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DURAG D-R 290, Operating Manual

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DURAG D-R 290 Operating Manual Download Page 90

5 | Installation

90

D-R 290

identified as the isolation switch for the device. The individual conductors of the mains 

power supply cable must be mutually secured in such a way that they cannot touch 

neighbouring terminals whilst being disconnected (e.g. using cable ties).
If monitoring and control of the fail-safe shutter is performed via the measuring head, 

the plug end of the 8-core cable already installed should be plugged into the respec­

tive panel jack in the measuring head. The free end of the cable is connected to the 

respective terminals in the control device of the protective device (D−SK AE) 

(

Fig. 5.23 

).

Summary of Contents for D-R 290

Page 1: ...nual D R 290 Dust Concentration and Opacity Monitor of the Second Generation GmbH Kollaustraße 105 22453 Hamburg Germany www durag com Before starting any work please read the operating manual Article no 4 009 352 ...

Page 2: ...have not been purchased or parts thereof may not be reproduced or distributed without express permission from DURAG GmbH irre spective of how this is done in what language or by what medium electronic or mechanical relates to the current design of the device at the time of this documentation being updated see page 2 above for production date contains figures which may differ due to further technic...

Page 3: ...in the event of a system fault 26 2 7 Device specific hazards and safety measures 26 2 7 1 Hazard to the device due to purge air failure 26 2 8 Description and location of safety equipment and emergency stop mechanisms 27 3 Delivery 31 3 1 Delivery information 31 3 2 Transportation packaging and storage 31 3 2 1 Safety instructions for transport 31 3 2 2 Incorrect transport 31 3 2 3 Transport insp...

Page 4: ... 79 5 4 6 Meaning of the LEDs 80 5 4 7 Configuration of the relay outputs 81 5 5 Installation of the D SK 290 protective device 83 5 5 1 Installation sequence for the measuring head and reflector when the D SK 290 protective device is used 84 5 5 2 Display LEDs of the control electronics 87 5 5 3 Installation protective device D SK 290 87 5 5 4 D SK AE electrical connection 88 5 5 5 Configuring th...

Page 5: ...lue correction 129 7 5 3 1 Principle of measured value correction 130 7 5 3 2 Integration time 131 7 5 3 3 Offset a0 131 7 5 3 4 Slope a1 a2 a3 132 7 5 3 5 Signal range 133 7 5 3 6 Settings 133 7 5 3 7 Zero range 133 7 6 Example Assignment of the device outputs 134 7 6 1 Current output 134 7 6 2 Relay settings 135 7 6 3 Relay logic 137 7 7 Maintenance setup 139 7 7 1 Reference point check setpoint...

Page 6: ...f the measuring head reflector 182 9 3 2 Dimensional diagram of the measuring head reflector with fail safe shutter 184 9 3 3 Dimensional diagram of the welded in pipe with adjustment flange 185 9 3 4 Dimensional diagram of the control electronics D SK AE 186 9 3 5 Dimensional diagram fail safe shutter D SK MA 187 9 3 6 Dimensional diagram supply unit terminal box D TB 100 187 9 3 7 Dimensional di...

Page 7: ...tion of the fail safe shutter to the 8 core plug cable of the measuring head 91 Fig 5 24 Control electronics front panel 93 Fig 5 25 LED control electronics 94 Fig 5 26 D SK AE control electronics 95 Fig 5 27 Shutter motor 95 Fig 5 28 Connecting the D R 290 as an individual sensor to the D TB 100 supply unit 96 Fig 5 29 Connecting the D R 290 as an individual sensor directly to the D ISC 100 contr...

Page 8: ...50 Fig 8 1 Purge air filter 156 Fig 8 2 Optical surfaces 157 Fig 8 3 EPA Test filter 158 Fig 8 4 Insert the test filter into the device 159 Fig 8 5 Example of a linearity test without scaling 160 Fig 8 6 Example of a linearity test with scaling 161 Fig 8 7 Turntable plate 162 Fig 8 8 LED 5 164 Fig 8 9 Attachment screws for thehousing cover 164 Fig 8 10 Undo 165 Fig 8 11 Changing the battery 165 Fi...

