DURAG D-R 800 User manual

D−R 800
Dust concentration meter
Before starting any work, read the operating instructions (the manual)!
GmbH Kollaustraße 105 · 22453 Hamburg · www.durag.de
Article No.: 115 550

Translation of the original operating instructions Dust concentration meter D−R 800
Document: man_dr800_uk.doc Version: 05.10.2009
Last update: 10.02.2010 Print date 10.02.2010
Order No.: 115 550
This documentation is
valid from: Serial number: Firmware-Version
Article No.: 115 550 V. 1.76
DURAG GmbH Tel: [phone] – 0
Kollaustraße 105 Fax : [phone]
22453 Hamburg e-mail: [email protected]
Internet:
www.durag.de
This documentation
(approx. 154 pages) was prepared with very great care, however no liability for errors and
omissions can be accepted.
is not intended for the US American market. Documentation to ANSI Z535 is available on
request. Reference addresses can be found on page 153.
or parts thereof may not be reproduced or distributed without express permission from DURAG
GmbH, irrespective of how this is done, in what language or by what medium, electronic or
mechanical.
always relates to the complete device, even if individual program modules or equipment (parts)
were not procured.
relates to the current design of the device at the time of update of this documentation (see
above).
can be changed in respect of its contents without notification.
© DURAG GmbH 2010 Editor: Herbert Lange.
Alle Rechte vorbehalten - All rights reserved.

Contents
D−R 800 3
Contents
0Foreword 7
1General 11
1.1 Brief overview of the contents 11
1.2 Typographical conventions 12
1.3 Meaning of the warnings and instructions used 12
2Safety instructions 17
2.1 General safety instructions 17
2.2 Responsibility of the operating company 18
2.3 Avoidance of consequential damage in the event of a system fault 18
2.4 Hazards due to electrical equipment 19
2.5 Hazard due to laser light 20
2.6 Hazard due to hot, aggressive or explosive gases or high pressure of the measurement 20
2.7 Hazard to the device due to purge air failure 21
2.8 Use for the intended purpose 21
2.9 Qualified personnel 21
3Brief information 25
3.1 Safety 25
3.2 Brief instructions 26
3.3 Calibration 26
3.4 Operation 27
4Product description 31
4.1 Scope of supply 31
4.2 Accessories 32
4.3 Instructions for delivery 33
4.4 Instructions about the product 33
4.5 Conformity/approvals 34
4.6 Instructions on warranty 34
4.7 Limitations of liability 34
4.8 Disposal of the D−R 800 35
4.9 Identification of the product 35
4.10 Device description 35
4.11 Application areas 36
4.12 Terminology 37
4.13 Equipment 38

Contents
4D−R 800
5Layout and function 41
5.1 Functional description of the system components 41
5.2 Functional diagram 42
5.3 Supply unit 43
6Configuration, installation, commissioning 47
6.1 Safety 47
6.2 Installation 48
6.3 Installation 53
6.4 Commissioning 61
7Optional accessories, installation and use 67
7.1 Purge air heating 67
7.2 Purge air monitoring 74
7.3 Weather protection hood 79
7.4 Modbus 81
7.5 Modbus register definitions 85
8Operation 97
8.1 Menu structure 98
8.2 Edit mode: 100
8.3 Brief commands 102
8.4 Description of the individual display and input fields 102
8.5 Set-up, adjustment 113
9Maintenance 120
9.1 Customer service information 120
9.2 Safety 120
9.3 Maintenance work 121
9.4 Messages 126
10 Technical data 131
10.1 Performance features 131
10.2 Dimensions and weights 131
10.3 Power supply 131
10.4 Connections 132
10.5 Ambient conditions 132
10.6 Purge air heating 132
10.7 Purge air monitoring 133
10.8 Preset values for purge air monitoring (flow rate monitor) 133
10.9 Preset values for the Modbus 133
10.10 Dimensional drawings 134

