation of a measure gas, a burner with a flame resp. with a catalytic reactor. If the sample gas cannot burn in a stable flame due to its physical or chemical characteristics, the catalytic reactor developed by AMS will installed instead of the burner. The reaction chamber will fill and heat with a noble metal functioning as catalytic converter.

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1.3 As built

The analyser consists of the following main components:

1. two-part housing, Left side Pneumatic for gas mixing and analyse Right side power supply, electronic, evaluation

2. Electronics, wiring terminal, Display und Functional keys

3. Solenoid Valve(s) for Gas shut-off / change

4. Pressure reducer for Instrument Air / Process Gas

5. Oxygen analyse in raw Gas (*Option)

6. Analogue solenoid Valve and Gas mixing with Pressure monitoring

7. Measuring catalyst followed by residual oxygen analysis

8. Density measuring cellblock

9. Catalytic combustion for bypass gas (*Option)

10. Purge Gas Unit for Ex-Zone 2

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1.4 Technical Data RHADOX 7300

Voltage Supply 110230VAC / 50/60Hz

Power Consumption max. 1000 VA

Ambient Temperature -5 up to +45C

Influence of Temperature 20 up to 40C: 0,04% /C

Display 2*16-digit back-lit LCD

Analogue Outputs 4-20 mA, ohmic load max. 500 Ohm max. 4 outputs, possible settings: WI, CARI, LCV, SG (Please refer to the test report) *Option: measuring ranges galvanically isolated

Measuring Ranges(s) according to the application, programmable

Accuracy depends on the quality of the test and references gases

Repeatability Wobbe index : 1,0% of the current value Air Demand : 1,0% of the current value Gas Density : 2,00% of the current value Calorific Value : 2,00% of the current value

Noise 0,3% of the current value Drift 0,5% of the current value / month

Response Times Wobbe Index and Air Demand T90% :10-40 sec. depending by application Specific Gravity and Calorific Value T90% : 10-40 sec. depending by application

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Analyser Messages

Analyser State : 4 messages signalising the analyser state Potential-free pins

max. load: 24V/0,3A ohmic load

1x Status message (measuring values available (Yes/No))

3x indicating the operating status 1. Service Request (YES / NO)

2. Calibration active (YES / NO) 3. Service active (YES / NO)

Serial Interface : RS 232 C (please refer to chapter # 9: cable and protocol)

Calibration : semi-automatic calibration with two bottled gases Manual start of the calibration Manual switching between the calibration cal gases (*Option Automatic calibration Automatic monitoring of the calibration

Dimensions : W x H x D ca. 900*1.000*350 mm

Weight : ca. 150 kg

Flow Rates

Instrument Air : max. 250Nl/hr at 2,0 6 bar-g Measuring Gas : max. 100Nl/hr during application Calibration Gas : max. 100Nl/hr during application

II. Ex-relevance Data corresponding nameplate

Labelling ATEX Ex II 3G IIB+H2 T3

Ambient Temperature + 5 Temp + 55 C

Housing protection IP65

Purge gas instrument quality air (oil- / dust free) / Inert gas

min / max purge air pressure 2 / 6 bar (g)

min / max protection over-pressure 0,8 / 15 mbar (g)

min. purge air flow 100 l/h (during operation)

AMS GmbH, 2012, subject to modification

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2. Information for the Operator 2.1 How to use the Instruction Manual

Please read this Manual before the start-up of the instrument!

The manual contains important data and information. Observing this information guarantees safe operation of the analyser and will result in reliable measuring values.

This Manual describes the standard instrument. Deviations are marked at the corresponding part of the documentation.

Of particular importance are the information and warning texts identified by the appropriate pictograms. These symbols serve the personal safety and provide useful tips on how to avoid malfunction.

This Manual comprises all necessary information for the application-oriented use of the instrument. Therefore, only qualified and authorized personnel may work with the instrument. The personnel should properly train in measuring and control instrumentation for process automation.

This Manual is an integral part of the system supplied. For clarity reasons this Manual cannot cover all details of the various versions supplied. If it is intended to use the instrument in a different way as described herein, please contact AMS GmbH, Dielheim before starting the analyser.

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2.2 Approved Use

The product supplied has been developed, manufactured and tested according to the relevant safety standards. It may used only as approved by AMS GmbH, Dielheim. Proper transport, storage and installation are a must, as well as careful operation and maintenance to guarantee the safe and reliable operation of the instrument.

Only qualified and authorized personnel may install and operate this instrument. The personnel shall be familiar with the safety concept of this instrument. Severe injuries and/or substantial damage to property may occur by not observing the warning texts in this manual or attached to the analyser or if unqualified actions are carried out.

Intended use in the sense of this manual means that the instrument may only use in applications described in this manual. Auxiliary equipment or other components used in conjunction with this instrument have to approve by AMS GmbH, Dielheim.

Observing the safety and operation rules described in this manual helps to avoid personal and property damages during regular operation.

Warning

While opening the housing of the analyser please observe that certain parts of this device may carry dangerous voltages. Therefore, only authorized and qualified personnel may open the instrument.

Note

The conformity declaration of this instrument must renew if the operator, e.g. using a different sensor type, has carried out modifications in this instrument.

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2.3 Safety Information

The following information serves for your personal safety as well as to protect the described product from damage.