Page 9: ...engths 52 Table 4 14 Reflectors 52 Table 4 15 Designation of device components Measuring head and reflector 54 Table 4 16 Designation of device components Supply unit 56 Table 4 17 Designation of device components Purge air unit 56 Table 4 18 Where do I find the type label 58 Table 4 19 Example of a type label D R 290 59 Table 5 1 Preconditions for operation 66 Table 5 2 Equation 10 68 Table 5 3 M...

Page 10: ...290 167 Table 8 3 List of warnings for the D R 290 168 Table 8 4 List of simple faults for the D R 290 171 Table 8 5 List of critical faults for the D R 290 172 Table 9 1 Technical data D R 290 application data 179 Table 9 2 Technical data D R 290 measuring head 179 Table 9 3 Technical data D R 290 reflector 180 Table 9 4 Technical data D SK AE control electronics protective device 180 Table 9 5 T...

Page 11: ...ity Monitor of the Second Generation 1 1 General 1 1 Information on this manual 1 2 Explanation of symbols 1 3 Limitation of liability 1 4 Instructions regarding warranty 1 5 Spare parts 1 6 Customer service 1 7 Copyright 1 8 Trademarks ...

Page 12: ...12 D R 290 ...

Page 13: ...quirements for the device and its application must also be complied with NOTICE Before starting any work read the Operating manual Don t let ignorance lead to personal injuries and damage to the equipment In particular read the section 2 Safety 21 and the respective safety instructions in full This manual is an integral part of the product and must be kept in the immediate vicinity of the device a...

Page 14: ...ot avoided WARNING indicates a possible situation of danger that will lead to death or serious injury if not avoided CAUTION indicates a possible situation of danger that can lead to minor or slight injury if not avoided CAUTION indicates a situation that may result in material or environmental damage if not avoided Information or a tip is shown as follows highlights useful tips and recommendation...

Page 15: ...m is explained in the glossary The number after the indicates the page on which you can find this information If you are reading this manual on a PC as a PDF you can also click on the link with the mouse You then skip directly to the link destination Before you do this make a note of the page you are on so that afterwards you can return to it without problems Limitation of liability All informatio...

Page 16: ...y Only use genuine spare parts supplied by the manufacturer Spare parts can be obtained from an authorised agent or directly from the manu facturer Customer service If anything is unclear contact the manufacturer Our Service Department is available to provide any technical information you may require Information about responsible offices and partners can be obtained at any time over the Internet F...

Page 17: ...al program names and designations such as Microsoft Windows and Ex cel used in this manual may also be registered trademarks of their respective manu facturers and may not be used commercially or in any other way Errors and omissions excepted 1 8 ...

Page 18: ...1 General 18 D R 290 ...

Page 19: ...tive equipment 2 6 Basic hazards 2 6 1 Hazards due to electrical equipment 2 6 2 Hazard due to hot aggressive or explosive gases or high pressure of the measuring gas 2 6 3 Hazard due to automatic closing mechanisms 2 6 4 Avoidance of consequential damage in the event of a system fault 2 7 Device specific hazards and safety measures 2 7 1 Hazard to the device due to purge air failure 2 8 Descripti...

Page 20: ...20 D R 290 ...

Page 21: ...onents changes in power consumption without obvious cause the tripping of monitoring devices abnormal strong fluctuations or shifts in the measurement results Use other than in accordance with the designated use or handling can result in health hazards or material damage Follow the instructions for all actions on the product D R 290 and the safety instructions and warnings in the individual sectio...

Page 22: ...ghout the period of use of the device the operating company must check that the operating instructions they have written satisfy the latest issue of the regu lations and must update them as required The operating company must clearly regulate and specify who has responsibility for installation operation maintenance and cleaning The operating company must ensure that all employees who deal with the...

Page 23: ...t knowledge of the D R 290 Dust and Opacity Monitor To acquire specialist knowledge of the device DURAG offers appropriate courses Information on these is available online on the DURAG website or by telephone see the manufacturer s address on page 2 Service technicians because of their specialist training knowledge and experience of the applicable standards and regulations are able to carry out wo...

Page 24: ...injury due to electric shock Touching live parts poses an immediate risk of fatal injury Damage to the insulation or to individual components can lead to fatal injury If there is any damage to the insulation switch off the power supply immediately and have it repaired Permit only qualified electricians to work on electrical equipment Before opening the casing of a device or removing a guard protec...

