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4000 series

(includes 4100, 4200 & 4900)

Please record your analyser details below

Part Number

Serial Number

Tag Number
This page intentionally blank
A
1 2

3 4 5 6

B 1 2 3 4 5

No. Value Unit Name

I1 12.6 % OXYGEN

I2 15.75 % OXYGEN
6
I3 123.4 vpm OXYGEN

I4 10.3 vpm OXYGEN


ALARM WARM AUTO MAINT FAILURE
UP CAL!

7 8 9 10 11

Figure A
Figure B

4000 Series - Configuration and Operation 04000/003C/4 i


C
FLUSH TIME FLUSH TIME FLUSH TIME FLUSH TIME

HI

1 2 4 6

SAMPLE

LO

3 5 7
T

AUTO AUTO AUTO AUTO


CAL! CAL! CAL! CAL!

AUTO AUTO AUTO


CAL! CAL! CAL!

Figure C

ii 4000 Series - Configuration and Operation 04000/003C/4


MANUAL CAL LOW CAL
D HIGH CAL
PRESS* MEASURE P OFFSET
SPECIFY P OFFSET
HISTORY LOW HISTORY
CALIBRATE HIGH HISTORY
P OFFSET HISTORY*
CHK L & H CHECK LOW
CHECK HIGH
AUTO CAL SET UP AUTO CAL CONFIG TXD CAL
ONE CYCLE CONFIG TXD GROUP
SET UP SET ALARM
ASSIGN RELAYS
mA OUTPUT
mA INPUT
DISPLAY OUTPUTS RELAYS
ALARMS mA OUTPUT
DIAGNOSTICS
ID
UTILITY INST PARAMETERS CLOCK
NEW PASS SUPERVISOR
OPERATOR
COMMS SET COMMS PARMS
SET COMMS MODE
SCREEN SELECT SCREEN
[ EDIT KEY ]
DEFINE SCREEN
LNG

TXD PARAMETERS LABELS


FACTORS TIME CONSTANT
LO & HI TOL DERIVE N0x**
DECI
ALARMS DISPLAY ALARMS
ALARM HISTORY DISPLAY FAILURES
FAULTS FAILURE FAILURE HISTORY
MAINTENANCE DISPLAY MAINT
MAINT HISTORY

*FOR Pm OXYGEN PURITY MODULE ONLY


** FOR Gfx NO MODULE ONLY
Figure D

4000 Series - Configuration and Operation 04000/003C/4 iii


NOTES

iv 4000 Series - Configuration and Operation 04000/003C/4


1 INTRODUCTION

1.1 Warnings, Cautions and Notes


This publication includes WARNINGS, CAUTIONS and NOTES which provide
information relating to the following:

WARNINGS

Hazards which could result in personal injury or death.

CAUTIONS

Hazards which could result in equipment or property damage.

NOTES

Alert the user to pertinent facts and conditions.

1.2 About this manual (Key to Figures)


This manual covers software configuration and operation. Further copies of this manual
may be ordered, reference part number 04000/003C.

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.

Modbus is a trademark of AEG-MODICON.

4000 Series - Configuration and Operation 04000/003C/4 1


KEY TO FIGURES

Figure A Analyser front view

1. Sample filter (optional) 4. Keypad


2. Flowmeters (optional) 5. Display contrast adjustment
3. Display 6. Sample needle valves (optional)

Figure B Display

1. Titles 7. Alarm icon


2. Module location (2 characters) 8. Warm up icon
3. Measurement value (6 characters) 9. Autocalibration icon
4. Engineering units (3 characters) 10. Maintenance icon
5. Measured name (6 characters) 11. Failure icon
6. Measurements

Figure C Typical autocalibration sequence


(In this example calibration gas 1 is the 'zero' gas, calibration gas 2 is the 'span' gas.)

1. Autocalibration commences, calibration gas 1 is supplied to the analyser


2. Measuring calibration gas 1
3. Calibration gas 2 is supplied to the analyser
4. Measuring calibration gas 2
5. Calibration gas 1 re-applied to the analyser
6. Re-measuring calibration gas 1
7. Sample gas is supplied to the analyser to flush out sensor ("post flush")

Figure D User interface menu map

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.

2 4000 Series - Configuration and Operation 04000/003C/4


CONTENTS
Page
Section 1 INTRODUCTION
1.1 Warnings, Cautions and Notes 1
1.2 About this manual (Key to Figures) 1
1.3 Introduction to the user interface 4

Section 2 INITIAL CONFIGURATION


2.1 Power Up and Shutdown procedure 7
2.2 General access to analyser functions 7
2.3 Setting languages 7
2.4 Setting passwords 8
2.5 Setting time and date 8

Section 3 MAIN CONFIGURATION


3.1 Component name and unit definition 9
3.2 Alarms 10
3.3 Allocation of relays 11
3.4 External analogue input configuration 13
3.5 Analogue outputs 13
3.6 Defining and selecting measurement display screen 15
3.7 Response time 16
3.8 Serial communications 16
3.9 Calculation of total nitrogen oxides (NOx) concentration 18

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

Section 5 VIEWING CONFIGURATION AND HISTORY FILES


5.1 Displaying 'Current' alarms and faults 29
5.2 Displaying alarm settings 29
5.3 Displaying output configuration 30
5.4 Displaying analyser histories 31
5.5 Displaying analyser identity and diagnostics 33

4000 Series - Configuration and Operation 04000/003C/4 3


1.3 Introduction to the user interface
The user interface consists of a keypad and a large LCD. During normal use the LCD will
show either the default measurement display or a menu based screen editor display.