Safety information and warnings to prevent danger to the life and health of users identified by pictograms in this Manual matched to the significance of the accompanying text.

Note is important information on the product itself and its handling.

Danger means that death, severe personal injury and/or substantial damage to property will occur if the appropriate safety precautions has not observed.

Warning means that death, severe personal injury and/or substantial damage to property can occur if the appropriate safety precautions has not observed.

Caution with a warning triangle means that slight personal injury can occur if the appropriate safety precautions has not observed.

Caution without a warning triangle means that damage to property can occur if the appropriate safety precautions not observed.

Attention without a warning triangle means that an undesirable effect or state can occur if the corresponding information has not observed.

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3. Relevant Information for Instruments protected against Explosions

Note For a safe application of the RHADOX 7300 the analyser features an approved purge unit. Please read the instruction manual of this purge unit as well as the instruction manual of the RHADOX itself before the initial start-up of the RHADOX.

Danger Please read the separate manual of the purge unit and proceed accordingly. Lack of knowledge of the purge units functioning and its safety concept might cause substantial material damage of the complete analysing system. Furthermore, disregarding the safety instructions may lead to life-threatening injuries and/or death.

Note In addition to the purge unit, an optional catalytic combustion of by-pass gas is available.

3.1 Ignition Protection Type EEx-p (pressurised enclosure) Instruments with the ignition protection type EEx-p labelled according to the hazardous area (Ex-Zone 1 or Ex-Zone 2).

The basic principle of the ignition protection type is to keep explosive gas mixtures clear of non-hazardous instruments. An excess pressure against the atmosphere inside the protected housing, which has monitored, achieves this.

Gases (generally instrument air or Nitrogen) passed into the protected housings. Hereby a slight excess pressure built up inside the tightly sealed housings reliably preventing the intrusion of vapours of dangerous atmosphere. Therefore, the protective housings may only have opened being in a voltage-free state.

For ensuring the permanent leak-tight containment is at least 1x per year to provide the evidence on testing the tightness of the containment technology with 1.5 times the operating pressure. For this, the standard EN 1127-1 should be considered.

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Please comply all of these technical formalities for the containment system:

Gas inlet pressure: max 5 bar (g) Air inlet pressure: max. 5 bar (g)

Flow rates during operations

Air: app. 250 - 500 l/h Gas: app. 50 - 150 l/h

For assessing and establishing, a tight containment considered the norm EN 1127-1 approach. As permanently sealed containment, devices apply if:

I. They are constructive in such a way, that they remain tight due to technical, or II. Their technical tightness is ensured by servicing / maintenance and monitoring

Please use only trained and qualified personal to check for leaks in the analyser suitable use in hazardous areas.

The service and maintenance of the analyser includes the following measures:

1. Visual inspection of the equipment and check for savour, noise due 2. Review of devices with mobile leak detectors and portable gas detection devices 3. Overpressure test of the entire system at 1.5 times of the normal operating pressure

The operator of the system, at least monthly for point 1, shall determine the frequency of testing. and 2., and quarterly for testing the entire system.

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3.2 General Information

The faultless and safe operation of the analyser and its optional catalytic combustion of by-pass gas require careful operation and maintenance. Only qualified personnel may work on these instruments.

The operator has to observe strictly the electric parameters of the label and of the test certificate.

Warning The housings of the measuring system (purge unit and calorific value analyser) may only have opened in a voltage-free state.

Warning If there is explosive dust in the ambient you have to clean the interior of the housings before closing the lids.

3.3 Purge Unit F840 / by Gnnheimer

To protect the analyser it is equipped with a purge unit by Gnnheimer. Please read the Gnnheimer manual before the start-up and proceed accordingly.

Parameters Ex-Zone 2

The purge unit pre-sets by the manufacturer. The general parameters lined out in the separate manual.

Attention The general settings has found in the corresponding manual.

After you have carefully read, the manual you may re-set all values. However, if the analyser used in the Ex-Zone 2 please make sure that there is no hazardous atmosphere, which might lead to an explosion.

The measures, which will take if the purge unit and/or purge air fail, are the sole responsibility of the operator. These should be in accordance with the general regulations of the plant operator.

The purge unit of the analyser for calorific value AMS 7300 protects the analyser via instrument air against intruding hazardous atmosphere. Further functions, such as shutting down in case of failing purge air, has not intended.

We again refer to the safety concept of the plant operator. The operator has to guarantee the safe operation and has to arrange in case of failing instrument air to protect the personnel and the plant against explosions.

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3.4 Catalytic combustion of Bypass-gas

The optimized mixture of combustion air and sample gas leads to an increased production of fuel-/air mixture more that could burn in the measuring catalyst. Therefore, an optional catalytic afterburner is available. The catalytic afterburner integrated in the housing and in use in hazardous areas.

Without the catalytic afterburner, a costly disposal of the fuel-/air mixture is necessary. The disposal should carefully planned by the operator of the analyser to protect the exhaust pipes for explosion in hazardous areas.

3.5 In case of Purge Air Failure

Note In case of purge air failure, the EEx-p controller automatically shuts down the complete measuring system from the mains. In addition, it closes the sample gas valve. This will protect the analyser as well as the catalytic oven combustion of by-pass gas.

Danger After disconnecting the instrument or after a purge unit failure you have to wait at least one hour until you open the housings. The internal parts have to cool down to the maximum surface temperature. Please observe the temperature class, which has indicated on the type label.