Page 25: ...omponents only when the plant is shut down Before opening the duct access ports Make sure that no overpressure is present in the measurement duct Make sure that no toxic gases are present in the measurement duct If it is not possible to shut down the plant and toxic gases which may be at high tem perature or pressure are present in the measurement duct WARNING Health hazard due to hot and or toxic...

Page 26: ...ge air supply even for a very short time can lead to malfunctions damage or total write off of the measuring head In the event of over pressure in the measurement duct the gas can also pass through the purge air hose to the fan and filter and damage those system parts also NOTICE Potential damage to the measuring head s by hot gases in the measurement duct overheating of the measuring head s Befor...

Page 27: ... an extended period Description and location of safety equipment and emergency stop mechanisms The operating company must incorporate safety measures for the product Dust and Opacity Monitor D R 290 into the safety concept for the overall system This also in cludes setting up and describing safety and emergency stop mechanisms including giving the location of the associated emergency stop buttons ...

Page 28: ...2 Safety 28 D R 290 ...

Page 29: ...ation 3 2 Transportation packaging and storage 3 2 1 Safety instructions for transport 3 2 2 Incorrect transport 3 2 3 Transport inspection 3 2 4 Packaging 3 2 5 Storage conditions 3 3 Scope of supply 3 3 1 Standard scope of supply 3 3 2 Optional equipment 3 3 3 Reflectors 3 3 4 Optional version variants ...

Page 30: ...30 D R 290 ...

Page 31: ... transport WARNING Risk of injury due to incorrect transport Incorrect transport can result in serious personal injury and material damage When unloading the packages following delivery and internal transportation exer cise caution and observe the symbols and information on the packaging Where necessary use appropriate lifting gear to unload the packages The safe working load of the lifting gear m...

Page 32: ...ny cases can be reused or effectively processed and recycled Dispose of packaging materials in an environmentally friendly manner Observe the applicable local waste disposal regulations see also section 5 10 2 Disposal of the Dust Concentration and Opacity Monitor 104 Storage conditions Store the Dust and Opacity Monitor D R 290 and spare parts under the following con ditions Do not store outdoors...

Page 33: ...pply of the typical overall D R 290 system Quantity re quired per system Equipment Complete measuring system D R 290 consisting of 1 piece D R 290 M measuring head Pitch circle diameter 100 mm 1 piece D R 290 R reflector Pitch circle diameter 100 mm 1 piece e g D ISC 100 A 0 0 6 for use with a sensor e g for D R 290 consisting of Control and display unit Power supply unit 90 264V 200VA 6x M20x1 5 ...

Page 34: ...n 4 009 352 English x xxx xxx State the language check availability Standard for deliveries outside the EC is English unless specified otherwise Table 3 2 Operating manual Illustrations may differ from the actual appearance Optional equipment Article number Equipment 1 piece D R 290 M measuring head Pitch circle diameter 150 mm 1 piece D R 290 R reflector Pitch circle diameter 150 mm 4 004 908 e g...

Page 35: ...114 3 mm 500 mm ST 37 1 0037 1 122 578 316Ti 1 4571 1 107 246 Protective device automatic fail safe shutter D SK 290 MA 115 230 V and 50 60 Hz 2 items recommended one each for the measuring head and the reflector 1 123 903 D SK AE control device protective device incl supercaps complete with housing recommended 2 items one each for the measuring head and the reflector 1 109 0xx Air flow sensor pro...

Page 36: ...on cover for the control device protective device D SK AE stainless steel D SK AE WSH 1 106 794 Temperature transmitter transducer 0 600 C D FL 100 TM H 1 108 375 Temperature transmitter transducer 0 100 C or 0 400 C D FL 100 TM E Table 3 3 Optional equipment D R 290 Illustrations may differ from the actual appearance Reflectors The reflector type is selected according to the length of the measuri...

Page 37: ...KX Installation in zone 1 as an EEx p version with D TB 100 E in EEx d housing Ex purge air blower 3 phase 230 400 V purge air supply from zone 2 50 Hz control unit installed in a non Ex room max 1000 m dis tant D R 290 M XX2 XXXGX Installation in zone 22 as an EEx p version with D TB 100 E in EEx d housing Ex purge air blower 3 phase 230 400 V 50 Hz control unit in stalled in a non Ex room max 10...

Page 38: ...3 Delivery 38 D R 290 ...

