Enotec SILOTEC 8000 User manual
Doc.-ID: SILOTEC_11022020_EN
Installation and Operation Manual
SILOTEC
®
8000
O
2
/CO
e
Analyzer System for Silo Monitoring
Version 03
for software version: 4.13
Doc.-ID: SILOTEC_11022020_EN
Preface
Dear Customer,
Thank you for selecting the SILOTEC
®
8000 analyzer system.
Since 1980 our analyzer systems have been operating in numerous applications with tens of thousands of units being produced
and shipped worldwide. ENOTEC is committed to absolute quality and performance and over time we have continuously
enhanced our products to integrate various features and functions.
In this package, the electronic unit uses the very latest Microprocessor Technology, making the SME5 electronic unit one of the
most advanced and up-to-date monitoring units, permitting you to reduce your costs and to achieve increased measuring
accuracy with operational reliability.
The SILOTEC
®
8000 is a unique O
2
und CO
e
analyzer system for reliable measurement and analysis which enables a
redundant measurement of oxygen and combustibles with high accuracy. The MXP sensor measures not only CO but also all
other combustibles (hydrocarbons and hydrogen).
All ENOTEC instruments are thoroughly tested in the factory and are subject to a strict ISO9001 Quality Assurance Procedure.
Therefore, with the correct installation, the operation of the SILOTEC
®
8000 is straightforward and user friendly and will
provide you with many years of trouble free operation with perfect measuring results.
The device may only be operated if the manual has been fully understood.
On request, the manual is also available in other languages.
Symbols used in this Manual
The symbols below are found attached to the system and in this manual. They emphasize important information as well as
safety instructions for installation, operation and maintenance, to protect the personnel and the equipment.
Warning
Follow all instructions in this manual
Consider Information
Points out important information which must be
noted before execution
Warning hot Surface
Warns of danger of burns which could occur from
hot system parts
Info
Contain further detailed information
Caution
Warns of possible damage to the equipment
caused by improper handling or storage.
Ground earth electrical protection
The contents of this manual are protected by copyright.
Alterations and errors reserved.
Safety Instructions
This system is operated with line voltage. If covers are removed during which line voltage is still connected, an electric shock
hazard will occur.
Only well trained and authorized personnel are allowed to conduct work on this system. Personnel have to understand all
precautions, safety instructions, installation and maintenance instructions in this manual. The trouble free and safe operation
of this system requires safe transportation, professional storage, installation, operation and maintenance. Furthermore, all
local safety requirements have to be considered.
This system may not be used in the vicinity of combustible gases as parts of the system may cause a risk of explosion.
The device may only be put into operation if the enclosed instructions have been fully understood.
This manual is also available in other languages on request
Installation and Operation Manual – SILOTEC 8000 Table of Contents
Doc.-ID: SILOTEC_11022020_EN 3
Table of Contents
1System Description 4
1.1System Overview of the SILOTEC 8000 .............4
1.2Measuring Principles...........................................5
1.3Intended Use....................................................... 5
1.4Safety Hazards....................................................6
1.5Disruption of the Process ....................................6
1.6Storage instructions ............................................6
1.7Name Plates .......................................................7
1.8System description – Contents of GRP housing .8
2Installation 9
2.1Installation requirements for electronic unit.........9
2.2Installation of probe signal cable FEP-0007/8...10
2.3Access to the Terminals....................................11
2.4Ferrite Sleeves (EMC).......................................11
2.5Wiring diagram of the Electronic Unit ................12
2.6Wiring Diagram of the SILOTEC 8000 ..............13
2.7Gas Plans .........................................................16
2.8Installation of the probe.....................................18
2.9Mounting the Probe...........................................18
2.10Electrical Connections of the Cuvette ...............19
2.11Requirements for Pneumatic Cable FEP-0002 .19
2.12Preparation of the pneumatic Cable..................20
2.13Connections at the probe ..................................20
2.14Pneumatic Connections of Electronic Units ......21
3Initial Operation 22
3.1Checklist before commissioning the system .....22
3.2System Power Up .............................................22
3.3Display - Probe Heating Phase .........................23
3.4Display - Measuring Mode ................................23
