Novatech CONTROLS 1734 User manual

November 2009
Carbon Controller
Model 1734
Operators Manual

March 2009 Operators Manual
1734 carbon controller 1
TABLE OF CONTENTS
TABLE OF CONTENTS.................................................................................................................................... 1
1. USING THIS MANUAL ................................................................................................................................. 3
1.1 CAUTIONS.................................................................................................................................................. 3
1.2 CONNECTING THE CONTROLLER TO THE POWER SUPPLY ............................................................................. 4
1.3 MOUNTING POSITION OF THE CONTROLLER ................................................................................................. 4
1.4 WARNING SYMBOLS ................................................................................................................................... 4
2. INTRODUCTION........................................................................................................................................... 5
3. SPECIFICATIONS......................................................................................................................................... 7
3.1 HARDWARE SPECIFICATIONS....................................................................................................................... 7
3.2 OPERATIONAL SPECIFICATIONS................................................................................................................... 8
3.3 HEATER INTERLOCK RELAYS....................................................................................................................... 9
4. DISPLAY AND KEYPAD ............................................................................................................................ 11
4.1 DISPLAY................................................................................................................................................... 11
4.2 KEYPAD ................................................................................................................................................... 12
4.2.1 KEYPAD IN RUN MODE ...................................................................................................................... 12
4.2.2 KEYPAD IN SETUP MODE.................................................................................................................... 13
4.2.3 INFORMATION SCREEN....................................................................................................................... 13
5. SETUP MODE............................................................................................................................................. 15
5.1 SETUP MODE FUNCTION SUMMARY........................................................................................................... 15
5.2 SETUP MODE DETAILS.............................................................................................................................. 15
5.2.0 TO CHANGE AN OPTION IN THE SETUP MENU ...................................................................................... 15
5.2.1 PROBE 1&PROBE 2OFFSET ............................................................................................................. 16
5.2.2 LOWER LINE ITEMS ............................................................................................................................ 16
5.2.4 DAMPING FACTOR.............................................................................................................................. 17
5.2.5 PROCESS ALARMS............................................................................................................................. 17
5.2.6 CARBON CONTROLLER....................................................................................................................... 17
5.2.3 CARBON SET POINT........................................................................................................................... 18
5.2.6 HIGH CARBON ALARM &ALARM DELAY............................................................................................... 18
5.2.7 LOW CARBON ALARM &ALARM DELAY................................................................................................ 19
5.2.8 CARBON DEVIATION ALARM &ALARM DELAY....................................................................................... 19
6. ALARMS ..................................................................................................................................................... 21
6.1 CHECKING AND ACCEPTING AN ALARM ...................................................................................................... 21
6.1.1 CURRENT ALARMS............................................................................................................................. 22
6.1.2 ALARM LOG....................................................................................................................................... 22
6.2 ALARM RELAYS ........................................................................................................................................ 22
6.3 COMMON ALARMS .................................................................................................................................... 22
6.4 SELECTABLE PROCESS ALARMS................................................................................................................ 24
6.5 WARNING MESSAGES............................................................................................................................... 24
7. PROBE PURGE.......................................................................................................................................... 25
7.1 NOTES ON PURGING THE PROBE................................................................................................................ 25
7.2 ACTIONS THAT OCCUR WHEN THE GAS SOLENOID KEYS ARE PRESSED....................................................... 26
8. UPDATING THE SOFTWARE.................................................................................................................... 27
9. INDEX.......................................................................................................................................................... 28

Operators Manual November 2009
21734 carbon controller
©Copyright NOVATECH CONTROLS PTY LTD — 2009
This manual describes the controller firmware version 1.00, November 2009
Neither the whole nor any part of the information contained in, or the product described in, this manual may
be adapted or reproduced in any material form except with the prior written approval of Novatech Controls
Pty Ltd (Novatech).
The product described in this manual and products for use with it are subject to continuous developments
and improvement. All information of a technical nature and particulars of the product and its use (including
the information in this manual) are given by Novatech in good faith. However, it is acknowledged that there
may be errors or omissions in this manual. A list of details of any amendments or revisions to this manual
can be obtained upon request from Novatech Controls Technical Enquiries. Novatech Controls welcome
comments and suggestions relating to the product and this manual.
All correspondence should be addressed to: -
Technical Enquiries
Novatech Controls Pty Ltd
309 Reserve Road, Tel: [phone]
Cheltenham Fax: [phone]
Victoria 3192 Email: [email protected]
Australia Web site: http://www.novatech.com.au/
Novatech Controls or their authorised dealers should carry out all maintenance and service on the product.
Novatech Controls can accept no liability whatsoever for any loss or damage caused by service or
maintenance by unauthorised personnel. This manual is intended only to assist the reader in the use of the
product, and therefore Novatech Controls shall not be liable for any loss or damage whatsoever arising from
the use of any information or particulars in, or any error or omission in, this manual, or any incorrect use of
the product.