The measurement display


The measurement display is shown by default and can be user configured to show the
measurements made by the analyser. The status of the instrument plus the occurrence of an
alarm or fault is also displayed via icons at the bottom of the screen. The display line for
each measurement consists of four fields:

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.

2) The measurement value field is a 6 character number showing the concentration


measured.

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.

4 4000 Series - Configuration and Operation 04000/003C/4


NOTE

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.

The screen icons

Autocalibration icon is displayed when autocalibration is active.

Alarm icon is displayed if any of the concentration alarm


levels are reached.

Warm Up icon is normally displayed when the instrument is


turned on. If a sensor fails to achieve its normal
temperature operating conditions within a
specified time, the icon will be turned off and a
failure icon raised.

Failure icon is displayed if any serious fault condition occurs


within the analyser.

Maintenance icon is displayed if a condition arises that requires


operator attention.

4000 Series - Configuration and Operation 04000/003C/4 5


The menu display
To access the menu, the 'MENU' key should be pressed. The analyser will then present the
top level menu, which in turn leads on to other menus. The overall menu structure is shown
in Figure D.

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.

Numeric data input may be set to:

i) Any number in the range 0 to 9.


ii) A minus sign (only as the first character)
iii) A decimal point - the position of the decimal point may be changed
from that offered as a default. Any position except the right most
digit may be used.

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.

6 4000 Series - Configuration and Operation 04000/003C/4


2 INITIAL CONFIGURATION

2.1 Power Up and Shutdown procedure


When initially powered up, a message sequence will be displayed. This will start with the
term: 'SYSTEM OK'and progress through a number of screens detailing the analyser, it's
configuration and the software fitted, before displaying: 'MEASURING'.

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.

2.2 General access to analyser functions


It is recommended that the user refers to the menu map (Figure D) and locates the
function required. Then, using the keypad and display follow the route as mapped. It will
often be necessary to enter the password, which is factory set to 4000.

At display screen: The cursor will initially be on the digit furthest


to the left. Use the up arrow to increment the
ENTER PASSWORD first digit to 4. The display should now be
0000 showing 4000. Press ENTER

2.3 Setting language

Go via SETUP/UTILITY to LNG - press ENTER


At display screen Operation
ENGLISH / DEUTSCH Select required language and press 'ENTER'.

4000 Series - Configuration and Operation 04000/003C/4 7


2.4 Setting passwords

Go via SETUP/UTILITY to NEW PASS - press ENTER


At display screen Operation
SUPERVISOR Select either supervisor or operator password then
OPERATOR press 'ENTER'.
NEW OPERATOR Using the arrow keys, specify the new password.
(NEW SUPERVISOR)
PASS = 0000 When the value shown is correct press 'ENTER'.
NEW PASS IS ???? Confirmation is required, select 'YES' or 'NO' then
ACCEPT YES/NO press 'ENTER'.
SUPERVISOR To return to measurement display press
OPERATOR 'MEASURE'.

2.5 Setting time and date


The time and date must be set correctly before setting up autocalibration and for history log
entries to have the correct time and date stamp. The time and date are retained for at least
two days while the analyser is switched off.

Go via SETUP/UTILITY to CLOCK - press ENTER


At display screen Operation
TIME = 12:54 Current time/date is temporarily displayed, (no
DATE = 10/12/01 action is required).
CHANGE DATE,TIME Select 'YES' or 'NO' then press 'ENTER'.
YES/NO
SET CLOCK Use the arrow keys to set, when the value shown is
SET YEAR 0000 correct press 'ENTER'.
SET MONTH 00 "
SET DAY 00 "
SET HOUR 00 "
SET MINUTE 00 "
SELECT FORMAT Select format then press 'ENTER'.
DDMMYY/MMDDYY
TIME = 12:57 The new time/date is temporarily displayed
DATE = 10/12/01 (no action is required).

8 4000 Series - Configuration and Operation 04000/003C/4


3 MAIN CONFIGURATION

3.1 Component name and unit definition


The name of each measurement may be changed (six characters in length max).

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.

All analyser measurements are based on percentage concentrations. In order to convert to


vpm, for example, a 'scale factor' (of 10,000) is used. The user may 're-define' the
measurement units by adjusting this scale factor. This factor will be applied to the
displayed value, all outputs, alarm and calibration configurations.

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.

Go via SETUP/UTILITY to LABELS - press ENTER


At display screen Operation
I1 COMPONENT NAME Any combination of up to 6 characters may be used
|||||| e.g. "Oxygen" or "AT-123". Use the arrow keys to
change a character and when the name is correct
press 'ENTER'.
I1 ENG UNIT This entry only defines the label which follows the
||| measurement value, it does not actually affect the
(Factory set to '%' measurement value (see below).
or 'vpm') Change characters as above.
I1 SCALE FACTOR This entry may be used to rescale the factory
1.000 calibration. This factor will be applied linearly to
the displayed value, all outputs, alarm and
(E.g.: 1.000 for percent calibration configurations.
10000 for vpm) Change value as above.

