PCME QAL 181 X User manual

- PCME QAL 181 MANUAL: 1 -
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

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Analogue output odule (AOM) 8 x 4-20 A (500 Oh )
Alar output odule (ROM) 8 x Relay (1A @ 250V)
Isolating Spur Provides Surge protection

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2.2 Sensor Safety Description
Gas Category 3G (Zone 02)
IECEx Atex
Certificate
nu ber IECEx SIR 10.0125X Sira 10ATEX4260X
Certification
code
Ex nA IIC T4 Gc
Ex tb IIIC T63ºC Db IP66
Ta = -20ºC to +55ºC
Ex nA IIC T4 Gc
Ta = -20ºC to +55ºC
Dust Category 2D/3D (Zone 21/22)
IECEx Atex
Certificate
nu ber IECEx SIR 10.0125X Sira 10ATEX4260X
Certification
code
Ex nA IIC T4 Gc
Ex tb IIIC T63ºC Db IP66
Ta = -20ºC to +55ºC
Ex tb IIIC T63ºC Db IP66
The following special conditions apply
i.
The electronics enclosure is certified for an upper ambient of
55°C
and ambient
pressure. The optics probe is certified for an ambient temperature up to 250ºC or
500ºC (as marked). The user/installer shall ensure that maximum process
temperatures and pressures applied to the optics probe do not cause the
electronics enclosure to exceed 55ºC and ambient pressure.

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ii. Glands and blanking plugs shall be suitably-certified and fitted with a suitable
sealing washer so as to maintain the IP66 ingress protection of the enclosure.
iii. If the equipment is likely to come into contact with aggressive substances (e.g.
acidic liquids or gases that may attack metals, or solvents that may affect
polymeric materials relied upon for sealing), then it is the responsibility of the
user to take suitable precautions that prevent it from being adversely affected,
thus ensuring that the type of protection (notably IP66 ingress protection) is not
compromised.
iv. The enclosure shall be mounted such that the breather vent is on the underside of
the enclosure. If this is not possible, the breather shall be otherwise protected
from mechanical impact. Damaged breathers shall be replaced immediately and
a suitable sealing washer shall be fitted.
v. Torque settings for the terminal screws of the connectors: 0.22 to 0.25Nm

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3SENSOR INSTALLATION
3.1 Safety
DANGER FROM PROCESS
It is possible that the sensors are to be installed in ducting containing
process particulate that is a hazard to health. This may take one or more of
the following forms:
•Particulate which is inflammable or explosive
•Particulate which is toxic or in some other way a hazard to health
•Particulate contained within high temperature gas
Unless the process conditions are known to be entirely safe, suitable
precautions such as the use of breathing apparatus or duct
purging/detoxifying must be employed before any entry is made into the
duct for installation or maintenance purposes. If in doubt, consult the local
Safety Officer and/or local Safety procedures.
Probe Damage
Take care when handling the sensor to avoid damaging the probe. Probe
damage may result in inaccurate measurements.
Supply Voltage
The sensor operates at 24V DC supplied fro the Control Unit.
3.2 Location Requirements
•Mount in the longest, straightest, unrestricted duct available.
•Avoid excessive vibration.
•Don’t install too close to the top of an open stack where excessive ambient
light could prevent operation. It is recommended to install on the most shaded
side of the stack avoiding direct sunlight.
•Ambient or radiating temperatures in the vicinity of the mounting location
must not exceed 50°C.
See the Installation Guide for more details (available on CD).

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3.3 Installation Overview
Ensure air purge blower or filtered instrument air is connected and running
before inserting the probe into the stack
Remove the cover from the measurement volume (see section below)
before inserting sensor into the stack.
This is essential for the measurement to work and allow the air purge to
work correctly.
The installation of a PCME QAL 181 syste co prises the following steps:
Arrange location for sensor Location relative to sa pling ports and obstructions
Orientation of sensor
Provide orientation details to PCME on the site survey for
at ti e of order (horizontal or vertical stack).
Prepare flange mounting for
the sensor
Sufficient hole size
Correct flange type
Insertion distance (avoid approx. 150 boundary layer)
Prepare purge air supply
(unless using a blower)
Use air filter/regulator syste as reco ended by PCME to
ensure air is filter for water, oil and particulate.
Set flow rate 50 Litres/ in
Provide air heating so purge air > 0°C
Prepare blower mounting
(if using blower)
Requires ains power supply
Install within 2 of the probe
Blower tubing supplied (cut to length)

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Install control unit
(see separate anual section)
Requires ains power supply
Install cabling to sensor 4 core cable fro control unit to sensor (24V power +
RS485 co s)
Optionally install isolated spur between control unit and
sensor to provide surge protection
Install Probe into flange
mounting
Re ove cover fro easure ent volu e (see picture
above)
Ensure air purge blower or instru ent air is connected and
running before insertion
Additional optional setup Add other network devices to network
AIM unit to input analogue inputs for co pensation (T,P,O
2
)
Other PCME network sensors
Arrange data outputs from the control unit
Relay alar outputs
4-20 A outputs
RS232/485 or ethernet output to PCME Dust Tools software
Modbus RTU or odbus TCP output to PLC/DCS

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3.4 Measurement cover removal
Ensure air purge blower or filtered instrument air is connected and running
before inserting the probe into the stack
Remove the cover from the measurement volume before inserting sensor
into the stack.
This is essential for the measurement to work and allow the air purge to
work correctly.
5
1
3
4
2
6
To re ove the easure ent cover:
•Re ove the screws [1] fro the end cap (Allen key required)
•Slide the end cap [2] off the end of the instru ent. Keep the O-ring [3] attached to the
end cap.
•Re ove the Measure ent cover [4]. Keep this in case it is required for later ship ent.
•[IMPORTANT] Refit the end cap and screws.

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3.5 Sensor Tube Orientation
PCME supply instru ents with 2 options of probe tube orientation. This is to satisfy the following
installation require ent:
•the Inner Tube ust not obstruct the direction of flow
•the enclosure ust be installed with the cable glands and air purge entry pointing
downwards.
On the site survey for specify one of the following options:
VERTICAL Flow direction fro down to up
Flow direction fro up to down
HORIZONTAL Flow direction fro right to left
Flow direction fro left to right

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3.6 Insertion Distance
Ensure the easure ent volu e is at a sufficient distance fro the side of the stack. A general
guide is it should be at least 150 fro the stack wall to avoid the boundary layer.
The PCME QAL 181 is provided with a single length probe. However the flange position is site
adjustable to suit the installation details (stack dia eter, standoff distance).
See the diagra below for range of insertion distances fro the flange:
77
50
807 129
89 43 Variable from 600 to 15 mm
200
197
227
158