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4. Installation and Start-Up

ATTENTION: Strictly follow all working steps / control measures described below. The operator may not change anything concerning the operation, used components, and may not alter the control electronics in any way. Otherwise, the certificate is not valid anymore!

4.1 Technical Drawings RHADOX 7300

The controls of the analyser RHADOX 7300 as well as the electric and gas connections has outlined in the technical drawings in the appendix.

Please refer to the corresponding drawings in the appendix.

4.2 Electric Connections

4.2.1 Supply Voltage

Concerning the terminal assignment of the power supply line, please refer to the corresponding AMS GmbH technical drawing in the appendix.

Power Supply: 110230 VAC ; 50/60Hz ; max. 1000 VA, please refer to the test report and the technical drawings in the attachment.

Danger Only trained personnel may connect the power supply line since an inappropriate connection may harm the personnel and the systems. Under certain conditions, the internal parts may carry hazardous voltages.

Note Always operate the instrument after applying instrument air. This allows ventilating the catalyst and the optional catalytic combustion and diminishes the preheat sequence of a cool catalyst as well as the heating time of the complete system.

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4.2.2 Signal Outputs

The terminal assignment of the terminal row X4 has outlined in the appendix.

A.) Analogue Outputs

B.) Serial Interface RS232

Terminal Assignment Description 09 10 11

RS232 RXD TXD please refer to # 6 of the Instruction Manual GnD

C.) Messages via the relay contacts

Terminal Assignment Description 01 02 Analogue Output 1 420 mA current loop, measuring value freely

programmable 03 04 Analogue Output 2 420 mA current loop, measuring value freely

programmable 05 06 Analogue Output 3 420 mA current loop, measuring value freely

programmable 07 - 08 Analogue Output 4 420 mA current loop, measuring value freely

programmable

Terminal

Assignment Switch Position

Description

12 - 13 SYSTEM STATUS

12 - 13

Measuring values available Measuring values not available FAIL SAFE [NC]

12 - 14 Service Mode open 12 - 14

Measuring Mode Service Mode [NO]

12 - 15 Calibration open 12 - 15

Calibration inactive Calibration active [NO]

12 - 16 Service Request open 12 - 16

Message inactive Service request [NO]

17 -19 Relay 5 Back-up relay, not assigned 20 - 22 Relay 6 Back-up relay, not assigned

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4.3 Pneumatic Connections

In order to connect the calibration gases please refer to the corresponding AMS GmbH drawing in the appendix.

1. Gases for the measuring mode: Instrument Quality Air

Air pressure: 2,0 - 6,0 bar-g, dust-free and clear of hydrocarbon Flow rate: max 250Nl/hr

Non-condensing process gas Gas pressure: according to the application Flow rate: ca. 100Nl/hr

2. Gases for the calibration: Instrument Quality Air

Air pressure: 2,0 - 5,0 bar-g, dust-free and clear of hydrocarbon Flow rate: max 100Nl/h

2 calibration gas bottles with different gas compositions Gas pressure: according to the application

Flow rate: max. 100Nl/h

4.3.1 Gas Inlets

Note All gas inlets outside of the analyser cabinet labelled in plain text!

1. Instrument air "Instrument Air"

2. Sample gas "Process Gas"

3. Calibration Gases "Cal. Gas high"

"Cal. Gas low"

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4.3.2 Gas Outlets

Note The following indications of the gas connections can found at the outlet fittings!

4. "Bypass" combustor

Danger This is an inflammable gas/air mixture (ca. 300 Nl/hr)

The by-pass gas has to be disposed of via a back-pressure-free and safe conduit!

Disposal pressure-free and pressure-fluctuation-free

We recommend leading off the by-pass gas via a stainless steel conduit of 1-2 m with the appropriate connection size of the lines. If the by-pas gas is lead off via a longer conduit, the diameter of the lines has to be enlarged.

5. Reference air + purge gas OUT "PurgeGas"

The reference air and purge gas may be discharged freely to the ambient atmosphere.

6. Off-gas "Exhaust/Condensate"

Lead the off-gas away via a continually sloping 1 - 5 m conduit or hose. If the off-gas is lead off via a longer conduit the diameter of the line has to be enlarged accordingly. The off-gas conduit leads away max. 20 Nl/hr of a combusted water-saturated gas mixture. On falling below the dew point, the resulting water has to be disposed of to the rule. The off-gas temperature at the exhaust fitting of the analyser is below 60 C.

While installing the off-gas conduits make sure that the condensed water can flow off freely. A congested off-gas conduit can shut down the complete instrument.

Remark: If you want to install an upward off-gas conduit you have to connect a condense separator with a corresponding condensate separation at the analysers exit.

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5. Start-up

Note Before the start-up, all electrical and pneumatic connections have to connect according to their use. Make sure all pneumatic lines are gas-tight.

Attention strictly follows all working steps / control measures described below. The operator may not change anything concerning the operation and use components and may not alter the control electronics in any way. Otherwise, the certificate is not valid anymore!

Note If the analysing system features a catalytic combustion of by-pass gas it is important that the combustion reach its operating temperature before the RHADOX start-up since the catalytic combustion will provide the release signal for the RHADOX

Note The inlet valve closed during the preheating time of the pneumatic unit, of the catalyst, and of the ZrO2 sensor. Please set the gas inlet pressures to the correct values after all components have reached their operating temperature and after the main valve has opened. The required pressure values noted in the test report and next to the manometers.