Contents
D−R 800 5
10.11 Spares 134
10.12 Control parameters for code level 1 - overview 135
11 Menu structure 137
12 Standards and regulations 141
13 Declaration of Conformityand QAL1 143
14 Glossary 146
15 Index 149
16 DURAG GROUP company addresses 153
Figures
Figure 4.1: Position of the rating plates.................................................................................................... 35
Figure 4.2: Supply unit (above) (measurement) probe (below) ............................................................... 37
Figure 4.3: Vertical measuring probe for vertical ducts............................................................................ 38
Figure 4.4: Horizontal measuring probe for horizontal ducts ................................................................... 38
Figure 5.1: Components of the D−R 800 ................................................................................................. 41
Figure 5.2: Functional diagram I............................................................................................................... 42
Figure 5.3: Functional diagram II.............................................................................................................. 42
Figure 5.4: Layout of the supply unit ........................................................................................................ 43
Figure 6.1: Selection of the correct flange / lance length ......................................................................... 50
Figure 6.2: Dimensionaldrawing (measuring )probe ................................................................................51
Figure 6.3: Installation point of the probe; upstream section ...................................................................52
Figure 6.4: Installation point of the probe; shortened upstream section .................................................. 52
Figure 6.5: Welding-in drawing D−R 800 for a horizontal duct ................................................................ 53
Figure 6.6: Welding-in drawing D−R 800 for a vertical duct..................................................................... 53
Figure 6.7: Dimensional drawing for the supply unit D−R 800................................................................. 54
Figure 6.8: Changing the fuse in the supply unit D−R 800 ...................................................................... 55
Figure 6.9: Wiring diagram of the supply unit D−R 800 ........................................................................... 56
Figure 6.10: Purge air connection supply unit.......................................................................................... 58
Figure 6.11: Purge air connection measurement unit ..............................................................................59
Figure 6.12: Diaphragm openings............................................................................................................ 62
Figure 6.13: Miniature fuse holder............................................................................................................ 62
Figure 6.14: Evaluation unit with display and controls ............................................................................. 63
Figure 7.1: Installation of the purge air heating I...................................................................................... 67
Figure 7.2: Installation of the purge air heating II..................................................................................... 68
Figure 7.3: Installation of the purge air heating III (electrical connection)................................................ 69
Figure 7.4: Purge air heater internal control loop..................................................................................... 70
Figure 7.5: (optional) weather protection hood purge air heater.............................................................. 71
Figure 7.6: Installation of the purge air heater IV (weather protection hood, optional) ............................ 71
Figure 7.7: Adjustment of the purge air heater I....................................................................................... 72
Figure 7.8: Adjustment of the purge air heater II...................................................................................... 72
Figure 7.9: Dimensional drawing of the purge air heater .........................................................................73
Figure 7.10: Connection of the purge air monitoring unit......................................................................... 74
Figure 7.11: Local adjustment of the purge air monitoring.......................................................................75
Figure 7.12: Dimensional drawing rate of the flow / temperature monitor ............................................... 78

