Seitron CHEMIST 900 RACK User manual

SEITRON S.p.A. a socio unico - ALL RIGHTS RESERVED -
Any reproduction, in whole or in part, of this document by any means (including
photocopying or storing it in any electronic device) and the transmission of the latter to
third parties in any way, including electronically, is strictly forbidden without the prior
written approval by SEITRON S.p.A. a socio unico

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TABLE OF CONTENTS
Important information 07
Information about this manual 07
Danger levels and other symbols 07
Safety 08
Proper use of the product 08
Improper use of the product 08
ELECTRICAL CONNECTIONS 09
Electrical connections 11
Wiring the signal lines 12
Connection of the serial port RS485 half duplex according to MODBUS® RTU 13
Analog outputs through 37 poles connector 14
CONNECTIONS 17
Connection to PC via supplied USB cable 19
Connection to PC via Ethernet cable 20
Wiring diagram - Back panel 21
Remote air intake filter assembly 21
Junctions assembly - Optional 22
Wiring diagram - Back cover 23
Connection to the nitrogen/synthetic air cylinder 24
Pitot tube and Flue Gas sampling probe connection 25
Pitot tube 26
Features of the smoke suction line 27
Features of the heated smoke suction line (for the measurement of NOx - SOx) 28
Combustion air temperature probe 29
Draft measurement 29
Remote air suction spots 29
PRODUCT USE 31
Technical features 33
Product features 35
General overview of the Analyzer 35
Working principle 36
CO dilution 36
Fuel types 36
Peltier module condensation assembly (Cooler) 37
Remote condensate sink 37
External dust filters 37
Dust filter for the NDIR bench protection 37
Remote air intake 37
Remote air intake connected in Nitrogen or Synthetic air 37
Pressure sensor, piezoelectric, temperature compensated 37
Smoke suction pump 38
Condensate sink pump 38
Draft measurement with sensor automatic autozero 38
Temperature measurements 38
Calculating total carbon 38
Autozero difference in air, nitrogen and synthetic air 38
Available software 38
External size 39
Measurement and Accuracy Ranges 40
Components description 42
Front cover 42
Back panel 44
Startup 46
Preliminary operations 46
Instrument power supply 46
Warning 46

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Power on - off 48
Starting the device 48
Configuration 49
Configuration menu 49
Configuration=>Analysis 50
Configuration=>Analysis=>Fuel 52
Configuration=>Analysis=>Condensation 53
Configuration=>Analysis=>O2Reference 54
Configuration=>Analysis=>NOx/NO Ratio 55
Configuration=>Analysis=>Measure units 56
Configuration=>Analysis=>Measure list 57
Configuration=>Analysis=>Autozero 59
Configuration=>Analysis=>Other configs 60
Configuration=>Analysis=>Other configs.=>Sample processing 61
Configuration=>Analysis=>Motor eff. 62
Configuration=>Instrument 63
Configuration=>Instrument=>Time/Date 64
Configuration=>Instrument=>Brightness 65
Configuration=>Instrument=>Buzzer 66
Configuration=>Instrument=>Pump 67
Configuration=>Instrument=>4..20mA 68
Configuration=>Instrument=>CO protection 69
Configuration=>Instrument=>NDIR Bench 70
Configuration=>Instrument 71
Configuration=>Instrument=>MODBUS 72
Configuration=>Operator 73
Configuration=>Alarms 75
Configuration=>Information 77
Configuration=>Information=>Sensors 78
Configuration=>Information=>InfoService 79
Configuration=>Information=>Reminder 80
Configuration=>Diagnostic 81
Configuration=>Diagnostic=>Sensors 82
Configuration=>Diagnostic=>Pump 83
Configuration=>Diagnostic=> On-site calibration procedure of
electrochemical sensors and IR bench 84
On-site calibration procedure 85
Configuration=>Diagnostic=>Hardware 94
Configuration=>Diagnostic=>NDIR Bench 95
Configuration=>Diagnostic=>Sample processing 96
Configuration=>Language 97
Configuration=>Restore 98
Measurements 99
Measurements Menu 99
Measurements=>Velocity 100
Flue gas analysis 101
Preliminary operations 101
Emission analysis configuration mode 101
Performing the emission analysis 107
Electrochemical sensors 108
CxHy sensor for the measure of unburnt hydrocarbons (Pellistor) 108
CO2 sensor for the measure of carbon dioxide in combustion processes
( single NDIR sensor ) 108
NH3 sensor for measuring ammonia in combustion processes 109
Life of gas sensors 111