5.1 General Operation and Operation/Service Codes

The analyser operates via three keys. The F-key takes you to the menu. You can toggle through the menu via the two arrow keys and you can makes settings according to the direction of the arrows.

Note After you have changed values and/or settings via the arrow keys, you have to confirm the new values with the F-key. If the new values has not approved by the F-key, the former values remain valid.

Note The display will light as soon as you press any key. The lightning will go out if no key has pressed during the next 20 sec.

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Via pressing the F-key, you will reach the menu from which you can choose by pressing the F-key and/or the arrow keys. Sensitive data have protected by codes in the submenu.

1. Operation Code 111

2. Service Code 1111

The chapter submenu outlines when to enter which code. The entered code is valid until you switch back into the measuring mode.

Software pattern:

Measurement Mode Menu Submenu

Measure

Diagnosis F-key Submenu, please refer to # 6.3

Parameter F-key Submenu, please refer to # 6.4

Analogue Out F-key Submenu, please refer to # 6.5

Calibration F-key Submenu, please refer to # 6.6

Service F-key Submenu, please refer to # 6.7

Note Via pressing the F-key you will get from the measurement mode to the menu. Now you can select the corresponding submenu via the arrow keys. After you have quit the submenu by pressing return, select Measure and you will reach the measurement mode.

Note If you do not press any key for ca. 250 sec. the analyser automatically switches back to the measurement mode regardless of the menu level.

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5.2 Starting the Analyser

Note After starting the RHADOX 7300 the automatic start process follows as described like below.

Note The RHADOX 7300 only reaches its normal operating status if all gases (air, process gas) has connected to the corresponding gas lines. Please refer to # 5 of the instruction manual!

Note The inlet valve has shut off during the preheating time of the measuring catalyst and of the ZrO2 sensor. Only after both components have reached their operating temperature and the main valve is open, please set the gas pressures of the inlets to the correct values. These required pressure values can be found in the test report and are marked next to the manometer.

Display Description

AMS 7300 Ser.Nr.

After powering on the analyser, the start menu displayed. Among others, the system identification and serial number has shown.

Warmup ##,## h Catalyst Temp. ### C

During the pre-heating time, the sample gas catalyst has heated up to 400 C. Simultaneously the ZrO2 sensor is pre-heated.

Startup ##,## min Checking

Now further sensors are checked and the system levels out to the current measuring value = process gas

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5.3 Temperature Monitoring of the Pneumatic Unit (*Option)

The analyser features a temperature monitoring of the pneumatic unit. It can display as cabinet temperature in the second line. The cabinet temperature protects mounted parts and monitors the condensation formed by temperatures below dew point.

Note The measurement will stop if previously set temperature limits has exceeded or fallen below to protect the mounted parts. The operator can set the temperature limits. The factory-set limits has noted in the test report.

Note If the temperature inside the pneumatic unit is > 50 C, special parts have to use. These are optionally available at AMS GmbH.

5.3.1 Setting the Cabinet Temperature

The possibilities of settings of the temperature evaluation has described in # 6.7.3.

5.4 Measuring Mode

After the pre-heating sequence, the analyser automatically starts the intake of the measuring values. The current Wobbe index shows in the first line of the display. The second line of the display may be set by the user (choose from a list).

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6. Setting the User Parameters

6.1 Analyser Operation

The analyser has operated via three buttons. Via the F-key (=function key) you can choose menu items of the main menu. In addition, the F-key confirms altered values and parameters. Via the two arrow keys and (=justifying keys) you can change values according to the keys symbols (increasing/decreasing).

Note Please confirm any changes of values or parameters via the F-key.

Main Menu

Display Description

Measure

Diagnose Possible error messages are displayed

Parameter Parameters are displayed (cannot be altered in the measuring mode)

Analog Output Assignment of the analogue outputs and setting the measuring range limits, aligning the mA-signal to the evaluation unit

Calibration Read in the calibration values, carry out the calibration (Wobbe index and calorific value)

Service Parameter list (for sensor exchange), setting the relay outputs, expert modus

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6.2 Setting the Second Line

Note You can choose the parameters for the second line by pushing the resp. .

List of choices for the second line

Display Description

SG Specific Gravity (*Option)

CARI Air demand

LCV [MJ/m] / [MJ/kg] / [kWh/m]

Lower Calorific Value (*Option)

WI [MJ/m] Wobbe - Index

O2Air [%] Oxygen value of the reference sensor for SG measurement

O2Mix [%] Oxygen value of the reference sensor subsequent to the density mixing chamber

O2Gas [%] Oxygen value in raw gas for correction of Wobbe and SG measurement (*Option)

O2ZrO2 [%] Oxygen value Wobbe measurement

dp [mbar] Pressure difference at the gas and air nozzles

CAT AB [C] Temperature catalytic combustion (*Option)

CAT [C] Temperature sample gas catalyst

Cabinet Temp [C] Temperature pneumatic unit (*Option)

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6.3 Submenu Diagnosis

Note The submenu diagnosis indicates all pending errors (which e.g. caused the shutdown of the analyser).