3.5Keypad and Display ..........................................23
3.6Status LEDs ......................................................24
3.7Softkey Symbols ...............................................24
3.8System Code.....................................................24
4Software Overview and Explanations 25
4.1Software Overview - SYS-MENU ...................... 25
4.2Software Explanations - SYS-MENU ................29
4.2.1O2Measuring Ranges (Scaling)........................29
4.2.2Limit alarm settings ...........................................29
4.2.3O2Sensor calibration values.............................29
4.2.4Measuring value averaging for O2/ COe...........29
4.2.5mA output on system errors (O2/ COe).............29
4.2.6COeMeasuring Ranges (Scaling) .....................30
4.2.7COeSensor Calibration values..........................30
4.2.8Time per test gas apply.....................................30
4.2.9Delay time to process........................................30
4.2.10Pre-purge time ..................................................30
4.2.11Automatic Calibration (ACAL) ...........................30
4.2.12ENOTEC REMOTE...........................................31
4.2.13Measuring units.................................................31
4.2.14Language ..........................................................32
4.2.15Change system code ........................................32
4.2.16Load factory settings .........................................32
4.2.17Set COemeasurement to off/on ........................32
4.2.18Service.............................................................. 32
4.3System Checks................................................. 33
4.4CAL MENU ....................................................... 34
4.4.1Calibration Menu - Display Overview................ 34
4.4.21-point calibration (O2and/or COe) (manual) .... 35
4.4.32-point calibration (O2and/or COe) (manual) .... 35
5Service and Maintenance 36
5.1Exchange fuses ................................................ 36
5.2Pressure and flow rates .................................... 36
5.3Position of the adjustment valves ..................... 37
5.4Adjusting Flow Rate (SME-54 19” rack)............ 37
5.5Adjusting the sample gas extraction rate .......... 38
5.6Working on the Meauring Cuvette .................... 38
5.6.1Replace the probe inner part ............................ 39
5.6.2Replace the probe tube with O2sensor ............ 40
5.6.3Replace the COesensor ................................... 40
5.6.4Seal the COesensor guide tube........................ 41
5.7Blow-back (optional) ......................................... 41
5.8Relay Outputs / Functions and Correlation ....... 42
6Status Messages 43
6.1Error Messages ................................................ 43
6.2Alarm Messages ............................................... 45
6.3Service Messages ............................................ 45
7Troubleshooting 46
ATechnical Data 48
A.1Technical Specifications SME-53 Electronic Unit
.......................................................................... 48
A.2Technical Specifications - Probes ..................... 49
A.3Requirements of the Gas Supply ...................... 50
BDimensional drawings 51
B.1Electronic units dimensions ............................. 51
B.2Probe dimensions ............................................. 52
B.3Probe inner part SIK-0501 ................................ 52
CSILOTEC 8000 spare parts 53
C.1Overview........................................................... 53
C.2Mounting Plates of SME-53 Electronic Unit ...... 54
C.3Mounting Plates of 19" Rack SME-54............... 54
C.4Display Board ................................................... 55
DWarranty 56
EDeclaration of Conformity 57
Index 58
System Description Installation and Operation Manual - SILOTEC 8000
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1 System Description
1.1 System Overview of the SILOTEC
®
8000
Figure 1 - System overview of the SILOTEC 8000 analyzer system
Electronic unit SME5 (IP66)
Safe Area
Max. ambient temp.: -20 °C to +55 °C (-4 °F to + 131 °F)
Compressed air conditioning
(optional – if instrument air is
unavailable)
Dust Ex Zone 22
Max. ambient temp.: -20 °C to +55°C (-4 °F to + 131 °F)
Pneumatic cable Coal silo – Dust Ex Zone 20
Probe signal cable Manufacturer supply
SILOTEC O
2
/ CO
e
probe unit
(GRP cabinet / IP 65) Customer supply
Compressed air in (2-10 bar)
Control line probe Test gas in (max. 3 bar); Optional equipment, see offer
Counter flange
(DN65 / PN6: customer supply) Power supply
Output signals (analog und digital)
Compressed air in (2-10 bar) – 10 x 1,5 mm
Condensate - 6 x 1 mm
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1.2 Measuring Principles
The SILOTEC
®
8000 O2 / COe analysis system consists of a measuring cuvette including gas sampling with
extraction filter and air jet injector, which is installed in the atmosphere to be monitored on the silo roof. The
associated evaluation electronics, operates the analysis system and is used for signal processing
.