Page 39: ...le 4 2 3 Transmission 4 2 4 Opacity 4 2 5 Calculation of the opacity at the flue stack opening 4 2 6 Optical density extinction 4 2 7 Calculation of the dust concentration 4 3 System components 4 3 1 Possible system configurations 4 4 Applications Designated use 4 5 Conformity approval 4 6 Designation of device components for the D R 290 4 7 Identification of the product 4 7 1 Information about th...

Page 40: ...40 D R 290 ...

Page 41: ...ectly in the smoke gas flow contact free without extraction of a sample Long working life due to the use of a semiconductor light source Outstanding measured value basis thanks to use of a super wide band diode SWBD This broad spectrum enables a more stable measurement than can be achieved using conventional LEDs Cyclical system function test additional automatic internal contamination checks and ...

Page 42: ...safe shutter Control electronics Air flow sensor Connecting cable Principle of operation The Dust Concentration and Opacity Monitor D R 290 operates on the transmission principle 196 The measuring head receiver and reflector are mounted opposite each other Through the use of the auto collimation principle 195 the measuring light traverses the measurement path twice and the sensitivity of the measu...

Page 43: ...m see Fig 4 4 An optical receiver receives the measurement and comparative measure ment beams alternately The changeover between measuring light and comparison light is achieved by a stepper motor which rotates the turntable plate see Fig 4 3 so that the light path to the reflector is blocked whilst the optical path to the comparison standard is open The difference between the two measurements rep...

Page 44: ...cted directly in front of the measurement medium It thus passes through all the lenses and relevant optical com ponents just as in the real measurement procedure The measurement results for subsequent measurements are corrected to compensate for the measured difference in value contamination If the contamination exceeds a certain percentage configurable between 0 and 10 a warning is indicated If t...

Page 45: ... higher the dust den sity the greater the attenuation The attenuation of the light results from both absorp tion and scattering referred to in combination as Extinction 195 E extinction The extinction process is characterised by the light intensity diminishing exponentially as the length of the path travelled by the beam according to the Lambert Beer Law Equation 1 Table 4 1 Equation 1 Reflection ...

Page 46: ... Equation 3 Transmission Extinction Opacity Transmission Fig 4 8 Relationship between extinction transmission and opacity The auto collimation principle 195 on which the D R 290 operates means that the measurement light returned by the reflector passes twice through the measuring sec tion at the measuring point In this way the measurement light is subjected twice to an attenuation of the same inte...

Page 47: ... Diameter of the flue stack at the measuring point L2 Diameter at the flue stack opening PLCF Path length correction factor flue stack correction factor Table 4 4 Legends in the formulae Table 4 5 Flue stack correction factor Equation 4 Table 4 6 Equation 4 Based on the measured double attenuation of the measurement light at the measur ing point we have the following relationship Equation 5 Table ...

Page 48: ...le 4 9 Equation 1 Calculation of the dust concentration The measurement of the dust concentration is performed at constant emitted light in tensity I0 and a fixed value l for the measuring section The extinction coefficient k de pends on a number of parameters such as size of the dust particles or the material of the dust particles characterised by specific gravity refraction index and absorption ...

Page 49: ...curring plant loads and the difference filtering possibilities of the respective plant Check measurements for different types of fuel are necessary Only when these comparisons figures are available can the extinction values be correctly evaluated re garding the dust emission Since the dust concentration is subject to statistical fluctua tions statistical methods are best for determining the calibr...

Page 50: ...ion cover D Reflector G Temperature transmitter for stand ardisation E Welded in pipe with adjustment flange J Electronics for fail safe shutter H Purge air unit K D ISC 100 control unit Connections 1 Operating power supply 4 Control cable for the fail safe shut ter 2 Measurement cable for the volu metric flow sensor 5 Measuring head connection 4 3 ...

Page 51: ...eflector type Measuring path Pitch circle diameter Ø D R 290 M XX2 10XXX D R 290 R 1XX 10X Scotchlite 1 m to 2 25 m 100 mm D R 290 M XX2 15XXX D R 290 R 1XX 15X 150 mm D R 290 M XX2 10XXX D R 290 R 2XX 10X Triple with lenses 1 75 m to approx 8 m 100 mm D R 290 M XX2 15XXX D R 290 R 2XX 15X 1 75 m to approx 18 m 150 mm Table 4 12 Standard systems D R 290 Various different tube diameters are availab...