Note Errors cannot delete as long as their reasons have not been resolved. Only the message Service Request may delete via the F-key.

Second line

Display Description

NO ERROR No error message

Note During measuring, the upper message has indicated. Possible error messages have described in the corresponding error message chapter.

6.4 Submenu Parameter

Note All parameters may show in this submenu. The operator cannot change any parameters. The submenu intends to outline quickly the corresponding parameters in case of an error message.

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6.5 Submenu Analogue Out

The analyser RHADOX 7300 features max. 4 independent 4 20 mA analogue outputs, which can be freely scaled:

Note To choose and set the analogue output, please select the sub item Analog Out of the main menu via the F-key. You will reach the following submenu.

Note During the calibration, all analogue outputs are frozen to the latest valid values. They will be active again after the purge sequence has completed.

Note You can choose from values for the analogue outputs which are displayed in the second line (please refer to # 7.2).

Submenu Analogue Out

Display Description

return Back to the main menu

Analog out 1-4 Choose between analogue out 1-4 via F-key

extended parameter

A1 #### Please select from the list below which measuring value should be assigned to the analogue output, e.g. Wi Wobbe Index MJ/m

LCV Lower calorific value[MJ/m] / [MJ/kg] / [kWh/m] / [kcal/kg] LHV Lower heating value[kcal/kg] O2 Gas [Vol%] Oxygen concentration in the raw gas

A1 420 mA / 0...20 mA Via the F-key you can choose the limits at the output: 420 mA

420 mA ( E ), user defined constant current in case of error 020 mA 020 mA ( E ), user defined constant current in case of error 020 mA ( C ), with adjustment [value has to be programmed] OFF output is turned off frozen, output is frozen to the latest value Const. I, constant current at the output

Analog Min Measuring range onset, 4 mA

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Analog Max Measuring range limit, 20 mA

Const. Curr Constant current at the analogue output, adjustable via the arrow keys

Error Current Current in case of error at the analogue output, adjustable via the arrow keys

Note According to the test report, the analogue outputs 14 are galvanically isolated.

6.6 Submenu Calibration

After the calibration process of the analyser RHADOX 7300 has started, the operator has guided through the menu.

Note On request, please enter the corresponding code. Please refer to # 5.1.

Note The calibration has started manually but the calibration process itself is automatic and has monitored.

Note Each calibration has preceded and completed by a purge sequence. The purge sequence allows purging the lines and keeping the measurements stable.

Note During the calibration the analogue outputs are frozen. The analogue outputs activated again after the final purging.

Note valid for Ex-versions with EEx-p-controller of the RHADOX housing: The instrument may only calibrate with closed housing doors and active purge unit observing the excess pressure inside the housing. I.e. that after starting the calibration the housing doors have to shut and the by-pass of the purge unit Gnnheimer has to deactivate.

Note After starting the calibration, the calibration parameter and the calibration status will display in turns.

Note for Option AUTO CAL.: In case of Error during the auto cal.-Routine, the relay contact Service Requesthas switched and the operator can see by toggle the menu Diagnosiswhat happens during the calibration. Anyway, the error only appears if the analyser gets a right calibration.

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Submenu Calibration

Display Description

return Return to the main menu

Wi LO POINT Lower calibration point of Wobbe index in [MJ/m]

Wi HI POINT Upper calibration point of Wobbe index in [MJ/m]

SG LO POINT Lower calibration point specific gravity

SG HI POINT Upper calibration point specific gravity

CV Low Cal. Starts the calibration of the lower calibration point; follow the instructions displayed

CV High Cal. Starts the calibration of the upper calibration point; follow the instructions displayed

Show last Cal. Displays latest calibration; verifies latest calibration

Submenu Extended Parameter

return

Set the purge time which starts and terminates each calibration

Purge Time

Choose between active and frozen, i.e. analogue out status during calibration

Analog Out

Suppresses the monitoring during the calibration; only perform if directed

Service Cal.

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OFF Auto-calibration is switched off Low Auto-calibration starts with calibration of the lower calibration point High Auto-calibration starts with calibration of the higher calibration point Low-High Auto-calibration starts with calibration of the lower and higher calibration point High-Low Auto-calibration starts with calibration of the higher and lower calibration point

Auto Cal. Mode

Adjusting the time-interval between two auto-calibrations

Auto Cal. Time

Submenu O2 Gas Sensor (*option)

return

Oxygen concentration of the lower calibration point Gas Sensor

O2 Low Gas

Oxygen Sensor for the upper calibration point Gas Sensor

O2 High Gas

Starts the calibration of the lower calibration point; follow the instructions displayed

Lo Gas Calib.

Starts the calibration of the upper calibration point; follow the instructions displayed

Hi Gas Calib.

Displays latest calibration; verifies latest calibration

show last Cal.

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Note Any calibration can abort via the F-key.

Note After you have started the calibration; please do proceed according to the displayed directions.

Note After the sampling sequence (sequence of the measurement reading), the result of the calibration will displayed. Note for Option AUTO CAL.: In case of Error during the auto cal.-Routine, the relay contact Service Requesthas switched and the operator can see by toggle the menu Diagnosiswhat happens during the calibration. Anyway, the error only appears if the analyser gets a right calibration.