A fine-pored 3 µm filter element safely separates the explosion protection zone 20 in the silo from the heated gas
sensors in the measuring probe. A monitored extraction system provides a continuous flow of sample gas with a fast
reaction time. If required, the optional blow-back can clean the sampling filter.
The sample gas flows through the measuring cuvette, which contains both O
2
and CO
e
sensors. The CO
e
sensor
detects combustible, gaseous molecules, whereby the measured value output corresponds to the CO equivalent
(CO
e
). The two catalytically active electrodes cause oxidation of the incompletely oxidized gas molecules, so that a
voltage builds up between the electrodes which depend on the CO
e
concentration. Thus CO, H
2
and the C
x
H
y
(hydrocarbons) can be measured.
The oxygen sensor works according to the zirconium oxide principle. A mV signal is measured between the reference
gas side of the sensor (inside, instrument air 20.95 % O
2
) and the measuring gas side, which logarithmically depends
on the ratio of the oxygen partial pressures of both sides of the sensor. The mV signal is converted by the Nernst
equation into the oxygen partial pressure in the sample gas, which determines the O
2
concentration in the sample
gas. The gas-tight separation between the reference air side and the sample gas side of the sensor is of particular
importance, as otherwise incorrect measurements will occur.
If a smoldering fire occurs in the silo, carbon monoxide is formed by the consumption of oxygen. SILOTEC 8000 can
detect this smoldering fire immediately on the basis of the increase in the CO
e
concentration and the decrease in the
O
2
content, and suitable safety measures can be taken.
1.3 Intended Use
Info
The SILOTEC
®
8000 InSitu Analyzer System is a system for measuring the oxygen concentration and the
concentration of CO
e
in storage container with pressures up to 0.5 bar.
Warning
For reasons of safety and the possible occurrence of accidents, unauthorized conversions and
modifications of the system are prohibited.
Warning
The analyzer system may not be used to determine the oxygen content in combustible gases or be
used in the vicinity of combustible gases. Doing this will cause a risk of explosion.
Info
The COe sensor requires a minimum O
2
concentration of 0,3 % for correct measurement.
O
2
concentrations below this limit will result in a increased inaccuracy of the measurement.
Caution
Under no circumstance should the measuring probe be directly connected to the 230V main power
supply, as this will immediately destroy the probe heater element!
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1.4 Safety Hazards
Warning hot Surface
During operation, the test gas inlet and outlet are directly connected to the heated cuvette. The surface
temperature of the sample gas inlet and outlet connections may exceed 100°C.
Direct contact with the hot parts for dismantling or maintenance will cause severe burns!
The cuvette may only be removed with heat-insulated gloves. Before removing the cuvette, always switch
off the supply voltage to the electronic system. After removal, store the probe in a safe, protected place
and wait until it has cooled downs below 35 °C (95 °F).
1.5 Disruption of the Process
The analyzer system has to be kept in operation also in the event of the process being disrupted or if the plant is
powered off temporarily (e.g. at night or during the weekend). Frequently cooling down and heating up of the cuvette
results in thermal stress of the hot probe parts (heater, thermocouple and sensor) and reduces their product life.