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1. USING THIS MANUAL
This manual is intended to be used by the operator. It is not intended to describe how the 1734 carbon
controller should be connected, configured or serviced. If more detailed information is required than is
shown in this manual the 1734 Technical Manual should be used. This is supplied with each controller and
is also available on the Novatech web site at www.novatech.com.au
It is assumed in this manual that the controller has been installed by competent personal and that the wiring
to the main power supply, the carbon probe and all the associated signal devices complies with the local
safety codes and regulations.
1.1 Cautions
Please read the safety information below before connecting power to the controller.
CAUTION
Please note that if this equipment is not installed and used in the manner described in this manual then the
safety protection provided by the equipment may be impaired.

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41734 carbon controller
1.2 Connecting the Controller to the Power Supply
•The mains power must be either 100/110VAC or 220/240VAC with a mains frequency of 50 or 60Hz
•The supply circuit must be fused to at least 10Amps and have a dual pole isolation switch within
easy access of the carbon controller. The isolation switch must be marked as the isolation switch for
this equipment. It is recommended that a separate isolation switch be used for each controller so
that a controller can be serviced individually.
•The power supply cables must be supplied and installed according to local regulations
•The earth connection must comply with the local regulations must have a current carrying capability
equal or greater than the supply fuse current rating
•The earth connection must be connected to the primary earth stud inside the controller on the right
hand side
•All other bonded earth connections from the external wiring must be connected to the primary earth
stud
1.3 Mounting Position of the Controller
•The controller should be mounted in a position where the ambient temperature will not exceed
55°C/130°F or be less than -25°C/-10°F ambient temperature
•It must not be exposed to:-
oradiation from appliances such as ovens or furnaces
odirect sunlight
orain, snow or sleet
•The ventilation must be adequate to remove excess heat build up from the internal circuit of the
controller
1.4 Warning Symbols
Danger, high voltage. Risk of electrical shock.
Caution hot surface.
Caution, risk of danger. See additional information in the manual.

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2. INTRODUCTION
The Novatech 1734 Carbon Controller provides in-situ measurement for one or two carbon probes in furnace
and gas generators with temperatures up to 1400°C. The controller provides local indication of carbon
percentage and oxygen, plus numerous other related measurements.
Within the same process either one or two probes can be controlled providing average and/or individual
probe readings. The controller provides two isolated 4-20mA outputs, 4 normally closed configurable relay
outputs and digital communications via MODBUS. Alarms are displayed at the controller and the relay
contacts can be configured to activate remote alarm devices. Using unheated Novatech zirconia carbon
probes the analyser also provides automatic probe filter purging.
The model 1734 carbon controller is based on the well known model 1634 controller. It includes a number of
hardware and software improvements such as a graphic display, larger characters, faster microprocessor,
simplified set up menu, alarm logging, faster probe heater control and more accuracy in the calculation of
carbon.
The 1734 Carbon Controller has a variety of user-selectable functions. The device is configured locally using
a menu driven interface and the local keypad & display. For a description of the configuration process refer
to Chapter Error! Reference source not found.
Features include:-
Inputs
Two Novatech zirconia carbon / oxygen probes
Carbon range up to 2.0%
Oxygen range from 10-30 to 100%
Furnace or auxiliary thermocouple, field selectable as type K, J, R, S or N
Purge pressure or flow switch
Outputs
Two linearised 4-20mA or 0-20mA DC isolated outputs, max. load 1000Ω
The output function and the range are field selectable
Common alarm relay
Three other alarm relays with selectable functions
Digital Interface
RS-232 or RS-485 MODBUS™for connection to a computer/DCS/PCL for diagnostics of the controller,
probe or combustion process.
Display
Multi font graphical display
Large font characters for the carbon % on the top line
Selectable lower line items for the secondary display functions. ie Probe temperature, carbon %
measurement on the second probe, oxygen etc
Alarm display mode that shows the time of the alarm, the acceptance time and the time that the alarm was
cleared of up to 4000 alarm events
Power
Universal mains supply voltage, 100 to 240VAC
Automatically detects the mains voltage and frequency and set the power control accordingly