4000 Series - Configuration and Operation 04000/003C/4 9


3.2 Alarms
The analyser has four concentration alarm settings for each measurement (referred to as
AL1, AL2, AL3 and AL4). Each may be enabled or disabled, and the states of the following
parameters need to be set up for every enabled alarm:

i) FREEZE to prevent alarms during calibration or FOLLOW so that


alarms may be activated by calibration gases.
ii) HIGH concentration alarm or LOW concentration alarm.
iii) The concentration LEVEL at which the alarm is to occur.
iv) The HYSTERESIS (dead band) of the alarm, this may be used to
avoid 'chatter' if the typical sample concentration is close to the alarm
level.

Go via SETUP to SET ALARM - press ENTER


At display screen Operation

SELECT MEASURE Select required measurement, (Oxygen % is shown


I1 Oxygen % as an example), press 'ENTER'.

I1 Oxygen Select required alarm, press 'ENTER'.


SELECT AL1/2/3/4
I1 Oxygen AL1 Select required state, press 'ENTER'.
ENABLE/DISABLE
I1 Oxygen AL1 Select required state, press 'ENTER'.
FREEZE/FOLLOW
I1 Oxygen AL1 Select required state, press 'ENTER'.
HIGH/LOW ALARM
I1 Oxygen AL1 LO Set the value to the required alarm level, press
LEVEL = 00.000% 'ENTER' when correct.

I1 Oxygen AL1 LO Set the value to the required hysteresis, press


HYST =00.000% 'ENTER' when correct.
I1 Oxygen Select other alarms as required and repeat above.
SELECT AL1/2/3/4 When all alarms have been set for a gas sensor
module use 'QUIT' to select another module.

10 4000 Series - Configuration and Operation 04000/003C/4


NOTE
A high alarm will be signalled when the sample concentration rises
above the alarm level. This will be cleared when the sample falls
further below the alarm level than the value of hysteresis.
A low alarm will be signalled when the sample concentration falls
below the alarm level. This will be cleared when the sample rises
further above the alarm level than the value of hysteresis.

3.3 Allocation of relays


With the exception of dedicated external autocalibration relays, each relay may be set
up to respond to any combination of the following:

i) Failure of transducers I1 to I4, where fitted and of milliamp inputs E1


and E2.
ii) Maintenance required for transducers I1 to I4, where fitted.
iii) Calibration in Progress for transducers I1 to I4.
iv) Any concentration alarms.
v) Chassis Failure, Chassis Maintenance required.
vi) Warming Up, for transducers I1 to I4, where applicable.

Any existing relay allocation may be edited or cleared. When cleared the relays will remain
non-functional.

NOTE

Optional relays supplied specifically for external autocalibration or any


relay configured to control external valves will be used exclusively for
that purpose. Attempts to change such configuration via the 'allocation
of relays' function are inhibited and will result in the message "RELAY
ASSIGNED TO AUTOCAL".

4000 Series - Configuration and Operation 04000/003C/4 11


The identity of each relay conforms to the standard 4000 series output numbering system,
as listed in the installation manual, which also includes a list of default relay allocations.

Go via SETUP/ASSIGN to RELAYS - press ENTER


At display screen Operation
SELECT RELAY Use the arrow keys to select the required relay then
1.3 ASSIGNED OR press 'ENTER'.
1.3 UNASSIGNED
RELAY ASSIGNMENT Select 'EDIT' to edit allocation, or re-assign a
1.3 EDIT/CLEAR OR cleared relay OR select 'CLEAR' to clear the relay
1.3 ASSIGN? Y/N then press 'ENTER'.
1.3 I1 Oxygen AL1 The display will now show all available alarms and
HI 10.000 % Y/N functions which may be selected to operate the relay
or (1.3 in this example).
1.3 CAL IN PROG
YES/NO Select 'YES' and press 'ENTER' to allocate the item
or to the relay
1.3 FAILURE OR
YES/NO
or 'NO' and press 'ENTER' to move to the next item.
1.3 MAINTENANCE
YES/NO For concentration alarms the alarm set point will be
or displayed, an H or L will also be displayed to show
1.3 CHASSIS MAINT or the HIGH or LOW status.
CHASSIS FAILURE
YES/NO Maintenance, Failure and Warm up assignments
or can be made for each transducer and the chassis.
1.3 WARM UP
YES/NO
SELECT RELAY Use the arrow keys to select another relay then
1.3 ASSIGNED OR press 'ENTER'.
1.3 UNASSIGNED

12 4000 Series - Configuration and Operation 04000/003C/4


3.4 External analogue input configuration
Two external, linear analogue inputs are provided on the instrument, identified as E1 and
E2 . The name and units for these variables are modified using the LABELS menu entry,
in a similar manner to internal transducers (section 3.1). An additional
'ENABLED/DISABLED' command may be used to turn inputs on or off under the
SETUP/ASSIGN menu.

Input scaling (calibration) is set up via the MAN CAL menu, refer to section 4.3.

