PCME QAL 181 X User manual

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PCME QAL 181 X
USER MANUAL
The products described in this anual are subject to continuous develop ent and i prove ent
and it is, therefore, acknowledged that this anual ay contain errors or o issions. PCME
encourage custo er feedback and welco e any co ents or suggestions relating to the product
or docu entation. These should be forwarded to the Technical Depart ent at the address given
below.
This anual is intended as a guide to the use and installation of the product and, therefore,
PCME Ltd. shall not be liable for any loss or da age whatsoever arising fro the use of any
infor ation or details therein, or o ission or error in, this anual, or any iss-use of the
product.
PCME Ltd
Clearview Building
60 Edison Road
St Ives Cambs UK
PE2 3GH
Tel [phone]
Fax [phone]
Email: cont[email protected]o.uk
www.pcme.co.uk

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1 INTRODUCTION .................................................................................................. 6
1.1 P URPOSE OF THIS MANUAL ............................................................................................ 6
1.2 D ISCLAIMER ............................................................................................................. 6
1.3 P RODUCT S AFETY ....................................................................................................... 6
1.4 D ANGER FROM P ROCESS ............................................................................................... 7
1.5 L IMITS OF USE .......................................................................................................... 7
1.6 L IST OF ABBREVIATIONS ............................................................................................... 7
1.7 A SSOCIATED D OCUMENTS ............................................................................................. 7
2 PRODUCT DESCRIPTION .................................................................................... 8
2.1 S YSTEM D ESCRIPTION ................................................................................................. 8
Process and Application Conditions ........................................................................... 8
Sensor Specification ................................................................................................ 8
Sensor Options ....................................................................................................... 9
Sensor Accessories ................................................................................................. 9
Control Unit Specification ......................................................................................... 9
Syste Options .................................................................................................... 10
2.2 S ENSOR S AFETY D ESCRIPTION ..................................................................................... 12
3 SENSOR INSTALLATION ................................................................................... 14
3.1 S AFETY ................................................................................................................. 14
3.2 L OCATION R EQUIREMENTS .......................................................................................... 14
3.3 I NSTALLATION O VERVIEW ........................................................................................... 16
3.4 M EASUREMENT COVER REMOVAL ................................................................................... 18
3.5 S ENSOR T UBE O RIENTATION ....................................................................................... 19
3.6 I NSERTION D ISTANCE ................................................................................................ 20
3.7 F LANGE M OUNTING .................................................................................................. 21
3.8 S UPPLYING I NSTRUMENT A IR ....................................................................................... 23
3.9 M OUNTING THE BLOWER UNIT (O PTION ) ......................................................................... 25
3.10 E LECTRICAL C ONNECTION ...................................................................................... 28
Data Cabling Specification ..................................................................................... 28
Network Layout .................................................................................................... 28
Sensor Wiring....................................................................................................... 31
Cable Routing ...................................................................................................... 34
3.11 S ETTING U P ....................................................................................................... 34
Bus Ter ination Switch ......................................................................................... 34
Set address switch (SW100) .................................................................................. 35
Co unication Settings (SW101) ........................................................................... 35
4 MULTI-CONTROLLER INSTALLATION (PLUS VERSION) ................................... 36
4.1 S AFETY ................................................................................................................. 36
4.2 T OOLS AND M ATERIALS .............................................................................................. 37
Drilling Te plate .................................................................................................. 37
Data Cabling Specification ..................................................................................... 37
Power Supply Cabling Specification ......................................................................... 37
4.3 L OCATION R EQUIREMENTS .......................................................................................... 38
4.4 C OMPONENT L OCATION .............................................................................................. 38
4.5 I NSTALLATION ......................................................................................................... 40
Mounting the Control Unit ...................................................................................... 40