Page 52: ...th mm L2 Stud length mm 100 65 59 130 200 73 100 89 83 130 600 73 150 89 83 190 600 80 150 114 3 107 1 190 1000 80 Table 4 13 Welded in pipe lengths The following reflectors can be used for the D R 290 measuring system Suitable for measuring path Type Version 1 m to 2 25 m D R 290 R 1XX 10X Scotchlite D R 290 R 1XX 15X 1 75 m to approx 8 m D R 290 R 2XX 10X Triple with lenses 1 75 m to 18 m D R 29...

Page 53: ...pes or flues on ventilation units generally on incineration plants generally on waste special waste and sewage sludge incineration plants on cement manufacturing plants on power stations with gas oil coal or mixed fuel firing on plants for incineration of biomass Refineries and other petrochemical plants Soot factories conversion plants asphalt mixing plants dust filter plants The Dust Concentrati...

Page 54: ...e under normal circumstances no hazards arise from this device either for the health of personnel or for damage to equipment To minimise hazards compliance with the handling regulations and safety instructions in this manual is essential Com ply with these instructions for configuration installation designated use and mainte nance Further information on the standards and directives that have been ...

Page 55: ...suring head 11 Purge air sensor connection and fail safe shutter reflector 12 Viewing window for device alignment sighting mechanism 13 Measuring window 14 Zero point reflector in the measuring position 15 Filter adapter without filter 16 Zero point reflector in the reference position Table 4 15 Designation of device components Measuring head and reflector ...

Page 56: ...vice components Supply unit 1 Stainless steel baseplate 2 Filter housing 3 Filter adapter 4 Filter lower part with air inlet 5 Filter spring clip 6 Blower motor 7 Cable gland for connection cable 8 Junction box Table 4 17 Designation of device components Purge air unit The designation of the device components of the optional D ISC 100 universal opera tion unit is described in the operating manual ...

Page 57: ...entification of the product The type label is located on the measuring head on the device side on the reflector on the device side on the supply unit on the device side on the blower assembly purge air unit on the baseplate 4 7 Standard ...

Page 58: ... on the fail safe shutter D SK 290 MA on the shutter bracket alongside the motor on the control electronics D SK AE on the device cover on the control unit D ISC 100 on the device side Table 4 18 Where do I find the type label Option ...

Page 59: ...nlet D 40 mm purge flange with swirl generator tested for suitability protection type IP 65 for installation in the N EX zone interface M23 connection for sensor USB SSK M SSK R 5 PN Order number 6 SN Serial number 7 U 24VDC 48VA Operating voltage 8 IP65 Protection type 9 Before starting any work read the operating manual 10 Declaration of conformity and type approval supplied 11 Date Date year of...

Page 60: ...4 Product description 60 D R 290 ...

Page 61: ...ousing 5 3 System installation sequence 5 4 Installation of the D R 290 measuring head and reflector 5 4 1 Standard installation of the welded in pipes with adjustment flanges 5 4 2 Installation variants 5 4 3 Alignment of the tube stubs 5 4 4 Installation of the measuring head and reflector 5 4 5 Electrical connections to the measuring head 5 4 6 Meaning of the LEDs 5 4 7 Configuration of the rel...

Page 62: ...the D TB 100 supply unit 5 7 2 Electrical connection to the D TB 100 supply unit 5 8 Installation of the purge air unit 5 8 1 Selection of an installation location of the purge air unit blower 5 8 2 Arrangement and installation of the purge air unit 5 8 3 Electrical installation of the purge air unit 5 8 4 Electrical connection for the purge air motor 5 9 Active operation 5 10 Dismantling and disp...

Page 63: ...t is shut down Before opening the duct access ports Make sure that no overpressure is present in the measurement duct Make sure that no toxic gases are present in the measurement duct If it is not possible to shut down the plant and toxic gases which may be at high tem perature or pressure are present in the measurement duct WARNING Health hazard due to hot and or toxic gases in the duct When a du...

Page 64: ...tallation and commissioning Installation and commissioning of the of the Dust and Opacity Monitor must be carried out by skilled personnel see section 2 4 1 Personnel skills 22 Specialist staff and for electrical work electricians with special knowledge of the supply unit Service technicians can be involved for support as necessary The operating company must provide employees with training in the ...