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Gas sensor life table 111
Infrared bench 112
Infrared bench for heat treatment 112
Troubleshooting 113
Troubleshooting guide 113
Spare parts and servicing 115
Spare parts 115
Accessories 115
Service centers 116
MAINTENANCE 117
Routine maintenance 119
Scheduled maintenance 119
Cleaning external dust filters 120
Replacement of external anti-pollution filter on IR line 121
Replacement of external anti-cleaning filter on remote air intake 121
Fuse replacement 122
On-site calibration 123
AACSE79 Sensor Factory Calibration 123
Firmware update 130
ANNEX 131
Annex A - Fuel Coefficients and formulas 133
Annex B - Law directions 134
Annex C - Optional measures list 135
WARRANTY CERTIFICATE 137
WARNING
We encourage you to consult the owner's manual in its most up-to-
date version by downloading it from the website www.seitron.com.

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1.1 Information about this manual
 This manual describes the operation and the characteristics and the maintenance of the Combustion Analyzer
Chemist 900 RACK.
 Read this operation and maintenance manual before using the device. The operator must be familiar with the
manual and follow the instructions carefully.
 This use and maintenance manual is subject to change due to technical improvements - the manufacturer
assumes no responsibility for any mistakes or misprints.
1.2 Danger levels and other symbols
Information on LCD
Ensure correct disposal
Touch keyboard
with main control functions.
1.0 IMPORTANT INFORMATION
Symbol Meaning Comments
Read information carefully and prepare
safety appropriate action!
To prevent any danger from personnel or other
goods. Disobey of this manual may cause
danger to personnel, the plant or the
environment and may lead to liability loss.
31/07/15
10:00
Information
Service
Esc
[email protected]
www.seitron.it
Fax. [phone]
Tel. [phone]
Mussolente, VI
Via del Commercio, 9/11
Seitron S.p.A.
Dispose of the battery pack at the end of its
working life only at the dedicated collecting bin.
The customer takes care, on his own costs,
that at the end of its working life the product is
collected separately and it gets correctly
recycled.

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1.3 Safety
1.3.1 Proper use of the product
This chapter describes the areas of application for which the CHEMIST 900 RACK is intended.
All products of the series CHEMIST 900 RACK are stationary measuring devices, in a 19” metal case, for rack
mounting; these instruments are capable of measuring gas in the following plants:
 Boilers (fuel oil, gas, wood, coal)
 Low-temperature condensing boilers
 Gas heaters
 Emissions control measurements
 Installations compliance tests
 Gas turbines
 Gas engines
 Furnaces and boilers technical assistance
 Technical assistance in industrial heating systems
 Process control
1.3.2 Improper use of the product
The use of CHEMIST 900 RACK in application areas other than those specified in Section 1.3.1 "Proper use of
the product" is to be considered at the operator’s risk and the manufacturer assumes no responsibility for the loss
damage or costs that may result. It is compulsory to read and pay attention to the instructions in this use and
maintenance manual.
CHEMIST 900 RACK should not be used:
 as an alarm device for safety purposes
 in classified zones with explosion risk (ATEX or equivalent)