3.5 Analogue outputs


The analyser can have up to eight analogue outputs depending on the number of options
fitted. Each output has two ranges: R1 (the default range) and R2 (selected using the
external contact). Maximum output span is limited to twice the full scale range of the
transducer (except Zirconia sensors).

Note: performance typically will begin to degrade above 120%FSD.

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:

i) Gas sensor module to which analogue output is to be assigned.


ii) Scale (Lower & Upper limits) of the analogue output, range 1.
iii) Scale (Lower & Upper limits) of the analogue output, range 2.
iv) 0 to 20mA or 4 to 20mA. In the case of a 4 to 20mA, the actual
minimum current allowed in normal operation must also be specified.
v) FREEZE the analogue output during calibration or allow it to
FOLLOW calibration sample concentrations.
vi) Set the output to JAM LOW or JAM HIGH in the event of a
measurement failure condition. The output will be forced to zero or
20.5mA respectively - this only applies to 'Failures' (not
Maintenance faults).

4000 Series - Configuration and Operation 04000/003C/4 13


NOTE

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).

Go via SETUP/ASSIGN to mA OUTPUT - press ENTER


At display screen Operation
SELECT mA OUTPUT Use the arrow keys to select the required output then
1.1 ASSIGNED OR press 'ENTER'.
1.1 UNASSIGNED
mA OUTPUT ASSIGN Select 'EDIT' to edit allocation, or re-assign a cleared
1.1 EDIT OR relay OR select 'CLEAR' to clear the relay, then
1.1 ASSIGN? Y/N press 'ENTER'.
SELECT MEASURE Select the measurement to be output, then press
I1 Oxygen % 'ENTER' (I1 Oxygen used in this example).
1.1 I1 Oxygen R1 Set Lower and Upper limits for the output, the
L=000.00U=100.00 decimal point may be moved and negative values
may be entered for the lower limit.
When both values are correct press 'ENTER'.
1.1 I1 Oxygen R1 Select required state and press 'ENTER'.
0-20mA/4-20mA
1.1 I1 Oxygen R1 Adjust lower output current limit (range: 0, 3.6 to 4.0),
LOW LIMIT= 4.0mA if necessary, and press 'ENTER'.
1.1 I1 Oxygen R1 Select required state, press 'ENTER'.
FREEZE/FOLLOW
1.1 I1 Oxygen R1 Select required state, press 'ENTER'.
JAM NONE/LOW/HIGH
1.1 I1 Oxygen R2 Repeat the above process for range R2.
L=00.00 U=100.00
SELECT mA OUTPUT Use the arrow keys to select another output, then
1.1 ASSIGNED OR press 'ENTER'.
1.1 UNASSIGNED

14 4000 Series - Configuration and Operation 04000/003C/4


3.6 Defining and selecting measurement display screen
By default, one factory measurement display screen is provided. If required, up to five
different measurement display screens may be defined and displayed in succession. Each
screen definition may show up to four measurements. Screen definitions can be scrolled
manually (press MEASURE) or automatically (every 8s).

Use the EDIT key to go to DEFINE SCREEN - press ENTER


At display screen Operation

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'.

MORE MEASURES? Choose 'YES' to add more measurements to this


YES/NO screen definition, or 'NO' to finish or select another
screen for definition. When all required screen
definitions have been entered go to SELECT SCRN
menu.
SELECT ORDER Use the arrow keys to select the required 1st screen
1ST SCREEN IS : 1 then press 'ENTER'.

MORE SCREENS? Select as required, press 'ENTER'.


YES/NO
AUTOSCROLL ? Select required state, press 'ENTER'.
YES/NO

The number of decimal places displayed for each measurement may be selected.

Go via SETUP/UTILITY to DECI - press ENTER


At display screen Operation
SELECT MEASURE Use the arrow keys to select the required sensor
I1 O2 % b module, then press 'ENTER'.
I1 O2 % Select as required then press 'ENTER.'
DECI PTS=0/1/2/3

4000 Series - Configuration and Operation 04000/003C/4 15


3.7 Response time
The response time for each measurement may be increased by adding a user time constant
in order to reduce noise. The displayed reading and analogue output are both affected.
Normal setting for this additional constant is 0, maximum is 60 (selection is empirical).

Go via SETUP/UTILITY to TIME CONSTANT - press ENTER


At display screen Operation
SELECT MEASURE Use the arrow keys to select the required sensor
I1 Oxygen % module, then press 'ENTER', if only one module is
fitted this section will be omitted.
I1 Oxygen % Set between 0 and 0200 then press 'ENTER'.
TIME CONST = 0000

3.8 Serial communications


This section details the analyser configuration of the serial communications. For details of
connection, continuous output interpretation and Modbus data mapping refer to the 4000
Series installation manual. A choice of RS232 and RS485 interfaces is available in all
modes.

SET COMMS MODE

Go via SETUP/UTILITY to SET COMMS MODE - press ENTER


At display screen Operation
SELECT MODE Use arrow keys to select the required
NONE communications mode, then press ENTER.
or
CONTINUOUS b
or
MODBUS ASCII b
or
MODBUS RTU

FRAME FREQUENCY= Present only if CONTINUOUS mode is selected.