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Data Cable Connection .......................................................................................... 40
Bus Ter ination Switch (SW200) ........................................................................... 41
RS232/RS485 Connections (PL2) ............................................................................ 41
Digital Input Connections (PL3) .............................................................................. 41
4-20 A Output Connections (PL4) .......................................................................... 42
Alar Contact Connections (PL5) ........................................................................... 42
Power Supply Connections (PL6) ............................................................................ 43
5 INTERFACE MODULE INSTALLATION ............................................................... 44
5.1 S AFETY ................................................................................................................. 44
5.2 T OOLS AND M ATERIALS .............................................................................................. 45
Data Cabling Specification ..................................................................................... 45
Power Supply Cabling Specification ......................................................................... 45
5.3 L OCATION R EQUIREMENTS .......................................................................................... 45
5.4 C OMPONENT L OCATION .............................................................................................. 46
5.5 I NSTALLATION ......................................................................................................... 47
Mounting the Interface Module............................................................................... 47
Data Cable Connection .......................................................................................... 47
RS232/RS485 Connections ..................................................................................... 47
Digital Input Connections ...................................................................................... 48
4-20 A Output Connections .................................................................................. 48
Alar Contact Connections .................................................................................... 48
Power Supply Connections ..................................................................................... 49
6 INITIAL SET-UP ................................................................................................ 50
6.1 I NTRODUCTION ....................................................................................................... 50
6.2 P OWER -U P ............................................................................................................. 50
6.3 C HECKING THE C OMMUNICATIONS M ODE ......................................................................... 50
6.4 A UTODETECT S ENSORS .............................................................................................. 51
6.5 E DITING B ASIC S ENSOR S ETTINGS ................................................................................ 52
6.6 C ALIBRATION F ACTOR ............................................................................................... 53
6.7 E MISSION A LARM S ETTINGS ........................................................................................ 54
6.8 S ET T IME / D ATE ..................................................................................................... 55
6.9 4-20 M A S ETTINGS ................................................................................................... 56
Scaling and Filtering 4-20 A Outputs ..................................................................... 56
Testing and Calibrating 4-20 A Outputs ................................................................. 57
Analogue Output Modules ...................................................................................... 58
Testing and Calibrating AOM 4-20 A Outputs .......................................................... 59
6.10 R ELAY S ETTINGS ................................................................................................. 61
Multicontroller and Interface Module Relays ............................................................. 61
Relay Output Modules (ROM) ................................................................................. 63
Testing Relay Output Modules ................................................................................ 65
6.11 L OG R ATES ........................................................................................................ 66
6.12 M ORE S ENSOR S ETTINGS ....................................................................................... 66
Manually Add Sensors ........................................................................................... 67
Editing Sensor/Device Settings ............................................................................... 68
Delete Sensor/Device ............................................................................................ 68
Editing Settings for all Sensors/Devices at Once ....................................................... 69
Advanced Settings ................................................................................................ 69
QUALITY ASSURANCE AND SELF TESTS ........................................................... 0

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7.1 I NTRODUCTION ....................................................................................................... 70
7.2 PCME QAL 181 S ENSOR S ELF T ESTS ............................................................................ 71
Zero Test ............................................................................................................. 71
Span Test ............................................................................................................ 71
Self Test Values .................................................................................................... 72
Disabling Self Tests ............................................................................................... 73
Co s Check ...................................................................................................... 74
8 MAINTENANCE MODE ....................................................................................... 5
9 SERVICE MESSAGES ..........................................................................................
9.1 C LEARING S ERVICE M ESSAGES ..................................................................................... 77
9.2 I NSPECTING AND C LEANING S ENSORS ............................................................................. 78
10 CALIBRATION ................................................................................................... 9
10.1 I NTRODUCTION ................................................................................................... 79
10.2 C ALCULATING THE C ALIBRATION F ACTOR .................................................................... 79
10.3 C ALIBRATION P ROCEDURE ...................................................................................... 80
10.4 U SING THE C ALIBRATION T OOL ................................................................................ 81
Calculating the Calibration Factor: Manual Method .................................................... 82
Calculating the Calibration Factor: Auto atic Method ................................................ 82
11 TROUBLESHOOTING ......................................................................................... 84
11.1 C OMMUNICATION F AILURE ...................................................................................... 84
11.2 D IAGNOSTICS ..................................................................................................... 84
11.3 C HECKING S PURS ................................................................................................ 84
11.4 S ENSOR P OWER C HECK ......................................................................................... 84
11.5 S ENSOR C OMMUNICATIONS C HECK ............................................................................ 85
11.6 P OWER L OSS ...................................................................................................... 85
11.7 F ROZEN READINGS ............................................................................................... 85
11.8 S ENSOR R EADING TOO L OW OR TOO H IGH .................................................................. 86
12 MENU MAPS ...................................................................................................... 88
Main Screens ....................................................................................................... 88
More Sensor Settings ............................................................................................ 90
Basic Syste Setup ............................................................................................... 91
Other Functions .................................................................................................... 92
QA and Calibration ................................................................................................ 93
13 CLEANING PROCEDURES .................................................................................. 94
Document Control Information
SOP Reference PCME QAL 181 X
Issue No 3d
Issue Date 1/3/2012
Software Version 7.00
Filena e PCME QAL 181 v3d.doc