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2.0 ELECTRICAL CONNECTIONS

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2.1 Electrical connections
WARNING
- CONNECT THE DEVICE TO MAINS POWER THROUGH A BI-POLAR SWITCH COMPLYING WITH
CURRENT STANDARDS AND WITH CONTACTS APERTURE DISTANCE OF AT LEAST 3 MM IN EACH
POLE.
- THE INSTALLATION AND THE ELECTRICAL WIRING OF THE DEVICE MUST BE PERFORMED BY
QUALIFIED TECHNICIAN AND IN CONFORMITY WITH CURRENT STANDARDS.
- THE MINIMUM CROSS SECTION OF THE POWER CABLE SINGLE CONDUCTORS MUST BE 1 mm2.
THE CROSS SECTION OF THE PE CONDUCTOR MUST NOT BE SMALLER THAN CONDUCTORS L
AND N CROSS SECTION.
THE CABLE MUST BE SUITABLE FOR A MINIMUM TEMPERTURE OF 70 °C (158 °F) AND MUST BE
HOMOLOGATED FOR THE COUNTRY AND PLACE OF USAGE.
- BEFORE PERFORMING ANY CONNECTION MAKE SURE THAT MAINS POWER IS OFF.
- INSTALL THE MAINS POWER LINE SEPARATELY FROM THE SIGNALS LINES.
WARNING
MISSING GROUND/PE CONNECTION
ELECTRIC SHOCK DANGER
DEPENDING ON THE MODEL OF THE DEVICE, CONNECT THE POWER SUPPLY AS FOLLOWS:
•POWER PLUG: MAKE SURE THAT THE PLUG HAS A CONNECTION FOR THE PE/GROUND
CONDUCTOR. CHECK THAT THE CONNECTION FOR THE GROUND/PE CONDUCTOR AND THE
POWER PLUG ARE COMPATIBLE.
•TERMINALS CONNECTION: CONNECT THE TERMINALS AS ILLUSTRATED IN THE WIRING DIAGRAM.
CONNECT FIRST THE GROUND/PE CONDUCTOR.
WARNING
CONDENSATE INSIDE THE DEVICE
THE DEVICE COULD BE DAMAGED BY CONDENSATE IF THE GAP BETWEEN THE TRANSPORTATION
OR STOCK TEMPERATURE AND THE INSTALLATION SITE IS HIGHER THAN 20 °C (68°F).
•BEFORE OPERATING THE DEVICE MAKE SURE THAT IT IS PLACED ON THE NEW OPERATION SITE
FOR A FEW HOURS SO THAT IT CAN ADAPT TO THE NEW CONDITIONS.
WARNING
DANGEROUS CONTACT VOLTAGE
ELECTRIC SHOCKS MAY HAPPEN IF THE WIRING HAS NOT BEEN PERFORMED PROPERLY.
•FOR INFORMATION ABOUT THE WIRING TECHNICAL SPECIFICATIONS SEE THE CHAPTER
"CONNECTION TO MAINS POWER (PAGE 74)".
•ON THE INSTALLATION SITE OF THE DEVICE RESPECT THE DIRECTIVES AND LAWS IN FORCE
ABOUT ELECTRICS SYSTEMS WITH NOMINAL VOLTAGES BELOW 1000 V.

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2.2 Wiring the signal lines
 The connection lines to the relays outputs, to the binary inputs and to the analog outputs must be shielded.
 Connect the signal lines to D-sub connectors on the back of the instrument.
 In order to suppress the formation of sparks through the relay contacts (e.g. limiter relay) some RC elements
are to be connected as shown on the figure below. About this topic, it is a good rule to remember that an RC
element delays the switch off of an inductive component (e.g. A solenoid valve). So the element C should be
calculated on the basis of the following empiric rule:
- R = RL/2; C = 4L/R2L.
Normally these values are sufficient R = 100 Ω and C = 200 nF.
- For the RC element it is recommended to use a non-polarized capacitor.
 When operating with DC it is also possible to install a spark extinguishing diode instead of the RC element.
Figure: Sparks suppression on a relay contact
 Analog outputs
Figure: Connection of the load resistance to the analog output.
WARNING
UNSUITABLE POWER VOLTAGE
THE POWER VOLTAGE AT 24 V/1A MUST BE A SAFETY LOW VOLTAGE AT LIMITED POWER WITH
SAFE ELECTRICAL SEPARATION (SELV).
CONNECT THE SIGNAL LINES ONLY TO DEVICES THAT ARE FEATURED WITH A SAFE ELECTRICAL
SEPARATION ON THEIR POWER SUPPLY.
INSTRUMENT SIDECONNECTION SIDE
Solenoid valve
CONNECTION SIDE INSTRUMENT SIDE
Resistor load
max. 1KOhm ANALOG OUTPUT
ACTIVE LOOP
4-20mA
2 WIRES
TRANSMITTER