Cal. successful Result of calibration displayed after sampling sequence, calibration successful

6.6.1 Adjusting of Auto-calibration Auto-calibration is available as option. It includes the possibility to pre-select the type of calibration and the time interval by using the counter in the time range of max. 9999 h between two calibrations. AMS recommends setting the time range at 600 1000 h.

To set the times please proceed as follows:

1. Press the F-key and select the submenu Calibration

2. Select Extended Par. via the arrow keys and choose the following sub item:

Auto-calibration mode

Press the F-key and set the desired calibration. OFF indicates that Auto-calibration is deactivated.

Auto-calibration time interval

Press the F-key and set the time interval between 2 calibrations. 0000 h indicates that auto-calibration is not active. In this setting the auto-calibration can be started at any time with an external actuator.

The counter shows the remaining time until the next auto-calibration in the second line of the display.

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6.6.2 Start of Auto-calibration

Note: The Auto-calibration will starts after the adjusted time-interval. Note for Option AUTO CAL.: In case of Error during the auto cal.-Routine, the relay contact

Service Requestswitched and the operator can see by toggle the menu Diagnosiswhat happens during the calibration. Anyway, the error only appears if the analyser gets a right calibration.

Additional start of the Auto-calibration:

Via potential-free contact: after press the contact longer than 3 seconds the auto-calibration will start, according Auto-calibration mode

Abort of the Auto-calibration:

Via potential-free contact: If you press the contact for longer then 10 seconds the auto-calibration aborts

Via F-key pressed at the analyser

6.6.3 Calibration Errors

Note The semi-automatic calibration requires the user to monitor the calibration process. The automatic calibration needs no monitoring but also there can be an error. The calibration result will show after the calibration has completed; the following messages may displayed:

Note for Option AUTO CAL.: In case of Error during the auto cal.-Routine, the relay contact

Service Requesthas switched and the operator can see by toggle the Menu Diagnosiswhat happens during the calibration. Anyway, the error only appears if the analyser gets a right calibration.

Display Description

Cal. Scale ERR Calibration point and actual measuring value too distant, indicating wrong cal gas Troubleshooting: apply correct cal gas, check calibration

parameters

Cal unstable Fluctuations during sampling sequence are too high, no calibration possible

Troubleshooting: prolong purge sequence, prevent pressure fluctuations

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6.7 Submenu Service

After you have exchanged the Oxygen sensor for the Wobbe measurement, you can set the sensors parameters with the help of the menu. The analyser will electrically adjust to the new sensor. Furthermore, special settings allow adjusting the analyser to the complete system.

Note On request, please enter the corresponding code. Please refer to # 5.1.

Note If you have ordered the sensor at AMS GmbH, you will receive the calibration parameters ibidem.

Note The electric adjustment of the system after a sensor exchange does not replace the calibration as described in # 7.5.

Note The menu items listed below are always visible; however, they will only be analysed if the according option has ordered previously.

Note Optional parameters are marked with (*

Submenu Service

Display Description

return Return to the main menu

O2 Air Offset You receive the value of the reference sensor of the SG measurement (*Option) O2 Air Span

O2 Mix Offset You receive the value of the sensor of the SG measurement (*Option) O2 Mix Span

O2 Gas Offset Sensor to determine the Oxygen concentration in raw gas (*Option) O2 Gas Span

ZrO2 Offset Sensor to determine the Wobbe Index ZrO2 Span

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Fixed Density #.### kg/m Calculation of the calorific value from the Wobbe index, without the option SG measurement, only available with the corresponding option (*

Relay Set. Set the relay to report the analyser status (NC/NO)

Submenu Relay Set

Return to the main menu via the F-key

return

Choose the operation of the relays via the arrow keys

Service Relay is not failsafe / is failsafe


Calib. Relay is not failsafe / is failsafe


S.Req. Relay is not failsafe / is failsafe

Reserve Relay 5 Relay 5 is not failsafe / is failsafe

Reserve Relay 6 Relay 6 is not failsafe / is failsafe

Service Request Count down, can be set 099999 hr between two services

Parameter Direct parameter input sets subjacent layers of the analyser; please contact AMS GmbH

Cab. Temp Setting the monitoring of the housing temperature Select the corresponding parameters via the F-key

Submenu Cabinet Temperature (*Option)

Return to the service menu via the F-key

return

The temperature sensor can be selected via the F-key

LM 35 installed / not installed

Adjusting the Temperature Deviation

LM 35 Offset (normally = 0)

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Wi ##,## MJ / m Service Request

The following message is displayed (alternating with the previously set second row)

Note The relay Service Request 12 -16 is active according to the adjusted operation; please refer to # 7.6 of the manual.

Note An active message does not influence the measurement.

Deleting the active message

The operator can delete the active message in the submenu diagnosis at any time. Please select the menu diagnosis via the arrow keys; now confirm the message Service Request via the F-key. The timer is re-set to the chosen time interval and the countdown is re-started. Remark: The active message serves as an indication for the operator of maintenance work at the instrument (e.g. filter exchange or absorber replacement).

Temperature Monitoring on/off Check CT ON/OFF

Temperature approval for the sample gas solenoid valve

Cab. Temp. ON/OFF

Setting the lower temperature limit to avoid condensate

Cab. Temp. LO

Setting the upper temperature limit to protect mounted parts

Cab. Temp. HI

Expert Mode This mode is exclusively reserved for AMS GmbH experts

Restart After you have changed the parameters, AMS GmbH recommends a restart of the analyser. Please confirm with the F-key

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6.7.1 Fixed Density (*Option)

Note If the SG varies within a very small range, a fixed value for SG can used for converting the Wobbe index into the calorific value. The calculation based on the measured Wobbe index and the fixed SG value.