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1INTRODUCTION
1.1 Purpose of this manual
This anual contains all the infor ation necessary for correct installation and co issioning of
the instru ent. The procedures given in this anual ust only be carried out by suitable trained
and qualified personnel.
1.2 Disclaimer
PCME Ltd. will not be liable for any injury or da age caused by incorrect installation, set-up,
operation or aintenance resulting fro a failure to follow the procedures given in this anual.
1.3 Product Safety
This product is designed for use in Explosive
gas and dust hazardous zones:
•NOT TO BE SERVICED BY USER
•THE SENSOR REQUIRES SERVICE AFTER 4 YEARS OF USE.
AFTER 4 YEARS, A “MAJOR SERVICE DUE” MESSAGE WILL BE
DISPLAYED ON THE CONTROL UNIT. THE SENSOR MUST BE
SERVICED BY PCME OR ITS DESIGNATED REPRESENTATIVE.
PCME is an EN ISO 9001 accredited design and anufacturing organisation, and within the li its
specified in this anual, anufactures instru ents which confor to the essential health and
safety require ents of the following European Union directives:
Low Voltage Directive ( 3/23/EEC)
EMC Directive (89/336/EEC)
In particular, the following har onised standards have been applied:
IEC61010-1:2001
EN61326:2005
All due care has been taken in the design and anufacture of the equip ent to eet the safety
require ents of the above directives. However individuals installing, operating or aintaining the
equip ent are responsible for personal safety and for correct use of the equip ent in accordance
with the procedures detailed in this anual
The following sy bols are used throughout this anual to indicate procedures that, if not
followed correctly, ay result in injury to personnel or da age to equip ent.

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WARNINGS ARE USED TO ALERT THE READER TO A PROCEDURE OR
PRACTICE, WHICH IF NOT FOLLOWED CORRECTLY, COULD RESULT IN
PERSONAL INJURY.
Cautions are used to alert the reader to a procedure or practice, which if not
followed correctly, could result in damage to the system or ancillary
equipment.
Notes are used to highlight i portant infor ation that ay assist the reader in carrying
out a procedure or in understanding the text.
1.4 Danger from Process
It is possible that the sensors are installed in ducting containing process particulate that is a
hazard to health. This ay take one or ore of the following for s:
•Particulate which is infla able or explosive
•Particulate which is toxic or in so e other way a hazard to health
•Particulate contained within high te perature gas
Unless the process conditions are known to be entirely safe, suitable precautions such as the use
of breathing apparatus or duct purging/detoxifying ust be e ployed before any entry is ade
into the duct for installation or aintenance purposes. If in doubt, consult the local Safety Officer
and/or local Safety procedures.
1.5 Limits of use
To achieve opti u perfor ance and safe operation the equip ent ust be operated within the
li its detailed in the Product Description. Operation outside these li its ay result in da age to
the equip ent.
1.6 List of abbreviations
The following abbreviations are used in this anual:
AIM Auxiliary Input Module
AOM Analogue Output Module
PSU Power Supply Unit
ROM Relay Output Module
1. Associated Documents
Control Unit Reference Manual
Installation of Network Devices: Reference Manual
PCME Installation Notes