0000 S Use the arrow keys to select the required frequency,
(in seconds, maximum value of 9999S) then press
ENTER. A zero value will disable serial data output.
MODBUS ADDRESS = Present only if MODBUS ASCII or MODBUS RTU
247 mode is selected. Use arrow keys to enter the
required Modbus address (valid addresses are from
1 to 247).

16 4000 Series - Configuration and Operation 04000/003C/4


SET COMMS PARMS, Default Listing

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 CONTINUOUS communications these parameters should be set as required by the


receiving device. For Modbus communications they should be set as required by the
Modbus master device

Go via SETUP/UTILITY to SET COMMS PARMS - press ENTER


At display screen Operation
SELECT RS232/RS485 Select as required, then press 'ENTER'.
SELECT STOP Select as required, then press 'ENTER'.
BIT 1/1.5/2
SELECT DATA BITS 8/7 Select as required, then press 'ENTER'.

SELECT PARITY Select as required, then press 'ENTER'.


EVEN/ODD/NONE
SELECT BAUD RATE Select as required, then press 'ENTER'.
9K6/4K8/2K4/19K2
232,1, 8, E, 9K6 Confirm 'YES' that the specified communications
ACCEPT ? YES/NO parameters are correct, or 'NO' to re-edit.

4000 Series - Configuration and Operation 04000/003C/4 17


3.9 Calculation of total nitrogen oxides (NOx) concentration

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:

[NOx] = a * [NO] + b * [NO]2

In most simple combustion processes it is recognised that the NO concentration accounts


for approximately 95% of the total NOx. In this case the total NOx content can be estimated
using factors (a) of 100/95 ( = 1.053), and (b) of zero (0.00).

Go via SETUP/UTILITY to DERIVE NOx - press ENTER


At display screen Operation
I1 NOx LINEAR Set as required, then press 'ENTER'.
COEF 00.000
I1 NOx SQUARE Set as required, then press 'ENTER'.
COEF 00.000

18 4000 Series - Configuration and Operation 04000/003C/4


4 CALIBRATION

4.1 Introduction to calibration


Analyser calibration may checked or adjusted manually or automatically. These activities
will result in an entry in the calibration history log, labelled as a "CHK" or a "CAL".

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.

Autocalibration or autocheck are referred to together as "autocalibration". Progress may be


monitored on the display (see Figure C) and the measurement of the sensor(s) being
calibrated will flash. The autocalibration cycle can be initiated in four ways:

by the internal timer


by external contact closure
by keypad entry
by Modbus command

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

Autocalibration cannot be configured to perform a HIGH calibration


(21% oxygen "air point") with a zirconia oxygen gas sensor module.
The instrument will only respond to autocalibration initiation from the
internal timer, external input or Modbus command if no faults are
indicated. Autocalibration can be initiated from the keypad when there
is a fault condition.
All of the following sections assume that calibration gases as
recommended in the installation manual are available to the
analyser!

If the analyser is still warming-up and a manual calibration is attempted, a warning


message will be given with an option to proceed. For optimum performance, all gas sensor
modules should reach operating temperature before performing initial calibration.

Autocalibration can be configured to calibrate all gas sensor modules independently, or in


any simultaneous combination.

4000 Series - Configuration and Operation 04000/003C/4 19


4.2 Setting Low and High calibration tolerances
A limit may be placed on the amount by which a calibration may be changed. If exceeded
during autocalibration it will be aborted and a fault indicated. If exceeded during manual
calibration a warning will be given with an option to proceed.

Go via SETUP/UTILITY to LO & HI TOL - press ENTER


At display screen Operation
I1 Oxygen LO TOL Set the required low cal tolerance*
00.00% then press 'ENTER'.
I1 Oxygen HI TOL Set the required high cal tolerance*
00.00% then press 'ENTER'.

* It is recommended that the tolerance should not be greater than 10% of sensor FSD - the
factory default settings.

4.3 Manual calibration and checking


In most cases it is recommended that a LOW calibration is made before any HIGH
calibrations, however, if both points are to be calibrated for a Zirconia sensor, the
reverse is true.

Notes: (apply to the calibration procedure on the next page)

PRESS (pressure) calibrations are only applicable to Oxygen Purity sensors

* If the module is warming-up a warning will be given with an option to proceed.

** 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

If autocalibration is configured, manual calibrations will activate the


valve signalling, however, the relays must first be set up within
autocalibration.

20 4000 Series - Configuration and Operation 04000/003C/4


An oxygen sensor in module position 1 has been used in this example of calibration:

