PE氢探头使用说明H2Smart_User_V1

H2SMARTUSER MANUALLEGAL NOTICEMay 2008 – Revision 1THIS MANUAL IS SUPPLIED IN ONE (1) COPY.No part of this publication may be duplicated, copied, and/or transmitted without the prior written permission of United Process Controls.The information contained in this document is STRICTLY CONFIDENTIAL and PROPRIETARY to United Process Controls, and shall not be: i) reproduced or disclosed in part or in whole, ii) used for any design or manufacturing of heat treating and/or control equipment, or any other purpose except for that which it is supplied under the terms of the Contract, unless the express written authorization is obtained from United Process Controls.Drawings and photographs included in the documentation are the property of United Process Controls, and it is strictly forbidden to reproduce them, transmit them to a third party, or use them for manufacturing and/or design of equipment. Sub-licensing of any technical information contained in this Documentation is strictly forbidden under the terms of the Contract.United Process Controls reserves the right to modify this document without prior notice. WARRANTYUnited Process Controls (UPC) warrants its goods as being free of defective materials and faulty workmanship. Contact your local sales office for warranty information. If warranted goods are returned to UPC during the period of coverage, UPC will repair or replace without charge those items it finds defective. The foregoing is Buyer's sole remedy and is in lieu of all other warranties, expressed or implied, including those of merchantability and fitness for a particular purpose. Specifications may change without notice. The information we supply is believed to be accurate and reliable as of this printing. However, we assume no responsibility for its use.CE Conformity (Europe)This product conforms to 73/23/EEC, the Low Voltage Directive, and 89/336/EEC, the EMC Directive.AMS Conformity (North America)This product conforms to SAE Aerospace Material Specifications AMS 2759/10 for nitriding and 2759/12 for nitrocarburizingTABLE OF CONTENTS1. INTRODUCTION (5)1.1. Overview (5)2. SPECIFICATIONS (6)2.1. Physical (6)2.2. Performance (6)2.3. Operating (6)2.4. Calibration (recommendation) (6)3. INSTALLATION (7)3.1. Overview (7)3.2. Panel Mount Model (7)3.3. Port Mount Model (10)3.4. Installation Steps – Panel Mount (14)3.4.1.Step 1 (14)3.4.2.Step 2 (14)3.4.3.Step 3 (15)3.4.4.Step 4 (16)3.5. Installation Steps – Port Mount (16)3.5.1.Step 1 (16)3.5.2.Step 2 (17)3.5.3.Step 3 (18)4. ELECTRICAL INSTALLATION (19)5. OPERATING INSTRUCTIONS (26)6. MAINTENANCE (27)6.1. Sample Gas Filter (27)6.2. Sample Gas Pump (29)7. CONFIGURATION (29)8. CUSTOMER SUPPORT (29)8.1. Contacts (29)TABLE OF FIGURESFigure 1 Panel Mount Model (7)Figure 2 Panel Mount Front View (8)Figure 3 Panel Mount Side View (9)Figure 4 Panel Mount Bottom View (10)Figure 5 Port Mount Model (10)Figure 6 Port Mount Front View (11)Figure 7 Port Mount Side View (12)Figure 8 Port Mount Side View (13)Figure 9 Panel Mount Step 1 (14)Figure 10 Panel Mount Step 2 (14)Figure 11 Panel Mount Step 3 (15)Figure 12 Panel Mount Step 3 (15)Figure 13 Panel Mount Step 4 (16)Figure 14 Port Mount Step 1 (16)Figure 15 Port Mount Step 1 (17)Figure 16 Port Mount Step 2 (17)Figure 17 Port Mount Step 3 (18)Figure 18 Electrical Installation (19)Figure 19 Connectors (21)Figure 20 Connectors (22)Figure 21 LAN Connector (23)Figure 22 CAN Connector (23)Figure 23 Filter Cover (27)Figure 24 Filter Holder (28)Figure 25 Filter Cartridge (28)1. INTRODUCTION1.1. OverviewThe H2Smart is an integrated sampling system designed to measure hydrogen content with high accuracy in nitriding and nitrocarburizing atmospheres and to calculate the parameters necessary for process control. A unique measuring cell design and advanced electronics eliminate the need for a reference gas cell, thus simplifying the installation.An integrated sampling pump with variable output and a flow monitoring circuit with alarm and pump saturation warning insure reliable sampling. The pump provides a continuously controlled flow despite most sampling line obstructions or filter contaminations, thus assuring accurate measurements and better process control. In addition, an alarm is triggered notifying that the lines are clogged.The sample gas flow is measured with a thermal mass flow meter with integrated thermal conductivity compensation ensuring accurate flow measurement for all gas compositions of the specified gas system. A sample gas