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2PRODUCT DESCRIPTION
2.1 System Description
Process and Application Conditions
Certification range 0-15 g/
3
(EN15267-3 QAL1 approved)
Long ter zero drift <0.1 g/
3
Measure ent capability 0-200 g/
3
Inspection frequency 3 onths
Application conditions
For easure ent in non-condensing flue gases
Not suitable for applications with water droplets
Velocity dependency Negligible
Stack dia eters 250 - 3
Sensor Specification
Enclosure te perature rating -25°C to +55°C
Stack te perature rating -25°C to +250°C ( option to +500°C)
Enclosure rating IP-65
Enclosure aterial Die-cast alu iniu (polyester powder coated)
Sensor body aterial 316 stainless steel
Sensor weight 11.5kg
Connection required on duct Hole pattern to suit DN80 PN10/PN16 or 3” 150lb ANSI (hole
ID at least 88 )
Power require ents 24V provided by the control unit
Local outputs RS-485 connection to control unit
Cable entries 3 x M20 gland/conduit entries
Cable type 4 core screen (see installation section for details)

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Air Purge require ents
Requires continuous air supply of 50 litres/ inute.
Provided either by a blower (PCME supplied) or instru ent air.
With instru ent air, filtration is require (the use of PCME
supplied air filtration kit is strongly reco ended).
Sensor Options
Sensor Type options
Standard sensor
High te perature
sensor
0-250°C
0-500°C
Insertion length The insertion length can be adjusted fro 15 to 600
by adjusting the flange position.
ATEX/ IECEx Category options
ATEX : Category 3 gas (Zone 02) , Category 2 dust (Zone 21)
IECEx : Category 3 gas (Zone 02) , Category 2 dust (Zone 21)
Sensor Accessories
Air Filtration Kit See section in manual
Low Pressure Blower
Di ensions: 300 x 300 x 180
Rating: 100-240V 1.3A 50-60Hz
Control Unit Specification
Standard System PLUS System
Controller type Interface Module MultiController
No of sensor
channels 1 1 -16

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ICON driven
ultilingual enus
E ission and Alar levels
Quality Assurance results
Calibration screens
Review data logs
Show graph and bar chart
Set up and password
Advanced calculations (Mass,
nor alisation)
E ission and Alar levels
Quality Assurance results
Calibration screens
Review data logs
Show graphs and ulti bar charts
Set up and password
Advanced calculations (Mass,
nor alisation)
Bagfilter
opti isation
diagnostics
Pulse log review for diagnosing
location of leaking bags
Pulse log review for diagnosing
location of leaking bags
E ission data logs
Long
Short
Pulse
Alar s
Capacity stated for 1 se
nsor
(plus QAL3 channels)
2 onths @ 15 inutes
7 days @ 1 inute
2 hours @ 1 second
500 entries
Capacity stated for 4 sensors
(plus QAL3 channels)
2 onths @ 15 inutes
7 days @ 1 inute
2 hour @ 1 second
500 entries
Ethernet enabled
option None Ethernet (Modbus TCP) (optional)
Outputs
1 x RS
-
485 (Modbus RTU)
1 x 4-20 A (500 oh )
2 x Relay (2A@250V, user
selectable)
1 x RS
-
485 (Modbus RTU)
4 x 4-20 A (500 oh )
4 x Relay (2A @250V, user
selectable)
Inputs
1 input for plant off indication, bag
cleaning reference and ultiple
calibrations
4 inputs for plant off indication, bag
cleaning reference and ultiple
calibrations
Enclosure Size
(LxHxD) 220 x 123 x 80 263 x 160 x91
Power Supply 90 to 260 VAC (50/60Hz), 1A 90 to 260 VAC (50/60Hz), 1A
System Options
4-core Cable Specify length required (10 per sensor included as standard)
Spur Divides cable into 2 branches
Power supply / repeater Voltage and signal boost for extended cabling runs with
ultiple sensors
Analogue input odule (AIM) 4 x 4-20 A inputs
4 x Digital inputs