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3. SPECIFICATIONS
3.1 Hardware Specifications
Number of carbon probes: 2 maximum
Carbon range: up to 2.0%
Oxygen range: 1 x 10-30 to 100%
Oxygen accuracy: ±1% of actual measured oxygen value with a repeatability of ±0.5% of the measured
value
Thermocouple types: Type K, J, R, S & N
Temperature accuracy: ±2°C
Analogue outputs: 0-20mA or 4-20mA field selectable
Active outputs (Do NOT loop power these outputs)
Output load: 1000 ohm max
Alarm relays: 4
Alarm relay contacts: 2A/240VAC, 2A/30VDC
(WARNING: Do not use both mains voltage and low voltage connections to adjacent alarm contacts)
Mains voltage supply: 100 to 240VAC, -6 +10%, 50/60 Hz
Overvoltage: Category II (IEC60364-4-443)
Power: 5W for controller plus probe power
Fuses: 3A, fast blow, 250v, 20x5mm (heater fuses, 2 of)
1A, slow blow, 250v, microfuse (PCB mtg fuse, 1 of)
Environmental Rating: Operating Temperature -25°C to 55°C
Relative Humidity 5% to 95% (non-condensing)
Altitude 2000m maximum
Degree of Protection: IP65
IP54 with internal reference air pump
Case Size: 260mm (10.2”) wide, 160mm (6.3”) high, 90mm (3.5”) deep
Weight: 3 Kg (6.6 lbs.)
WARNING: All signal level connections onto the controller must be treated as safety extra-low voltage (SELV) as
defined in the standard IEC61140. Double insulation must be used when connecting these terminals to systems
that might carry high voltage.

Operators Manual November 2009
81734 carbon controller
3.2 Operational Specifications
The 1734 controller has two fully configurable 4-20mA analogue outputs. The channels can be configured
independently to output one of several calculated values.
The following outputs are available on channel #1:
Output Zero Span Step Min Span Default
Probe 1 Carbon % 0% 0.1 to 1.5% 0.1% 0.1% 0 to 1.5%
Average Carbon % ** 0% 0.1 to 1.5% 0.1% 0.1% 0 to 1.5%
Probe 1 EMF 0 to 1400mV 100 to 1500mV 100mV 100mV 0 to 100mV
Probe 1 TC Temperature 0 to 1500°C 100 to 1600°C 100°C 100°C 0 to 1300°C
Probe 1 Oxygen % 0 to 99% 1 to 100% 0.1% 1% 0 to 25%
Reducing Oxygen 1 exp +2 to -28 0 to -30 1 2 decades -1 to 30
Aux TC Temperature * 0 to 1500°C 100 to 1600°C 100°C 100°C 0 to 1300°C
No Output - - - - -
** Only available in dual probe mode. * Only available in single probe mode.
The following outputs are available on channel #2:
Output Zero Span Step Min Span Default
Probe 1 Carbon % * 0% 0.1 to 1.5% 0.1% 0.1% 0 to 1.5%
Probe 2 Carbon % ** 0% 0.1 to 1.5% 0.1% 0.1% 0 to 1.5%
Average Carbon % ** 0% 0.1 to 1.5% 0.1% 0.1% 0 to 1.5%
Probe 1 EMF * 0 to 1400mV 100 to 1500mV 100mV 100mV 0 to 100mV
Probe 2 EMF ** 0 to 1400mV 100 to 1500mV 100mV 100mV 0 to 100mV
Probe 1 TC Temperature * 0 to 1500°C 100 to 1600°C 100°C 100°C 0 to 1300°C
Probe 1 TC Temperature ** 0 to 1500°C 100 to 1600°C 100°C 100°C 0 to 1300°C
Probe 1 Oxygen % * 0 to 99% 1 to 100% 0.1% 1% 0 to 25%
Probe 1 Oxygen % ** 0 to 99% 1 to 100% 0.1% 1% 0 to 25%
Reducing Oxygen 1 exp. * +2 to -28 0 to -30 1 2 decades -1 to 30
Reducing Oxygen 2 exp. ** +2 to -28 0 to -30 1 2 decades -1 to 30
Aux TC Temperature * 0 to 1500°C 100 to 1600°C 100°C 100°C 0 to 1300°C
No Output - - - - -
** Only available in dual probe mode. * Only available in single probe mode.
The zero and span of the selected output are set in the following two menus (functions 11&12 and 14&15).
Range of local indication:
The measurement of carbon is shown as the main and largest value on the display. It is shown with 2
decimal places as #.## %.
The measured oxygen content displayed on the Lower line is shown in either %, or in scientific notation.
The format of the oxygen display changes to maintain the best resolution for the measurement.
Range Display format
30.0 to 100.0% ##.#%
1.00 to 29.99% ##.##%
0.100 to 0.999% #.###%
< 0.100% scientific notation (#.## x 10- ## % )