Contents
6D−R 800
Figure 7.13: Dimensional drawing (optional) weather protection hood .................................................... 79
Figure 7.14: Dimensional drawing (optional) weather protection hood for purge air heater .................... 80
Figure 7.15: Activation of the Modbus terminating resistor on the D−R 800 printed circuit board no. 2.. 83
Figure 8.1: Menu structure: vertical: Main menu ...................................................................................... 98
Figure 8.2: Menu structure, horizontal: submenu..................................................................................... 99
Figure 8.3: Menu, edit mode, example: Edit number ............................................................................. 100
Figure 8.4: Menu, edit mode, example: parameterisation of temperature measurement ...................... 101
Figure 8.5: Range switch-over - output ranges ...................................................................................... 108
Figure 8.6: Filter installation for checking the linearity ........................................................................... 117
Figure 9.1: Miniature fuse holder in the supply unit D−R 800 ................................................................ 121
Figure 9.2: Diaphragm openings on the measuring probe..................................................................... 122
Figure 9.3: Cleaning the optics on the measuring probe........................................................................ 123
Figure 9.4: Probe cap with light trap....................................................................................................... 123
Figure 9.5: Exchanging the filter (supply unit) ........................................................................................ 124
Figure 9.6: Overheating protection......................................................................................................... 125
Figure 11.1: Menu structure D−R 800 part 1/3....................................................................................... 137
Figure 11.2: Menu structure D−R 800 part 2/3....................................................................................... 138
Figure 11.3: Menu structure D−R 800 part 3/3....................................................................................... 139
Figure 13.1: Declaration of Conformity................................................................................................... 143
Figure 13.2: QAL1 to DIN EN 14181 and DIN EN 14956 page 1/2 ....................................................... 144
Figure 13.3: QAL1 to DIN EN 14181 and DIN EN 14956 page 2/2 ....................................................... 145
Tables
Table 6.1: Checklist: Preconditions for the operation of the D−R 800 ..................................................... 49
Table 6.2: Selection of the correct flange / lance length .......................................................................... 50
Table 6.3: Terminal assignment ............................................................................................................... 57
Table 6.4: Selection of the purge air restrictor ......................................................................................... 59
Table 6.5: Checklist: Preconditions for commissioning the D−R 800....................................................... 61
Table 7.1: LED display for the purge air monitoring unit .......................................................................... 75
Table 7.2: Possible causes / remedies for "Error during device adjustment"........................................... 76
Table 7.3: Teminal assignment for Modbus ............................................................................................. 83
Table 7.4: Abbreviations and terms in the tables ..................................................................................... 85
Table 7.5: Data formats in the tables........................................................................................................ 86
Table 7.6: Unsupported function codes.................................................................................................... 86
Table 7.7: General parameters and functions .......................................................................................... 90
Table 7.8: Status codes............................................................................................................................ 91
Table 7.9: D−R 800 Messages................................................................................................................. 92
Table 7.10: D−R 800 Parameters and functions ...................................................................................... 93
Table 8.1: Value pairs table from gravimetric comparison measurement .............................................. 114
Table 8.2: Value pairs table for the calibration function ......................................................................... 115
Table 8.3: Table for documentation of the calibration as it is being performed ..................................... 117
Table 9.1: Messages from the measuring unit ....................................................................................... 126
Table 9.2: Messages from the measuring unit (causes and remedies) ................................................. 128
Table 10.1: Overview of control parameters for code level 1................................................................. 135

Foreword
D−R 800 7
0 Foreword
This manual is intended to assist you in starting to use your DURAG product.
In this publication you will find information and technical data for planning,
installation / commissioning, operation and maintenance of the D−R 800.
The functional diagram for the overall equipment and the device components,
together with a spare parts list complete this information.
We hope that our products and services make a significant contribution to your
success. We will be delighted if the information provided achieves this.
If you have further questions on the products or applications of the
DURAG GROUP, please contact our Support & Service!
Their addresses and phone numbers can be found on page 153 (DURAG
GROUP company addresses).
Further information is also available at www.durag.de
Please read the following information carefully! It is important for your safety
and to avoid damage to the D−R 800 and to the environment.

D−R 800
Dust concentration meter
0 01 1
1General
1.1 Brief overview of the contents
1.2 Typographical conventions
1.3 Meaning of the warnings and instructions used