6.7.2 Service Request

Note The operator may set a timer to adjust the service request. After the set time has elapsed, the instrument displays a message for service request. The operator also requests to check the gas sampling and gas conditioning.

Note If you reset the timer to zero, the message will deactivate.

Wi ##,## MJ / m Service Request

The following message is displayed (alternating with the previously set second row)

Note The relay Service Request 12 -16 is active according to the adjusted operation; please refer to # 7.6 of the manual.

Note An active message does not influence the measurement.

Deleting the active message

The operator can delete the active message in the submenu diagnosis at any time. Please select the menu diagnosis via the arrow keys; now confirm the message Service Request via the F-key. The timer is re-set to the chosen time interval and the countdown is re-started.

Remark: The active message serves as an indication for the operator of maintenance work at the instrument (e.g. filter exchange or absorber replacement).

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6.7.3 Cabinet Temperature (*Option) The temperature monitoring / indirect heating of the pneumatic unit and therefore the monitoring of the cabinet temperature prevent the mounted parts from overheating. Further, they avoid formation of condensate resulting from undershooting the dew point in the gas lines using humid gases. The lower temperature limits (Cab. Temp. Lo) should choose such as the formation of condensate normally prevents. The upper temperature limits (Ca. Temp. High) protects the mounted parts and allows a max. temperature of 50 C. Only if special parts for temperatures above 50 C have previously ordered (please refer to your order and the test report) a higher cabinet temperature allowed.

Attentions do not expose the analyser to direct sunlight at any time. The installation site should protect from wind and weather conditions.

6.7.4 Expert Mode

Note This sub item protected by a code, which is only available for AMS GmbH experts.

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7. Serial Interface

Terminal assignment at terminal-row -X4:

In order to locate terminal-row -X4 please refer to the drawing in the appendix.

Terminal Name Description 9 10 11

RS232 RXD TXD GnD

Only potential-free units may connect to the serial interface, these are e.g. battery-driven laptops or galvanically isolated PCs.

Configuration of the RS 232-interface: - 8 data-bits - 1 start-bit - 1 stop-bit - parity-none - BAUD-rate: 19200 BPS - no hard nor software handshake

Voltages that are fed into the analyzer externally (e.g. RS232) must been idle with appropriate equipment during maintenance and in cases of switching off the analyzer.

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8. Error Messages

Note The instrument features an extensive self-monitoring. In case of an error message the second line will display the cause of the shutdown.

Note In case of an error, message the instrument switches to the stand-by mode. The main valve has shut. The combustion air down regulated and the catalyst(s) is/are shut off.

The following error messages might cause a shutdown of the system

System is OFF AB < 250C ERROR

System turns off since the temperature of the catalytic burner for low calorific gases is too low.

System is OFF CAT < 250C ERROR

System turns off since the temperature of the measuring catalyst is too low.

System is OFF APP Over Range

System is at the measuring range limit, i.e. the measurement is substoichiometric.

System is OFF CAB TEMP ERROR

System is turned off due to temperature error of pneumatic unit

Note The instrument can restart any time. Before a restart the operator, however, has to troubleshoot the error cause or to contact AMS GmbH.

System restart

Calibration Service * Restart

Enter the main menu via the F-key. Now choose the message Restart via the arrow keys. Confirm via the F-key. The system has restart.

Note If the cause of the shutdown still exists, the instrument again switches off the system right after the start-up sequence.

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I. Gas Alarm (*Option)

Optionally, the analyser can be equipped with a gas detector checking the analyser cabinet for leaks resulting out of the system or monitoring the system for vapours of explosive gas mixtures intruding from the environment.

If the measuring system is equipped with such a gas, detector this option encompasses the analysis via a central gas warning GasFlagnotifying the user visually and acoustically that explosive gases exist.

The measuring range of the gas detector is set according to the expected gas components; therefore, the message is specific for the measure task. Furthermore, the central gas warning shuts down the analyser and its by-consumers if the concentration of explosive gases is too high. Only the visual/acoustic alarm remains activated. At the same time service personnel requested since errors indicated via the Fail Safe circuit of the analyser.

ATTENTION: Quitting the alarms at the central gas warning only allowed if you have previously checked with an external gas detector that there is no danger for any persons or the instruments. Otherwise, persons and instruments may harm.

Structure of the gas alarm unit:

Gas detector: Crowcon XGard Type 5 Measuring range: 0 100 % LEL Hydrogen

Central gas warning: Crowcon Type: GasFlag Al1: 20 % LEL Hydrogen Al2: 40 % LEL Hydrogen

REMARK: Please refer to the corresponding instruction in order to operate and service the gas detector and its central gas warning; this instruction attached to the instruction manual.

Actions triggered by transgressing the alarm limits:

Transgressing Al1: - flashing light and horn are on

Transgressing Al2: - flashing light and horn are on - RHADOX 7300 turns off, I.e. gas supply stops - By consumer shut off

ATTENTION: After the measuring system has stopped by a gas alarm, you have to search for the cause before restarting the analyser. Make sure that you eliminate the cause of the error. The user has to undertake adequate measures for which he himself exclusively is responsible!