Page 65: ...d D TB 100 supply unit for power supply central monitoring in e g a monitoring room control room by a D ISC 100 universal operation unit data transmission from there by DURAG Modbus data transfer from the D ISC 100 to the PLS customer s system can be performed as required D Standard system two purge air units for systems with pitch circle diameter Ø 150 mm locally installed D ISC 100 universal ope...

Page 66: ... What is the gauge pressure in the measurement duct The maximum gauge pressure for the application of the standard blower is ap proximately 20 hPa Is suitable purge air available The fresh air sucked in by the blower for the purge air must be free of dust and oil and have a temperature of 20 to 40 C Is the measurement location outdoors In this case a weather protection cover should be fitted to pr...

Page 67: ...the measur ing head and reflector are installed at the measuring point and exposed to the hot gas to be measured Fail safe shutter optional if installed offer only short term protection The cabling between the supply unit and the customer interface PLS 196 in the control room must be carried out with screened data cables e g LiHCH TP 8 x 2 x 0 5 mm with twisted pairs of fine wire flexible cores op...

Page 68: ...d be at least 2 D see Fig 5 2 a If no such location is available the upstream section A should be longer than the downstream section see Fig 5 2 b On flues with round internal cross sections D means the internal diameter In the case of square or rectangular cross sections the hydraulic diameter is used Equation 10 F Area U Scope Table 5 2 Equation 10 The installation location should be as free fro...

Page 69: ...o their height The opening screws for the control electronics of fail safe shutters on the right hand side wall must also be accessible Otherwise it will not be possible to install the housings subsequently For this also see the section of dimensional diagrams 9 3 4 Dimensional diagram of the control electronics D SK AE 186 System installation sequence 1 Check the preconditions for operation 5 2 1...

Page 70: ...sion the D R 290 and perform a function test 6 Commissioning 107 14 Program the necessary measurement parameters and calibrate the units perform a function test 6 2 Parameterisation and operation of the measuring head 108 ff Installation of the D R 290 measuring head and reflector Adjustment flanges with welded in pipe connections are provided as standard for in stallation of the measuring head an...

Page 71: ...n pipes with adjustment flanges 2 Create an opening using a technique appropriate to the material and situation of the measurement duct 3 The tube ends should project approx 30 mm into the inside of the duct During installation note Important comments The red dot on the adjustment flange must always be at the top when installed The two threaded studs A and B see Fig on the left should be on the sa...

Page 72: ...5 Installation 72 D R 290 1 Duct wall 2 Insulation 3 Welded in pipe with adjustment flange 4 Red dot at the top of the flange Fig 5 5 Standard installation of a welded in pipe with adjustment flange ...

Page 73: ...ube with the adjustment flange is welded Comply also with the instructions and specifications as for the standard instal lation 5 4 1 Standard installation of the welded in pipes with adjustment flanges 70 1 Duct wall 2 Gusset plate 3 Welded in pipe 4 Red dot at the top of the flange 5 Attaching the gusset plate to stack wall Fig 5 6 Installation of a welded in pipe with adjustment flange in a bri...

Page 74: ... head and reflector are advisable not shown In this case it may also be necessary to fit fail safe shutters Comply also with the in structions and specifications as for the standard installation 5 4 1 Standard installation of the welded in pipes with adjustment flanges 70 1 Duct wall 2 Support for the welded in pipe 3 Welded in pipe 4 Red dot at the top of the flange 5 Wall reinforcement Fig 5 7 I...

Page 75: ... flanged tube due to thermal expansion Any additional mounting of the flanged tube on the outer wall must also allow this movement Please observe the maximum length of the welded in pipe see Table 4 13 and the tube cross sections associated with it which is limited due to the measurement beam For tube lengths 600 mm and greater the pitch circle diameter and flange diameter are different and so is ...

Page 76: ...ld the welded in pipe with the adjustment flange to the flue wall or fasten it by other means depending on the flue material and sur roundings of the measurement duct 5 Pull the guide tube out The installed flanges are now aligned For measurement ducts in which alignment by means of a tube is not possible an op tical laser adjustment device can be supplied D R 280 70 Installation of the measuring ...