Go via CALIBRATE to MANUAL CAL - press ENTER


At display screen Operation
CALIBRATE Select required measurement , then press 'ENTER', if
I1 Oxygen % only one module is fitted this section will be omitted.
LOW/HIGH/PRESS() Select 'LOW', then press 'ENTER'.
HISTORY/CHK L&H (*)
I1 LOW TARGET Set to the low calibration gas concentration, then
Oxygen 00.00% press 'ENTER'.
LT00.00 LC00.04 LT is the target concentration.
I1 Oxygen OK? Y/N LC is the current concentration.
Introduce low cal gas, when 'LC' has stabilised it
may be accepted (**) or rejected.
LOW CAL IN Temporary message, no action required.
PROGRESS
CAL RESULT The calibrated reading is displayed for 1 minute (***) -
LT 00.00 LC 00.00 press QUIT to obtain next menu.
LOW/HIGH/PRESS The low point cal is now complete, select another
HISTORY/CHK L&H function or press 'MEASURE' to go to measurement
display - assume that a 'HIGH' calibration has been
selected.
I1 HIGH TARGET Set to the high calibration gas concentration, then
OXYGEN= 99.98% press 'ENTER'.
HT99.98 HC99.85 HT is the target concentration.
I1 Oxygen OK? Y/N HC is the current concentration.
Introduce high cal gas, when 'HC' has stabilised it
may be accepted (**) or rejected.
HIGH CAL IN Temporary message, no action required.
PROGRESS
CAL RESULT The calibrated reading is displayed for 1 minute (***) -
HT99.98 HC99.98 press QUIT to obtain next menu.

4000 Series - Configuration and Operation 04000/003C/4 21


Manual checks should use the same samples as for calibration adjustment. An oxygen
sensor in module position 1 has been used in this example of checking calibration:

Go via CALIBRATE to MAN CAL - press ENTER


At display screen Operation
CALIBRATE Select required measurement , then press 'ENTER', if
I1 Oxygen % only one module is fitted this section will be omitted.
LOW/HIGH/PRESS Select CHK L&H and press 'ENTER'.
HISTORY/CHK L&H
CHECK LOW Select 'LOW' or 'HIGH'.
CHECK HIGH
I1 Oxygen CHK L Introduce low cal gas; when the reading has
CONC = 0.5% stabilised, press 'MEASURE' to return to the
measurement display and stamp the cal check result
OR in the cal history buffer.

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.

22 4000 Series - Configuration and Operation 04000/003C/4


4.4 Calibration of paramagnetic pressure transducer
(Only applicable to oxygen purity gas module.)
To perform this it is necessary to expose the pressure transducer to two different sample
pressures whilst sampling the HIGH cal gas:

i) analyser venting to atmospheric pressure


ii) analyser venting to a slightly elevated pressure of 1.25psig / 8.6kPag
above atmospheric pressure

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

Do not exceed the specified maximum sample inlet pressure (pressure


driven option) or maximum inlet flow rate (flow driven option) during
this procedure or transducer damage may result.

NOTE

This procedure must be preceded by a low calibration.


For most accurate results the high calibration gas should be pure
oxygen. Gases containing less than 15% oxygen must NOT be used
for the calibration of the pressure transducer.
This procedure must be immediately followed by a high calibration.

4000 Series - Configuration and Operation 04000/003C/4 23


Go via CALIBRATE to MAN CAL - press ENTER
At display screen Operation
CALIBRATE Select required measurement , then press 'ENTER'.
I1 Oxygen %
LOW/HIGH/PRESS Conduct a 'LOW' calibration as detailed in
HISTORY/CHK L&H section 4.3.
LOW/HIGH/PRESS Select 'PRESS', then press 'ENTER.
HISTORY/CHK L&H
MEASURE P OFFSET Select 'MEASURE P OFFSET' then press
SPECIFY P OFFSET 'ENTER'(If a low calibration has not been performed
a warning will be given).
O= 98.87 P = 14.70 Introduce HIGH cal gas with no outlet restriction,
LOW POINT OK Y/N and allow both readings of Oxygen and absolute
Pressure (psia) to fully stabilise
then note readings and sample flow rate (the
pressure reading updates every 10s)
press 'ENTER' to accept.
APPLY PRESSURE Temporary message, with the HIGH gas still flowing
I1 Oxygen increase the pressure in the sensor by partially
closing the outlet needle valve - adjust the supply to
maintain the noted flow rate.
O= 107.28 P = 15.95 The pressure reading should be increased by
HIGH POINT OK Y/N 1.25psi when both (oxygen and pressure)
readings have fully stabilised, press 'ENTER' to
accept. If the pressure change is inadequate a
warning will be given ('PRESS DIFF LOW') - with the
option to restart.
REMOVE PRESSURE Temporary message.
I1 Oxygen Remove the restriction from analyser vent by fully
opening the needle valve again.
P OFFSET psia Temporary display of resultant pressure offset figure.
I1 Oxygen 0.23
MEASURE POFFSET Press 'QUIT'.
SPECIFY P OFFSET
LOW/HIGH/PRESS Conduct a 'HIGH' calibration as detailed in
HISTORY/CHK L&H section 4.3 (then remove the needle valve).

24 4000 Series - Configuration and Operation 04000/003C/4


4.5 Autocalibration and autocheck setup
With the use of up to four autocalibration Groups it is possible to configure fully
independent calibration of any sensor configuration.

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:

Will be Autocalibrated together.


Share the same relays controlling calibration gases and by inference the same
calibration gases (but the definition of which cal gas is high or low for each sensor is
independent of group).
Require the same type of autocalibration; i.e: LOW & HIGH, check or cal.
Require the same flush time.

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.

4000 Series - Configuration and Operation 04000/003C/4 25


If autocheck is selected, corrections are not calculated or applied, however the magnitude
of the differences in reading are stored in the calibration history logs.