General
D−R 800 11
1 General
The product described in this manual left the factory in perfectly safe and inspected
condition. To maintain this condition and to ensure the correct and safe
operation of this product, it may only be used in the way described by the
manufacturer. In addition, faultless and safe operation of this product requires
appropriate transport, correct storage and installation, as well as careful
operation and maintenance.
This manual contains the necessary information for use of the product
described therein for the intended purpose. It is meant for the use of technically
qualified persons who have been trained on the product, specially educated or
have relevant knowledge of the field of measurement and control technology,
referred to below as automation technology.
The knowledge and technically sound implementation of the safety instructions
and warnings contained in this manual are a prerequisite for safe assembly
and commissioning, as well as for safety during operation and maintenance of
the described product. Only appropriately qualified personnel have the
necessary expertise to interpret the safety instructions and warnings provided
in a general manner in this document correctly in concrete individual cases
and to apply the appropriate procedure.
This manual is an integral part of the scope of supply, even if because of
logistical considerations it is physically ordered or delivered separately. It
always relates to the complete device, even if individual program modules or
parts were not procured. For reasons of clarity not all details of every product
variant are described, and not every conceivable case of installation,
operation, maintenance or use within systems is included.
The DURAG Group has a policy of continuous development of its products, to
bring you the optimum benefits from the devices you have procured. Therefore
please understand that the product may vary in some respects from the
descriptions in the manual.
Should you require further information or should problems that are
insufficiently covered in this document arise, please request further information
from the respective agent of DURAG GmbH (see page 153).
1.1 Brief overview of the contents
This manual describes the following areas:
Sections 1+ 2Information on using the manual, on the pictograms used, safety instructions
and requirements on operating and maintenance personnel.
Sections 3- 5 Information on the product, technical data, functional and system descriptions,
together with available options.
Sections 6- 9 Information on use of the product D−R 800, in respect of installation, assembly,
commissioning, operation, maintenance, troubleshooting, repair etc.
Appendix 10 - 16 Overview of technical data, standards and regulations to be complied with,
certifications, glossary, index and company addresses.

General
1.2 Typographical conventions
In order to make the text of this manual clear, text elements such as safety
instructions, warnings, tips, keyboard symbols, menu addresses etc. are
displayed differently.
The following conventions apply in this manual:
Safety instructions and warnings appear in this manual as follows:
WARNING Hazard due to electrical equipment
Before removing any casings or guards, deenergise the devices.
An instruction or tip is shown as follows:
No check cycle can be started during test measurements or simulation.
If a key on the measurement unit should be pressed, it is represented as:
+ MOD STO
The fields in the main menu (vertical) are shown by a list symbol in the
bottom left corner of the display (see section 8.1).
Menu addresses are shown as follows:
Measured value display A00
A () indicates that the following term is explained in the glossary. There
is generally a link to the glossary term in the pdf document.
Unless indicated to the contrary: all dimensions are in mm
This manual is also available as a pdf file on CD/DVD!
1.3 Meaning of the warnings and instructions used
Please comply strictly with the following warnings and. safety instructions in
this manual. They are there for avoidance of hazards to life and health of
users and maintenance personnel, and for avoidance of damage to property.
Attention is drawn to them in this manual by the signal terms defined here.
They are additionally identified by symbols at the locations where they occur.
The signal terms have the following meanings in this manual and in notices on
the product itself:
DANGER Disregard of instructions so marked can lead to severe or even fatal injuries.
It also means that major damage to property may occur if the respective
precautions are not taken.
> To avoid injuries, comply with all "DANGER" instructions.
12 D−R 800

General
D−R 800 13
WARNING Disregard of instructions so marked can lead to serious injuries or damage to
property.
> To avoid injuries and to ensure safe operation of the system, comply with all
"WARNING" instructions.
CAUTION Disregard of instructions so marked can lead to minor injuries or damage to
property..
> To avoid injuries and to ensure safe operation of the system, comply with all
"CAUTION" instructions.
In order to specify the potential risk the general warning sign can also be
replaced by a special warning sign.
General warning symbol
electrostatic sensitive
devices (ESD)
electric power Moisture
hot surfaces explosive atmosphere
Laser radiation
Read the manual before
use!
(applied to devices)
Apart from the warning and safety instructions, the following general
instructions and associated pictograms are used to draw particularly important
information to your attention:
Here you will find interesting instructions or tips regarding the product and its
handling.
contains instructions for environmental protection

