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Part Number
Serial Number
Tag Number
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A
1 2
3 4 5 6
B 1 2 3 4 5
I1 12.6 % OXYGEN
I2 15.75 % OXYGEN
6
I3 123.4 vpm OXYGEN
7 8 9 10 11
Figure A
Figure B
HI
1 2 4 6
SAMPLE
LO
3 5 7
T
Figure C
WARNINGS
CAUTIONS
NOTES
Addresses for technical assistance and spares are given on the rear cover.
An installation manual is supplied with the analyser which includes the technical
specification, routine maintenance and spares information, reference part number
04000/005C.
A service manual is available for use by qualified personnel, reference part number
04000/002C.
Figure B Display
WARNING
The user should note that 4000 series instruments contain no user
serviceable parts inside. The instrument enclosure protects the user
from electric shock and other hazards. All servicing should be referred
to qualified personnel.
Section 4 CALIBRATION
4.1 Introduction to calibration 19
4.2 Setting Low and High calibration tolerances 20
4.3 Manual calibration and checking 20
4.4 Calibration of paramagnetic pressure transducer 23
4.5 Autocalibration and autocheck setup 25
1) The module location defines the identity of the transducer for each
measurement. The letter "I" indicates an internal gas sensor module, the letter
"E" an external transducer (user supplied) and the letter "D" indicates a derived
measurement (as in the case of total nitrogen oxides - refer to section 3.9). The
letter is followed by a number defining the gas sensor module location.
3) The engineering units field is user defined with 3 characters showing the units
of measurement.
4) The measurement name field is a 6 character field to show the name or TAG
number.
The keypad
The display may be returned to measurement display at any time by pressing the
'MEASURE' key. If no key is pressed the analyser returns to the measurement display after
one minute. This timeout is extended to 20 minutes during the calibration options.
Press the 'MEASURE' key at any time to return to the default measurement display.
Pressing the 'MENU' key activates the top level menu. It does not affect the continuous
measurement activities of the analyser.
Within menu displays, the user highlights the desired option using the arrow keys
( ) and then presses the 'ENTER' key to action the indicated menu selection or to
confirm completion of text or numerical input.
Pressing the 'QUIT' key aborts the current activity and returns to the previous menu level.
The 'EDIT' key is a short-cut key to access the measurement display editing functions.
When inputting data, a key press will be ignored if the data entered is
invalid.
When entering numeric information or text, the left and right arrow keys
are used to move between characters or digits and the up and down
arrow keys are used to change each character or digit. Negative
imaging (white text on black background) indicates the active word,
character or digit position.
If the Measure, Menu or Quit keys are used to terminate a data entry
(rather than the Enter key) then the data entered is lost.
During any menu operation, the fundamental measurements are still being made by the
analyser and all relevant outputs, alarms and diagnostics remain active.
Data input
When alphanumeric text data input is required, the up and down arrow keys allow scrolling
and selection of any available item in the analyser's character set.
If an invalid data entry is made, the input will be ignored and the display return to the start
of the relevant data entry screen . No warning message will be generated.
Password protection
Certain operations require the use of a password. There are two passwords, a supervisor
password which gives access to SETUP and CALIBRATION and an operator password,
giving access to CALIBRATION only. These are factory set to 4000, but may be changed
if required; refer to section 2.4.
If the user does not wish to see the power up messages then these can be bypassed by
pressing the measure key during the 'SYSTEM OK' message.
The measurement display should now appear. The display "contrast" control may be
adjusted if necessary using a small flat bladed screwdriver. See Figure A for location of the
adjustment, accessed from the bottom of the front facia.
The warming-up icon (see Figure B) may be displayed until all heated gas sensor modules
are at their respective operating temperature. This may take up to 6 hours. The reading of
certain gas sensor modules may be replaced by a row of stars ('******') during the
warming-up period. Analyser may not have reached optimum performance after the
warming up icon is extinguished, see Installation Manual for recommended warm up times.
To shut down, disconnect the sample gas, flush through with a clean purge gas (e.g.:
nitrogen), then remove power.
The default character is '|' which cannot be displayed but is used to indicate the maximum
number of characters allowed. If fewer than the maximum number of characters is entered
the first '|' is taken to be the last character.
The measurement display units and component name are displayed, right justified, in fields
of three and six characters, respectively. To left justify or centralise them the appropriate
number of spaces can be added at either end of the string.
Any existing relay allocation may be edited or cleared. When cleared the relays will remain
non-functional.
NOTE
Input scaling (calibration) is set up via the MAN CAL menu, refer to section 4.3.
As a guide, minimum output spans should be at least 100 times the transducer noise level,
(refer to Installation manual, section 7).