NOTE

If an out of calibration tolerance fault is generated during the


autocalibration procedure then this may only be removed by
performing a subsequent successful one cycle auto or manual
calibration.
A sensor warming up or failure flag prevents autocalibration for all
sensors in a group.

Go via CALIBRATION/AUTOCAL to SET UP AUTO CAL - press ENTER


At display screen Operation
All sensor specific parameters will be set first:
CONFIG TXD CAL Select 'CONFIG TXD CAL', then press 'ENTER'.
CONFIG CAL GROUP
SELECT MEASURE Select sensor to configure. The following should be
set for all transducers.
I1 O2 Set to the concentration of the low gas, then press
LOW=00.00% 'ENTER'.
I1 O2 Set to the concentration of the high gas, then press
HIGH=100.00% 'ENTER (this display will not appear if 'LOW' has been
selected, ref next page).
I1 O2 Select which gas (CAL1 or CAL2) is the low gas for
LOW GAS IS 1/2 ? this sensor, then press 'ENTER'.
ASSIGN I1 to CAL Select which Autocalibration group to assign
GROUP 1 transducer to, then press 'ENTER'.
Once all parameters for all sensors to be calibrated have been set, it is
necessary to assign each to a group:
CONFIG TXD CAL Select 'CONFIG CAL GROUP', then press 'ENTER'.
CONFIG CAL GROUP
SELECT CAL GROUP Select the group to configure, if the group has no
sensors allocated to it, it cannot be setup. Use
CONFIG TXD CAL option to define a group.

26 4000 Series - Configuration and Operation 04000/003C/4


CAL GROUP 1 Set as required, then press 'ENTER'
ENABLE/DISABLE (When disabled, autocalibrations and remote
autocalibrations will not occur).
SELECT AUTOCAL Select as required, then press 'ENTER'.
LOW / LOW & HIGH
SELECT MODE Select as required, then press 'ENTER'.
AUTO CAL/CHK
SAMPLE/ CAL RELAY Set as required, then press 'ENTER'.
0.1 CURRENT
CAL 1 /CAL 2 RELAY Set as required, then press 'ENTER'.
0.2 CURRENT
SET FLUSH TIME Set as required, then press 'ENTER'.
0.5 Min
ENTER PERIOD Set as required, then press 'ENTER'.
DAYS 00
ENTER PERIOD Set as required, then press 'ENTER'.
HOURS 00
TIME 12:07:16 Temporary display of current time and date.
DATE 10/11/95
ENTER START TIME Set as required, then press 'ENTER'.
YEAR 0000
ENTER START TIME As above.
MONTH 00
ENTER START TIME As above.
DAY 00
ENTER START TIME As above.
HOUR 00
ENTER START TIME As above.
MINUTE 00
TIME 12:00:00 Temporary display of start time and date.
DATE 10/12/95
Repeat the above for all defined Calibration groups.

4000 Series - Configuration and Operation 04000/003C/4 27


Initiating autocalibration or autocheck from the keypad

Go via CALIBRATION/AUTOCAL to ONE CYCLE - press ENTER


At display screen Operation
SELECT CAL GROUP Select the group to autocalibrate, then press
'ENTER'.

Initiating autocalibration/autocheck by external contact closure


An autocalibration may be initiated by closing an external switch (refer to installation
manual for details). This initiates an autocalibration on all enabled groups in sequence.
This input will be ignored if an autocalibration is already in progress.

Initiating autocalibration/autocheck by Modbus communications


An autocalibration on an individual group may be initiated remotely by a Modbus master
(refer to installation manual for details).

Disabling/enabling autocalibration and autocheck


Choose ENABLE or DISABLE from the CONFIG CAL GROUP menu option, press
ENTER, then press QUIT at the "SELECT AUTOCAL" prompt, see page 26.

ALSO:
To run a single timed autocalibration, at the designated start time:

Set PERIOD DAYS = 00 and PERIOD HOURS = 00

Then, to re-enable timed autocalibration or autocheck:

i) set PERIOD to a proper (non zero) time


ii) reset the start time

Note: the ONE CYCLE menu option is always enabled.

28 4000 Series - Configuration and Operation 04000/003C/4


5 VIEWING CONFIGURATION AND HISTORY FILES

5.1 Displaying 'Current' alarms and faults

Go via ALARMS to DISPLAY ALARMS - press ENTER


At display screen Operation
I1 O2 AL1 The first alarm is displayed, if further alarms are
99.98 HIGH present an arrow will be shown, use the arrow keys
to access.

Go via FAULTS/FAILURE to DISPLAY FAILURES - press ENTER


At display screen Operation
I1 CELL TEMP The first fault is displayed, if further faults are present
LOW an arrow will be shown, use the arrow keys to
access.

Go via FAULTS/MAINTENANCE to DISPLAY MAINT - press ENTER


At display screen Operation
I1 LO CAL TOL FAIL The first fault is displayed, if further faults are present
an arrow will be shown, use the arrow keys to
access.