D−R 800
Dust concentration meter
0 02 2
2Safety instructions
2.1 General safety instructions
2.2 Responsibility of the operating company
2.3 Avoidance of consequential damage in the event of a system fault
2.4 Hazards due to electrical equipment
2.5 Hazard due to laser light
2.6 Hazard due to hot, aggressive or explosive gases or high pressure of the measurement
2.7 Hazard to the device due to purge air failure
2.8 Use for the intended purpose
2.9 Qualified personnel

Safety instructions
D−R 800 17
2 Safety instructions
Before starting any work, read the operating instructions (the manual)!
Comply strictly with the following warnings and. safety instructions in this
manual. They are there for avoidance of hazards to life and health of
personnel, and for avoidance of damage to property. Their purpose is safe and
uninterrupted operation. Disregard of operating instructions and safety
instructions shown in this manual can lead to significant hazards.
2.1 General safety instructions
The DURAG Dust concentration meter D−R 800 is designed and built to
current technology and satisfies the recognised safety regulations. Despite
this, hazards can arise.
Therefore operate the product only when it is in faultless condition, and comply
with the operating instructions. Any change to normal performance should be
taken as a serious indication of impaired functionality. In this connection, pay
attention to:
emission of smoke or unusual smells,
excessive temperatures of system components,
changes in power consumption without obvious cause,
the tripping of monitoring devices,
abnormal operating noises from the purge air blower,
unusual vibrations,
Abnormal, strong fluctuations or shifts in the measuring results.
The D−R 800 is used for measurement of emissions of dust in flue gas ducts
and dust extraction ducts etc. If it is used or treated incorrectly, damage to
health or material items can arise. Therefore please read of this section
thoroughly and comply with the instructions during all activities involving the
D−R 800. Comply also with the safety and warning instructions in the
individual sections of these operating instructions.
The following warning and safety instructions apply in full to the D−R 800:
When preparing and performing work:
Comply with the applicable statutory regulations for the equipment and the
corresponding technical rules.
Work in accordance with:
the local, plant-specific conditions,
the instructions regarding the hazards inherent in the process.
Operating D−R 800 manuals and documentation belong to the equipment
system must be present in-situ. Comply strictly with the instructions
displayed for avoidance of hazards and damage.
Suitable protective devices and personal protective equipment must be
available in sufficient quantities and used by the personnel in accordance
with the respective potential hazards.
The device may only be operated in perfect condition and in compliance
with the safety instructions!

Safety instructions
18 D−R 800
The device as an entity and also its individual components may be used
only when in their original configuration.
2.2 Responsibility of the operating company
The Dust concentration meter is intended for use in commercial operations.
The operating company of the Dust concentration meter is subject therefore to
the statutory duties of safety at work, coupled with the applicable guidelines,
statutes and standards.
In addition to the safe working instructions contained in these operating
instructions, the safety regulations, accident prevention regulations and
environmental protection regulations for the field in which the Dust
concentration meter is used must be complied with. These specifically include:
The operating company must obtain information about the applicable
provisions for safe working and perform a risk assessment to determine
any additional hazards that arise due to the special working conditions at
the place of use of the Dust concentration meter. He must convert these
into operating instructions for the operation of the Dust concentration meter.
The operating company must check, during the entire period of use of the
Dust concentration meter, whether the operating instructions that he has
written satisfy the latest issue of the regulations, and must update them as
required.
The operating company must clearly regulate and specify who has
responsibility for installation, operation, maintenance and cleaning.
The operating company must ensure that all employees who deal with the
Dust concentration meter have read and understood the operating
instructions. In addition at regular intervals he must train the personnel
and inform them about the hazards.
Furthermore the operating company is responsible to ensure that the Dust
concentration meter is at all times in a technically faultless condition, i.e.
that the maintenance work has been performed (see section 9).
The operating company must provide the necessary protective equipment
for the personnel.
2.3 Avoidance of consequential damage in the event of a
system fault
In order to prevent and limit faults that can directly or indirectly result in
physical injuries or damage to property, the operator must ensure that:
responsible maintenance personnel are available at short notice at any
time.
maintenance personnel have been trained to find and rectify faults in the
D−R 800 and the associated systems.
defective system components can be switched off immediately.
switching off the device will not lead to unpredictable consequential faults
and damage.