ENOTEC will not accept any responsibility for resultant damage
1.6 Storage instructions
ENOTEC equipment and spares are to be stored in a dry and ventilated environment at temperatures between
-40 °C to +80 °C (-40 °F to 176 °F)moisture?. Paint fumes, silicone sprays, etc. must be avoided in the storage
environment.
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1.7 Name Plates
The name plate contains information about the line voltage, the nominated current, frequency, protection class, year
of manufacture, serial number, order number and system order code.
The system order code refers to information which is detailed in the system test report and supplied with the system.
SIL-800000003
electronic unit in
field housing
SIL-800000004
(19" rack housing)
SIL-KES-0001
cuvette
Probe
in GRP housing
Figure 2 - Name Plates
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1.8 System description – Contents of GRP housing
Abb. 3 – Contents of the GRP housing
Injector 2-2-way solenoid valve for purging
Flow meter with alarm module 3-2-way solenoid valve for measuring
O
2
/CO
e
cuvette SIL-KES-0001 Throttle valve to fill purge tank
Gas sampling probe SIL-GSF-8000
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2 Installation
Warning
The electronic unit does not have a line voltage main switch. The line voltage power supply requires a
switch or breaker. The line voltage switch/fuse/breaker must be in accordance with the local technical
standards and should be in close proximity to the electronic unit and must be identifiable as such.
The probe cable is suitable for an ambient temperature range from -40°C to +90°C. All other installed
cables must be suitable for the ambient temperature range at side and must have the required size. All
electronic unit terminals are specified from 0,08mm² (AWG 26) to 2,5mm² (AWG 14). If wire end ferrules
are used the next smaller size is required. Before removal of the electronic terminal cover the line voltage
must be switched off. The line voltage to the electronic unit must be switched on again after the cover is
back in position. After installation, power conducting parts may not be accessible.
2.1 Installation requirements for electronic unit
Keep the minimum distance to adjacent objects
Install at eye level
Avoid vibrations greater than 2g
Mind the IP code
Ambient temperature limits
Min.: -20 °C (-4 °F) / Max.: +55 °C (+131 °F)
Heavy equipment, ensure proper lifting and carrying
Drilled holes for the electronic unit
Use suitable screws
Electronic unit
Figure 4 - Installation of the Electronic unit
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2.2 Installation of probe signal cable FEP-0007/8
Warning
The shielding of the probe cable FEP-0007 (armored) must be connected only to the electronic unit ground
(PE) clamp.
In no case should the shield of the probe cable be also connected at the probe end.
Abide by the maximum cable length (max. 50m)
Note the minimum bending radius.
FEP-0007Rmin=252 mm
FEP-0008Rmin=329 mm
Temp. during installation
Temp. during operation
Cross the probe signal cable (FEP-0007/8) at right
angle to any power supply cables
No. Function Diameter Colors Notice
1 O
2
measuring cell 2 x 0,75 mm
2
white-brown /
brown With shield
2 Thermocouple 1 2 x 0,75 mm
2
green / white With shield
3 Thermocouple 2 2 x 0,75 mm
2
green / white With shield
4 Probe heater 3 x 1,5 mm
2
black / blue /
green-yellow
5 Probe Solenoid
valve 2 x 0,75 mm
2
grey / grey-
blue
Figure 5 - Probe cable FEP-0007/
FEP-0008 (armored) 6 Shield of 1, 2& 3bare
7 CO
e
measuring cell 4 x 0,75 mm
2
white/ white/
red/ red
Warning
Only use ENOTEC probe cables, as the thermocouple cables 2and 3 are compensating cables and are
necessary for correct measurement.
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2.3 Access to the Terminals
Warning
Before removing the terminal covers, switch off the mains voltage to the system. Switch the mains
voltage on only after attaching the terminal cover. After the installation has been completed, live parts
may no longer be accessible.
Figure 6 - Access to the Terminals
2.4 Ferrite Sleeves (EMC)
Caution
In order to avoid cable related disturbances to the electronic unit, the supplied ferrite sleeves must be used.
CE-conformity is invalid if these ferrite sleeves are not fitted!