Furthermore, you have to check the gas protector and its alarm features in a quarterly interval. Please do not apply any cal gas corresponding with the alarm limits. Please refer to the attached instruction for the calibration of the central gas warning and of the gas detector.

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In order to check the gas protector with its central gas warning, a key switch has installed in the inner electronic housing; a key switch bridges Al2 of the central gas warning, which means that the gas alarms function can monitored although the Al2 limit has been crossed yet the analyser not turns off.

However, before using the key switch you have to make sure that the atmosphere is non-explosive during the deactivation of the alarm limit and during the monitoring.

For checking, switch the key switch to Pos. I. You are not able to take out the key in this position. Now you can check the functions of the gas protector, of the central gas warning, of the horn and of the flashing light (as described above with the help of the corresponding instruction manual which has enclosed to the users manual).

After checking the functionality, set the key switch back to Pos. 0 and remove the key from the lock! This is for your own safety and impedes unintended altering of any values!

Test gases necessary:

Alarm limit 1: 0,8 Vol% Hydrogen in air i.e. 20% UEG of Hydrogen Alarm limit 2: 1,6 Vol% Hydrogen in air i.e. 40% UEG of Hydrogen

II. Measuring Cabinet Cooler (*Option)

The measuring cabinets temperature has to remain constant. In order to achieve this, the measuring cabinet is equipped with a Vortex cooler that opens a valve (in housing 15) as soon as the temperature is T > 15-20 C; through this valve streams air through the cooler; this keeps the inner area at a set temperature.

As air use oil and dust-free compressor air. Please connect the air line at the right side of the measuring cabinet.

Inlet pressure : 5,5 bar-g Volume flow : max 100 m/hr at max. cooler power Temperature switch : > 15 C

The temperature switch has also installed into the housing (15). If you wish to reset the switching point, please see below:

III. Service Socket (*Option)

For later services, a service socket has installed in the inner electronic housing.

Technical data: 110 or 230 VAC / 50/60Hz Max. load: 60 VA

During the normal operating of the analyser, the socket must not used! It means only for a temporary use.

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IV. External Catalytic Combustion of By-pass Gases (*Option) The option catalytic combustion comprises an additional catalytic reactor and an external control unit working independently from the temperature controller of the RHADOX. The catalytic reactor built into a separate housing.

Please read chapter 3 of the instruction manual and the enclosed separate manual for a safe application of the catalytic combustion in the Ex protection zone 2.

FUNCTION DESCRIPTION:

If the excess bypass gas (sample gas mixed with air) cannot lead off into a safe and back pressure-free tube, it has to be burntdue to environmental reasons. Please make sure that the by-pass gas not burns via a naked flame due to safety reasons.

The catalytic reactor for the catalytic combustion has structured for a minimum flow resistance and for a complete combustion of the by-pass gas. The off-gas consists only of carbon dioxide and water at the outlet of the catalytic combustion. Therefore, the exhaust gas tube has to be sloping.

The separate temperature controller stabilises the temperature of the catalytic combustion at 400 C. The electronic unit monitors exceeding or falling below this temperature. If the temperature constantly exceeds or falls below the alarm values, the RHADOX will turn off. No sample gas will reach the analyser. Only instrument air still be applied and will be lead off via the catalyst protecting the catalyst at the same time.

ELECTRIC CONNECTION

Please refer to the technical drawings in the appendix for the electric connection of the catalytic combustion.

Please make sure that:

1. the cross section of the heat line measures min. 2.5mm

2. the temperature sensor is connected with thermal wire (suitable for thermo couple type NiCrNi) to the heat controller.

START-UP OF THE RHADOX

As soon as the catalytic combustion has reached its operation temperature, the LED of the heating control on the front panel flashes. Now the RHADOX can start by pressing the green start button (or any other start button previously installed by the operator). For the connection of an external start button, please refer to the technical drawings in the appendix of the instruction manual.

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V. Inside Catalytic Combustion of By-pass Gases (*Option) The option catalytic combustion of low calorific gases comprises an additional catalytic reactor built into the same housing as the pneumatic unit.

The catalyst has activated via the RHADOX electronic, too.

The system has fully configured and connected. No further working steps are necessary.

Failures will display and can solve after consultation with AMS GmbH.

The option catalytic combustion of low calorific gases features an additional gas outlet tube mounted to the instrument. The amount of condensate depends on the energy content of the by-pass gas.

While disposing the off-gas please make sure that the lines do not freeze and that the accumulated condensate is being disposed of according to the Ordinance of Hazardous Substances.

The current temperature of the catalytic combustion can display in the second line. Please choose AB (afterburner) in the second row to display the current temperature. The following message now displays:

Wi ##.## MJ/m AB ### C

Current measuring value Wobbe index Temperature of the catalytic combustion

Note The analyser monitors the catalytic combustion. Malfunctions have displayed.

Note After a restart, the instrument checks the temperature of the measuring catalyst as well as the temperature of the catalytic combustion considering the current temperature. Therefore, after a short shut-off the current temperature is immediately measured to determine the preheat sequence.

Note The temperature of the catalytic combustion has to reach a certain temperature range. Only then, the solenoid valve will open and the sample gas will reach the analyser.

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Instruction Manual RADOX analyzer