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2.3 Connection of the serial port RS485 half duplex according to MODBUS® RTU
protocol
The CHEMIST 900 RACK features a serial output RS485 half duplex, which can be used to connect the
instrument to a PC, through the communication protocol MODBUS® RTU.
The MODBUS® registry table is available at www.seitron.it.
Connection diagram:
WARNING
- THE RS485 NETWORK SUPPORTS UP TO 32 CONNECTED DEVICES.
- IF THERE ARE MORE INSTRUMENTS CONNECTED TO THE SAME RS485 NETWORK, IT IS ADVISED
TO SET THE SAME COMMUNICATION SPEED.
RS485 N
GND
GND
RS485 P
RS485 N
RS485 P
Bus wiring example:
900 RK
900 RK
900 RK
PC
Module subcon-plus - MODBUS ® /IL/BK
PHOENIX CONTACT Pn. 2310808
System available from:
Sn. ≥ 1115 and version FW ≥ 1.19

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2.4 Analog outputs through 37 poles connector (8 outputs 4..20mA and 1 relay output)
The CHEMIST 900 RACK features:
- Eight 4..20mA outputs, to which it is possible to associate, via the parameter "4..20mA configuration," one of
the measurements that the instrument can make, in order to translate a measurement into a current value
available at the output.
- A relay output, with voltage-free changeover contacts:
- Relay output 4 associated with the alarm, upon activation from the appropriate parameter "Alarms."
Standby Contact:
When the standby contact is activated via software, the analyzer displays the standby message, with the gas
pump off, the keypad disabled, and the standby pop-up present.
Then, when the standby contact is deactivated, the instrument resumes normal operation, with the gas pump on,
the keypad working, and the standby pop-up absent.
When the instrument resumes operation, it performs a cleaning cycle followed by an autozero cycle, with suction
from the "Zero Cal" nozzle.
If the instrument is started with the standby contact active, the standby pop-up is immediately present and the
instrument does not perform autozero.
Wiring diagram:
Relay 4
Analog output Loop -
Analog output Loop -
Analog output Loop -
Analog output Loop -
The outputs are internally
wired
The cables and connectors
must be shielded and
connected to the potential
reference of the case.
M
Contacts maximum load
max. 24 V/1 A, AC/DC
Voltage free contacts
Analog output 4 Loop +
Analog output 3 Loop +
Analog output 2 Loop +
Analog output 1 Loop +
Analog output 8 Loop +
Analog output 7 Loop +
Analog output 6 Loop +
Analog output 5 Loop +
Standby contact

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CAUTION.
If the current signal measured by the instrument is floating (or has unstable behavior), the ground reference
between the measure device and the instrument must be equipotential by shorting pins 28 and 1 of the 37-pin
connector.
This operation is not always necessary.
It becomes essential only when Chemist 900 Rack is connected via the 4 ... 20 mA output to an UNISOLATED
PC or PLC. Lack of isolation of the latter, in fact, causes instability of the current signal and consequently
incorrect measurement.
Short circuit diagram:
Wire bridge
(ϕ 0,5mm2)

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3.0 CONNECTIONS

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3.1 Connection to PC via supplied USB cable

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3.2 Connection to PC via Ethernet cable
ATTENTION
- IN ORDER TO SAVE, STORE ANALYSIS DATA AND MANAGE THE COMBUSTION ANALYSIS MAIN
PARAMETRS CONFIGURATION, CAN ONLY HAPPEN VIA THE PC, HAVING PREVIOUSLY INSTALLED
THE “CHEMIST SMART ANALYSIS” SOFTWARE PROVIDED WITH THE INSTRUMENT.
- IN ORDER TO CONNECT THE CHEMIST 900 RACK TO THE ETHERNET IT IS NECESSARY TO
PROPERLY CONNECT TWO USB => ETHERNET CONVERTERS.
- ONE OF THE TWO CONVERTERS MUST BE POWERED BY AN EXTERNAL SUPPLY SOURCE,
BECAUSE CHEMIST 900 RACK DOES NOT PROVIDE POWER TO THE USB PORT.
ATTENTION
- IT IS RECOMMENDED TO SUSPEND THE AUTOMATIC WINDOWS UPDATES AND THE STAND BY
STATE OF THE PC, BECAUSE IN CASE OF ACTIVATION OF EITHER OR BOTH PROCESSES, THE
COMMUNICATION WITH THE SOFTWARE "SEITRON SMART ANALYSIS" IS SUSPENDED.