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2.5 Wiring diagram of the Electronic Unit
Figure 7 - Wiring diagram of the electronic unit
A Ferrite sleeves (Enclosed) D Analogue output cable (customer)
B Power supply cable (customer) E Status signal cable (customer)
C Probe signal cable (enclosed) F Solenoid valve control cable (enclosed)
1 Power supply (115/230V AC, 50/60Hz)
1 8 Relay contacts for status signals - 8 Relay contacts for status signals -
Potential free
2 Potential
f
3 18 A/B maintenance
2 Functional earth 18 A/B
4 19 A/B
20 A/B
21 A/B
20 A/B used internal
5 21 A/B
6 22 A/B limit Alarm 2 (COe)
3 Shielding 9 Probe solenoid valve
4 Power supply probe heater (48V AC) 23 A Internal Power supply for probe
solenoid valve (48V AC)
8 23 B 23 B
9 24A 24A L
10 24B 24B N
5 O2-sensor signal 10 Measuring range O
2
(12..24 V DC - External supply)
12 25A 25A +
13 25B 25B -
6 Thermocouple (O2 sensor) 11 Calibration release (12..24V DC - External supply)
14 11 Calibration release (12..24V DC -
Et l l)
27A +
15 27A 27B -
7 Analogue outputs (active 4-20mA) 12 COe sensor
17A 12 COe sensor 32A COe sensor white 2
17B 32A 32B white 1
34A 32B 33A COe senso
red 4
34B
33A 33B red 3
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2.6 Wiring Diagram of the SILOTEC 8000
Figure 8 - Wiring diagram of the SILOTEC 8000
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Figure 9 – SILOTEC 8000 digital and analog signals
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Figure 10 - SILOTEC 8000 solenoid valves, flow meters
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2.7 Gas Plans
Figure 11 - SILOTEC 8000 standard gas plan
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Figure 12 - SILOTEC 8000 gas plan with options
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2.8 Installation of the analyzer
The temperature, pressure and all other process conditions must be in accordance with the specification. Leave
enough space for insertion/removal of the probe and ensure access to the measuring probe and/or GRP housing.
Accessibility to the probe or the GRP housing must be guaranteed. Before penetrating the silo roof, make sure that
there is enough space for installation, that there are no obstructions nearby and that there are no other obstacles in
the way.
Note the temperature limits Avoid vibrations greater than 2g Mind the IP code
2.9 Mounting the Probe
Sampling filter of the analyzer
Probe flange gasket
Counter flange (optional) (welded gas-tight)
Silo roof
Figure 13 – Mounting the probe
Warning
Be sure that the filter istight. During installation, the tight fit of the sintered metal filter and the function of the screw
lock must be checked. Tightening torque 250 Nm
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2.10 Electrical Connections of the Cuvette
Info
The Probe Signal Cable FEP-0007/8 has to be connected to the terminal board in the probe terminal box.
Do not connect the shield here.
Figure 14 - Electrical connections of the
probe connection box SIL-KES-0001
2.11 Requirements for Pneumatic Cable FEP-0002
Note the minimum bending radius.
FEP-0002R
min
= 138 mm
Temp. during installation
Temp. during operation
-
5 °C
Min.
+50 °C
Max.
-40 °C
Min.
+90 °C
Max.
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2.12 Preparation of the pneumatic Cable
Pneumatic tubing of the pneumatic cable
FEP-0002
Nut
Clamp ring
Support sleeve
Both, the pneumatic tubing for the reference air
(blue) and the test gas (green) have to be prepared
with support sleeves , clamp rings and nuts
.
Figure 15 -Preparation of pneumatic tubes
2.13 Connections at the analyzer
Sample gas and injector air out
Solenoid valve control cable
PE
Pneumatic cable FEP-0002
Probe signal cable FEP-0007
Figure 16 – Connections at the probe
Notice
The PE connection on the GFK analyzer must be connected by the customer to the PE potential of the
silo
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