5.2 Displaying alarm settings

Go via SETUP/DISPLAY to ALARMS - press ENTER


At display screen Operation
SELECT MEASURE Use arrow keys to select required measurement.
I1 Oxygen Then press 'ENTER'.
I1 Oxygen AL1 The configuration of each of the four alarms (AL1 to
LO80.00% DISAB AL4) is shown on two screens making a total of eight
I1 Oxygen AL1 LO screens to be viewed, use the up arrow to obtain the
HYST 0.1% FOL b next screen.
.....ETC.....
I1 Oxygen AL4 LO This is the last of the eight screens, press ' QUIT' to
HYST 0.1% FOL select another measurement.

4000 Series - Configuration and Operation 04000/003C/4 29


5.3 Displaying output configuration

Relays

Go via SETUP/DISPLAY to RELAYS - press ENTER


At display screen Operation
DISPLAY RELAY Use arrow keys to select the required relay
1.3 ASSIGNED then press 'ENTER'.
or
1.3 UNASSIGNED
1.3 I4 Oxygen AL4 The first allocation to this relay will be displayed, if
LO 0.000 % there are further allocations an arrow will be shown,
or use the arrow keys to access.
HI 98.00 %
or Press 'QUIT' to select another relay.
FAILURE
etc.

mA Outputs

Go via SETUP/DISPLAY to mA OUTPUT - press ENTER


At display screen Operation
DISPLAY mA OUTPUT Use arrow keys to select the required output then
1.1 ASSIGNED press 'ENTER'.
or
1.1 UNASSIGNED
1.1 I1 Oxygen R1 The information on each analogue output is shown
L=99.000U=100.00 on four screens, use the up arrow to obtain the next
1.1 I1 Oxygen R1 screen.
4-20mA FREEZE b
1.1 I1 Oxygen R2
L=99.000U=100.00 b
1.1 I1 Oxygen R2 This is the last of the four screens, press 'QUIT' to
0-20mA FOLLOW select another analogue output.

30 4000 Series - Configuration and Operation 04000/003C/4


5.4 Displaying analyser histories
The analyser retains history entries (up to 40 per 'section') for the following events:

Alarms: an entry is made each time an alarm appears ('ON') or is cleared


('OFF'), in the following format:

[gas sensor module site number] [measurement name][alarm no.]

[alarm level] [alarm sense]

e.g. I2 O2 AL2
98.00 LOW

Go via ALARMS to ALARM HISTORY - press ENTER


At display screen Operation
Oxygen AL2 ON Use up arrow to view next screen, press
12:13:20 12/06 'MEASURE' to return to measurement display.

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.

Refer to menu map, go to FAULTS - press ENTER


At display screen Operation
FAILURE Select either option as appropriate, then press
MAINTENANCE 'ENTER'.
DISPLAY FAILURES Select required history, then press 'ENTER'.
FAILURE HISTORY
OR
DISPLAY MAINT
MAINT HISTORY
SELECT OBJECT Select object to view the log for, then press 'ENTER'.
I1,I2,I3,I4,E1,E2,
CHASSIS or ALL.
I1 CELL TEMP LO Use arrow keys to view further entries.
12:13:20 12/06

4000 Series - Configuration and Operation 04000/003C/4 31


Calibration: an entry is made each time a calibration or calibration check is
performed, in the following format:

[gas sensor module site number] [measurement name] [type of calibration] [difference]
[time and date]

e.g. I3 Oxygen CML 0.213


14:54:20 24/07

Calibration types: C or V Calibration or calibration check (Validation).


M or A Manual or Auto.
L or H Low or High.
MPO Measured Pressure transducer Offset *
SPO Specified Pressure transducer Offset *

Difference: Difference between measured and target concentration, (current


measured value - target value of calibration sample, i.e. a
positive number indicates a positive drift).

* Applicable to paramagnetic oxygen purity modules only.

Go via CALIBRATE/MANUAL CAL to HISTORY - press ENTER


At display screen Operation
LOW/HIGH Select history to view, then press 'ENTER'.
P OFFSET HISTORY
I1OxygenCML0.213 Use arrow keys to view further entries.
01:15:20 28/11

32 4000 Series - Configuration and Operation 04000/003C/4


5.5 Displaying analyser identity and diagnostics

Identity

Go via SETUP/DISPLAY to ID - press ENTER


At display screen Operation
4000 SERIES Use up arrow to view next screen.
04000/CP0_xx
MODEL4104C1 Use up arrow to view next screen.
S NUM 1234 Press 'MEASURE' to return to measurement display.
ORDER NUM 845123
TRANSDUCER I1
PARAMAGNETIC
TRANSDUCER I2
ZIRCONIA etc

The measurement signals from gas sensors may be displayed for diagnostic
information, typical examples are shown below:

Go via SETUP/DISPLAY to DIAGNOSTICS - press ENTER


At display screen Operation
I2 CELL EMF Use up arrow to view next screen.
0.234 Volts
I2 CELL TEMP Use up arrow to view next screen.
35.5C
I1 CO2 DIF SIG Use up arrow to view next screen.
0.003 Volts
I1 CO2 GAS SIG Use up arrow to view next screen or press
0.900 Volts 'MEASURE' to return to measurement display.

For a more detailed assessment of the diagnostics information please refer to the 4000
Series Service manual part number 04000002C.

4000 Series - Configuration and Operation 04000/003C/4 33


NOTES

34 4000 Series - Configuration and Operation 04000/003C/4