Safety instructions
2.4 Hazards due to electrical equipment
This device is powered by electricity. Therefore only suitably qualified
personnel may work on it. These personnel must be thoroughly familiar with all
danger sources and repair measures in accordance with these operating instructions.
DANGER
Risk of fatal injury due to electrical power!
There is a risk of immediate fatal injury if live components are touched.
Damage to the insulation or to individual components can lead to fatal injury.
If there is any damage to the insulation, switch off the power and have it repaired.
Before starting work, switch off the power supply and secure it against
restoration.
Before removing any casings or guards, deenergise the devices and
check that they are dead.
Permit only electricians to work on electrical equipment.
Never bypass fuses or decommission them. When replacing fuses,
always comply with the correct amperage and the correct characteristics.
Keep moisture away from live components. Moisture can lead to short circuits.
The devices may:
- be connected only to the power supply listed on the rating plate.
-only be connected to a power supply that includes an earthing contact.
The protective action must not be cancelled by an extension without an
earthing contact. Any discontinuity of the earth conductor within or outside
the device is dangerous and is not permissible.
Cables must be routed so as exclude the possibility of an accident risk by
persons stumbling over them or hanging from them.
This device has been designed to ensure rigid segregation between primary
and secondary circuits. Low voltages that are connected must also be
generated with safe separation.
CAUTION Damage to electronic components due to
electrostatic discharge (ESD)
Electronic components are becoming ever smaller and more complex. Their
susceptibility to damage by electrostatic discharges is increasing
correspondingly. To protect these components, measures against electrostatic
discharge must be taken before starting any work on the opened device (ESD
protection).
As a precaution against electrostatic discharge from the human body, service
employees should be equipped with a personal earthing system.
D−R800 19

Safety instructions
2.5 Hazard due to laser light
CAUTION Danger due to laser light! There is a risk of blinding!
Laser protection class II (radiation power < 1 mW at 655 nm) is guaranteed
only at the unmodified (sealed) manufacturer's setting of the laser
potentiometer.
When dealing with the device take care:
- never look directly into the line of the beam
- never direct the laser beam D−R 800 towards any person
- always remember that the laser beam can be reflected.
2.6 Hazard due to hot, aggressive or explosive gases or
high pressure of the measurement
WARNING The use of the Dust concentration meter D−R 800 in explosion hazard areas
and its use for measurement in explosive gas mixtures is not permissible
The Dust concentration meter with measuring lance is mounted or
installed directly at the gas-transporting channel. In the case of systems
with a low danger potential (ambient pressure, low temperatures, no
health hazard), mounting/removal can occur during system operation.
When so doing, comply with the applicable regulations and safety
provisions for the plant and take all necessary and appropriate safety precautions.
Never touch parts that could be hot without temperature-resistant safety gloves.
WARNING If the measurement duct is carrying gases that are injurious to health, high
temperatures or high pressure, the Dust concentration meter with the
measurement probe may be fitted or removed only when the plant has been
shut down!
WARNING The flue gas temperature must not fall below the dew point, so that the gas
does not dissolve in condensate within the duct.
Otherwise, depending on the type of gas, acids can form on the measuring
probe, which can endanger the maintenance personnel and damage the
measuring probe!
Take account of changes in the temperature of the measured gas and the dew
point, particularly during run up / run down of the system to be measured.
20 D−R 800