pump with variable output and a digital flow regulator are used to form a closed loop sampling system that ensures constant gas flow through the analyzer.The measuring block is maintained at a set temperature to protect the system from moisture formation and cell contamination during nitrocarburizing and post oxidation processes.The system status and measured results are displayed on a large, easy to read alphanumerical display.2. SPECIFICATIONS2.1. PhysicalPanel mount modelWidth (including mounting bracket): 7.28” (185mm)Height: 8.25” (209.53mm)Depth: 7.6” (193mm)Weight: 8.8 lbs (4 kg)Furnace Port mount modelWidth: 5.91” (150mm)Height: 9.88” (251mm)Depth: 7.13” (181mm)Weight (including flange): 9.9 lbs (4.5 kg)2.2. PerformanceAccuracy: +/- 0.5% of reading+/- 0.2% of full scaleLinearity: < 0.5% of full scaleRepeatability: < 0.5% of full scaleZero drift: < 0.5% of full scale per month Sampling flow: 0.2 - 0.5 lpm / .42 - 1 cfhResponse time: 95% in 30 sec @ 0.5 lpm / 1 cfh2.3. OperatingPower requirements: 24VDC, 2.5 Amps max. Use only well regulated power supplyOutputs: 2 x analog, isolated with common positive rail4 – 20 mA (R<500 Ohm)1 x digital, PWM output 24 VDC2 x digital, 24 VDC, 1.5 A maxInputs: 1 x analog, temperature sensor2 x digital, 24 VDC2.4. Calibration (recommendation)Zero Calibration*every 6 months (or as required) Span Calibration not requiredFactory calibration once every 5 years*Zero calibration kit required3.INSTALLATION3.1. OverviewThe H 2Smart can be mounted in two different ways; panel mounting or port mounting.Panel mounting is typically used when the unit is located away from the furnace and the sample gases are tapped from the exhaust lines. This can be the method of choice when installation on the furnace cover is impractical and furnace body installation is not an option.When the port mounting option is chosen, the unit is installed directly on the furnace lid or body provided that a KF 50 adapter is available. This method may be desired due to its minimal piping requirements and quick response as the unit is directly in the work zone.3.2. Panel Mount ModelThe panel mount model allows for the mounting of the H 2Smart anywhere away from the furnace. Two brackets and four screws are used to attach the sensor.Figure 1 Panel Mount ModelCAUTIONHandle with care, do not drop. The sensor is susceptible to shock, and it is a static sensitive device, use proper handling proceduresPANEL MOUNT FRONT VIEWFigure 2 Panel Mount Front View1 Optional Interface for5 Digital I/OProfibus or Modbus 6 Analog Out2 CAN 7 Taux (temp sensor)3 SVC (service) 8 Gas Filter Cover4 LAN 9Digital DisplayPANEL MOUNT SIDE VIEW “V”Figure 3 Panel Mount Side ViewPANEL MOUNT BOTTOM VIEWFigure 4 Panel Mount Bottom View3.3. Port Mount ModelThe port mount option allows for the mounting of the H2Smart directly on the furnace port of the furnace cover. A KF50 flange is attached to the unit and then fastened to the port using a KF50 connector.Figure 5 Port Mount ModelPORT MOUNT FRONT VIEWFigure 6 Port Mount Front View1 Optional Interface for5 Digital I/OProfibus or Modbus 6 Analog Out2 CAN 7 Taux (temp sensor)3 SVC (service) 8 Gas Filter Cover4 LAN 9Digital DisplayPORT MOUNT SIDE VIEW “V”Figure 7 Port Mount Side ViewPORT MOUNT SIDE VIEWFigure 8 Port Mount Side View3.4.INSTALLATION STEPS – PANEL MOUNT3.4.1.Step 1Attach bracket to panel wall using four #10 (M5) screwsFigure 9 Panel Mount Step 13.4.2. Step 2Attach tubing to ExhaustFigure 10 Panel Mount Step 2Connect 1/4” tubing to Swagelok connector using two wrenches (5/8” and 9/16”) * Follow Swagelok instruction to assemble piping with tube fitting.Figure 11 Panel Mount Step 3Figure 12 Panel Mount Step 3Assembly Instructionsa) Insert tubing into the Swageloktube fitting.b) Make sure that tubing rests firmlyon the shoulder of the tube fitting body and that the nut is finger-tight.c) Scribe the nut at 6 o’clock position d) While holding fitting body steady,tighten the nut 1 1/4 turns to the 9 o’clock position.Reassembly Instructionsa) Insert tubing with pre-swaged ferrules into fitting body until the front ferrule seats. b) Rotate the nut with a wrench to the previously pulled-up position. At this point, asignificant increase in resistance will be encountered.c) Tighten slightly with the wrench. Note: don’t use the gap inspection gauge withreassembled fittings.For Ferritic Nitrocarburizing furnaceFigure 13 Panel Mount Step 4 Use pipe insulation with heat tracing3.5. INSTALLATION STEPS – PORT MOUNT3.5.1. Step 1Connect 