The parameters for an output may be edited or cleared. When cleared the output is non-
functional. Each may be assigned to any one gas sensor, and following parameters must be
set up for all outputs used:
If the 4-20mA output is used and a 'minimum current' of less than 4mA
is specified (in iv above), 4mA still corresponds to the lower limit of the
output range (set in ii or iii above).
SELECT SCREEN Use the arrow keys to select the required screen to
NUMBER : 1 define then press 'ENTER'.
SELECT MEASURE 1 Use the arrow keys to select the first required
I1 O2 % b measurement then press 'ENTER'.
The number of decimal places displayed for each measurement may be selected.
Parameter Default
Interface RS232 or RS485 RS232
Stop bit - 1, 1.5 or 2 1
Number of data bits - 7 or 8 8
Parity - EVEN, ODD or NONE EVEN
Baud rate ( characters per second ) - 9600
9600, 4800, 2400 or 19200
Hardware handshaking (fixed) NONE
For a 4000 analyser measuring nitric oxide (NO) the facility exists to calculate an estimate
of the total nitrogen oxides (NOx) level, based on the measured NO level. This estimate can
be displayed and output as a separate measurement, identified on the display by a "D"
prefix in the module location field. Units and calibration are fully dependent on the
associated NO measurement. The total NOx estimate is derived according to the formula:
In manual calibration (the term calibration includes 'checking') the operator is guided
through the sequence by messages on the display and each gas sensor module must be
calibrated separately.
Pressing any key during the cycle will allow the autocalibration to be stopped. If aborted,
the final "post flush" sequence is run. This may also be aborted in the same way.
Autocalibration may also be stopped by means of a Modbus command.
NOTE
* It is recommended that the tolerance should not be greater than 10% of sensor FSD - the
factory default settings.
** If the calibration has changed by more than the tolerance a warning will be given
with an option to proceed.
*** If the calibration was not successful a temporary message will be displayed
e.g. 'BAD [LOW/HIGH] CAL, CAL IGNORED'. This indicates that the output
of the gas sensor module is very significantly outside of the expected range for
the calibration gas entered. Check the value of the calibration gas.
NOTE
I1 Oxygen CHK H Introduce high cal gas; when the reading has
CONC = 99.85% stabilised press 'MEASURE' to return to the
measurement display and stamp the calibration check
results in the cal history buffer.
NOTE
It is not possible to quit from a calibration check without stamping the result in
the calibration history buffer. No warnings are given regarding the validity of the
calibration check.
The minimum pressure elevation required for this procedure is 1psig / 6.9kPag, the
maximum pressure elevation is 1.5psig / 10.3kPag.
This may be performed by temporarily fitting a suitable needle valve on the analyser
sample outlet for the paramagnetic purity module and adjusting it to restrict the outlet to
achieve an increase in sample pressure in the sensor. The overall sample flow, however,
should remain constant as far as possible during this procedure.
WARNING
NOTE
The following parameters must be set up for either autocalibration or autocheck, hereafter
referred to as "Autocalibration":
The time and date must be correctly set before using autocalibration.
Selection of 'LOW' or 'LOW & HIGH' autocalibration (remember that
Zirconia sensors cannot have a high autocalibration).
LOW and HIGH calibration gas concentrations.
Autocalibration period (i.e. time between successive autocalibrations;
minimum 1 hour, maximum 59 days + 24 hours).
Date and time of start of cycle (first autocalibration).
Flush time - this may be set, to suit the installation, to a value between 0.5
and 16 minutes so that each gas concentration stabilises before being read.
After each flush time the gas will flow for an additional minute to allow the
new 'calibrated' level to be viewed or recorded.
Selection of autocalibration or autocheck.
Calibration Gas Relays (if analyser relays are to be used).
It is necessary to specify which calibration gas (1 or 2) is used for the LOW
calibration of each sensor.
Autocalibration groups
An Autocalibration group (comprising one to four sensors) is a group of sensors that:
Groups are independent, but only one autocalibration can be in progress at any one time. A
queuing mechanism is used to ensure autocalibrations are not missed, however, the queue
is of finite length. The user is expected to avoid filling it by 'over' scheduling .
Figure C shows the response of a typical sensor during autocalibration in which CAL 1 is
used to set the sensor low (zero) and CAL 2 the high (span). Further explanation of the
events occurring at each stage is given in the installation manual along with configuration
details for users who use the serial output to control autocalibration valves.
NOTE
ALSO:
To run a single timed autocalibration, at the designated start time:
Relays
mA Outputs
e.g. I2 O2 AL2
98.00 LOW
Faults: an entry is made each time a fault appears or is cleared. There are
two history files, one relating to FAILURES, the other to
MAINTENANCE.
[gas sensor module site number] [measurement name] [type of calibration] [difference]
[time and date]
Identity
The measurement signals from gas sensors may be displayed for diagnostic
information, typical examples are shown below:
For a more detailed assessment of the diagnostics information please refer to the 4000
Series Service manual part number 04000002C.