1/4” tubing to Swagelok connector using two wrenches (5/8” and 9/16”) * Follow Swagelok instruction to assemble piping with tube fitting.Figure 14 Port Mount Step 1Figure 15 Port Mount Step 1 Assembly Instructionsa) Insert tubing into the Swageloktube fitting.b) Make sure that tubing restsfirmly on the shoulder of thetube fitting body and that thenut is finger-tight.c) Scribe the nut at 6 o’clockpositiond) While holding fitting bodysteady, tighten the nut 1 1/4turns to the 9 o’clock position.Reassembly Instructionsa) Insert tubing with pre-swaged ferrules into fitting body until the front ferrule seats.b) Rotate the nut with a wrench to the previously pulled-up position. At this point, asignificant increase in resistance will be encountered.c) Tighten slightly with the wrench. Note: don’t use the gap inspection gauge withreassembled fittings.3.5.2. Step 2Attach the KF50 flange to the casingFigure 16 Port Mount Step 23.5.3. Step 3Attach the K50 flange to the furnace port with a KF50 connectorFigure 17 Port Mount Step 34. ELECTRICAL INSTALLATIONConnect the system to a well regulated 24VDC power supply capable of supplying 2.5A minimum.Connect power cable to 24 V power supplyFigure 18 Electrical InstallationWithin the specified limits, the value of the supply voltage will not influence the accuracy, but a power supply with bad stability may increase measurement noise of the system. Use a well regulated power supply and do not operate other heavy loads from the same supply.The specified power consumption is only true during start-up, after operatingtemperature is reached, the power consumption will decrease to 20% - 40% of the specified value, depending on ambient temperature.Heat tracing the sample gas tubesIn order to avoid clogging of the sample gas tubes by ammonium carbonate and condensation, the sample tubes should be kept at temperatures above 149°F (65°C) by heat tracing. For this purpose typically, a heat trace cable is run close to the tube bundle, tightly pressed against the tubes by appropriate cable ties. The whole assembly is then wrapped in thermal insulation material, e.g. Armaflex foam tubing.CAUTIONThe H 2Smart will be permanently damaged if connected to 115 or 230VACprovides the necessary temperature regulator to operate the heat cable. To use this feature1. Mount the optional heat tracing temperature sensor to the tube bundleinside the thermal insulation, at a distance of 1 ft (30cm) from the H2Smartconnectors.2. Use an appropriate solid state relay controlled by the heat tracing controloutput to switch power to the heat tracing cable.See the wiring diagram below for more information.The H2Smart will regulate the heat tracing temperature to 149°F (65°C) as long as it is powered up without further user action.Figure 19 ConnectorsFigure 20 ConnectorsFigure 21 LAN Connector LAN 10BaseT Female DB-9 connectorFigure 22 CAN ConnectorCAN Male DB-9 connectorH2Smart digital input and output signalsConnector X1 is a 15pin DSUB male connectorPin Signal name Signal function1 +DigIn12 -DigIn1A 24VDC signal on DigIn1 enables sampling.3 +DigIn24 -DigIn2Reserved5 DigOut4 Open collector output. A low output signal indicates thestatus "Flow rate off limits" (flow alarm).6 DigOut3 Open collector output. A low output signal indicates apump saturation status (pump alarm).7 DigOut2 Open collector output. Outputs a 10Hz pulse widthmodulated signal used to control the power of the heattracing heater via a solid state relay. ***Caution Do notuse an electromechanical relay for this purpose***8 0V external loadsupply Connect to negative terminal of the external load power supply.9 Reserved10 Reserved11 Reserved12 Reserved13 Reserved14 Reserved Pins are reserved for future use, make no connections to them.15 0V external loadsupply Connect to negative terminal of the external load power supply.Digital inputs are electrically isolated from ground and each other.-Max. Input voltage is 28VDC-input Current is 6mA@24VDC.Digital outputs are open collector outputs referred to pins 8 and 15 of connector X1 (0V external load supply). Be aware that pins 8 and 15 of X1 are internally connected to 0V of the system power supply input.H2Smart analog outputsConnector X2 is a 9pin DSUB female connectorPin Signal name Signal function1 +AnaOut12 -AnaOut1Analog output 13 +Anaout24 -AnaOut2Analog output 25 Shield GND Cable shield connection, connected to PE6 Reserved7 Reserved8 Reserved9 Reserved Pins are reserved for future use, make no connections to them.***Caution***+AnaOut1(Pin 1) and +Anaout2(Pin 3) are internally connected.To avoid interference between both outputs, do not connect externallyThe analog outputs of H2Smart are internally powered 4 - 20mA current sources with common isolation, able to drive a maximum loop resistance of 500 ohms. Output assignment, scaling and electrical output range (0 - 20mA or 4 - 20mA) may be configured using the H2Smart service software.Factory default configuration:Output value Measurement result (H2% or dissociation%depending on calibration type)Analog output 1Scaling 0 -100% = 4 - 20mARange 4 - 20mAOutput value Sample gas flow rate [l/min]Analog output 2Scaling 0 – 1 l/min = 4 - 20mARange 4..20mAHeat tracing sensor connectorConnector X3 is a 9pin DSUB male connector. It is exclusively used for the optional heat tracing temperature sensor that enables H2Smart to control the temperature of the sample gas tube heat tracing.Do not connect anything else to this connector.5. OPERATING INSTRUCTIONSAfter power on, the system starts heating up to operational temperature, nominally 65°C. Flow measurement is disabled and the sampling pump is off during heat up to avoid contamination of the system with condensation. Depending on ambient temperature, heat up takes about 30 minutes, full accuracy is reached after 1h. It is recommended to keep the system powered up all times, using the "Sampling enable" digital input to activate or deactivate sampling.When the operating temperature is reached, the "Sampling enable" digital input must be activated to enable flow measurement and the sample gas pump.DisplayThe display shows the following information, depending on the system status:Display shows: StatusFlashes: Temp/Heat up or sampling disabledPump OffSampling enabledProcess Variable i.e. % diss.,K N, etc.Filter Sampling pump nearingsaturation, most probably dueto a clogged gas filterAlarm Sampling enabled, but thesample gas flow is outside theflow tolerance band6. MAINTENANCEAll maintenance must be carried out by trained personal only in compliance with the applicable safety standards.6.1. Sample gas filterMaintenance period Once per year or when H2Smartindicates a "Filter" alarm. Depending on the operating environment a shorterperiod may be required. Action Change the filter elementFilter element type Swagelok SS-4F-K4-7Tools needed A flathead screwdriverA 10mm Allen key1. Purge the furnace or process reactor with an inert gas (e.g. nitrogen) to makesure no burnable or explosive gas is left in the system.2. Disable sampling by deactivating the "Sampling enable" digital input signal.3. Use the screwdriver to remove the black filter cover on the front panel ofH2Smart.Figure 23 Filter CoverRemove filter cover4. Remove the filter holder using the 10mm Allen wrench.Figure 24 Filter Holder5. Remove the old filter cartridge. If necessary, use a pair of pliers for this task.Figure 25 Filter Cartridge6. Insert the new filter cartridge and reinstall the filter holder. Tighten the filter holderuntil it hits the final stop, but there is no need to apply much force to compress the seal.7. Reinstall the filter cover on the front panel.6.2. Sample gas pumpMaintenance period The life time of the sample gas pump is dependent on thecomposition of the gas.Action Replace the sample gas pumpGas pump type H2Smart gas pump assembly,part no. 1888Send the unit in for service in case of a pump failure.7. CONFIGURATIONField configuration of the H2Smart is limited to setting the IP parameters, selecting the temperature display unit (°C or °F) and configuring the analog outputs.All configurations are done using the H2Smart service software installed on a PC running Windows® XP O/S.There are two ways to connect to the H2Smart:•Using a standard UPC service cable to connect a standard Com port on your computer to the service port on H2Smart. This includes setting up a PPPconnection on your computer (see separate manual for that).•Using the LAN port on your computer with a special cable (not included).8. CUSTOMER SUPPORT8.1. ContactsIn the event of any major emergency situation, please call United Process Controls customer support department.Customer support department+1-514-335-7191Toll free North America1-877-335-7191Pager +1-514-854-0908If the offices are closed, please page us. Leave your message on the voice mail. State your company name, your name, the number where you can be reached and the nature of your emergency. If you have a tone dial phone, please enter your phone number only after leaving your message.。