Page 77: ...nger of burns due to hot surfaces Contact with hot components can cause serious burns Suitable heat resistant protective gear such as face mask safety gloves must al ways be worn where any work is undertaken in the vicinity of hot components Wherever possible allow components to cool down to ambient temperature before starting work Wherever possible install or remove components only when the plant...

Page 78: ...measuring head M or reflector R 11 Purge air flange per threaded stud Fig 5 10 Installation at the adjustment flange dimensional diagram D R 290 When installing the measuring head and reflector without protective devices fail safe shutters at the adjustment flange perform the operations in the following sequence 1 First pull the rubber sleeve Fig 5 10 6 over the flange tube in the measurement duct...

Page 79: ...tachment 1 Place 12 disc springs D in alternate directions on each of the 3 threaded studs of the flanged tube 2 Switch on the purge air unit for installation of the D BL purge air unit see 5 8 In stallation of the purge air unit 101 ff and slide the purge air flange of the measuring head or reflector connected to the active purge air supply on to the threaded studs 5 3 On each stud place a spheri...

Page 80: ...t for connecting a purge air sensor and protective device fail safe shutter for the reflector The D TB 100 supply unit or the control unit D ISC 100 is connected at the main connecting plug item 3 in Fig 5 12 This connection is described in section 5 6 1 Connecting the supply and control unit 96 The connection of the protective device for the measuring head at the socket item 4 Fig 5 12 and the pr...

Page 81: ...e DURAG Modbus frame has been re ceived see above Data errors 1 green 2 yellow 3 red 4 green Table 5 3 Meaning of the LEDs and their flash codes Configuration of the relay outputs The contact settings of the relays normally closed normally open on the D R 290 can be configured Risk of contamination perform the contamination check If the D R 290 device casing is opened the device together with the ...

Page 82: ...is supported by the lower arm 3 Put the housing cover aside Setting the relay outputs with switches SW1 and SW2 The switches SW1 and SW2 are located on the main circuit board see Fig 5 16 Fig 5 16 Position of the switches SW1 and 2 in the measuring head Fig 5 16 top right shows the available switch settings and their functions Switch SW1 designation on the printed circuit board configures relay 1 ...

Page 83: ...evices Such damage may be irreparable Installation of the optional D SK 290 protective de vice fail safe shutter is recommended here This protective device consists essential ly of a D SK 290 MA motorised fail safe shutter and D SK AE control electronics with the F3 air flow sensor The measuring system is designed optically and mechanically so that a D SK 290 MA fail safe shutter can be installed ...

Page 84: ...can cause serious burns Suitable heat resistant protective gear such as face mask safety gloves must al ways be worn where any work is undertaken in the vicinity of hot components Wherever possible allow components to cool down to ambient temperature before starting work Wherever possible install or remove components only when the plant is shut down Before opening the duct access ports Make sure t...

Page 85: ... threaded stud Fig 5 18 Installation at the adjustment flange dimensional diagram D R 290 When installing the measuring head and reflector with protective devices fail safe shutters on the adjustment flange perform the operations in the following sequence 1 Slide the gasket supplied Fig 5 18 14 on to the threaded studs of the welded in flanged tube 2 Also slide the D SK 290 MA fail safe shutter on...

Page 86: ...s E Spherical washer F Self locking nut G Adjustment flange with tube H Purge air flange Fig 5 19 Adjustable attachment 1 Place 12 disc springs D in alternate directions on each of the 3 threaded studs of the flanged tube 2 Switch on the purge air unit for installation of the D BL purge air unit see 5 8 In stallation of the purge air unit 101 ff and slide the purge air flange of the measuring head...

Page 87: ...ing area of the fail safe shutter Before maintenance work Unplug the connection plug at the measuring head for the fail safe shutter Caution when the connection is broken the fail safe shutter closes very quickly If several housings e g for a universal operation unit and control electronics for fail safe shutters are installed alongside each other allow sufficient clearance between them to allow t...

Page 88: ...fe shutter and the cable to the air flow sensor can be extended to 50 metres without problem air flow sensor 3 core cable with an overall screen 1 Air flow 2 red colour marking Fig 5 21 Air flow sensor After removing the cover screws PG 7 install the air flow sensor in the opening alongside the purge air connection for the measuring device so that the air flow pass es through the transverse hole i...

Page 89: ...le for connection of the cables The M20 cable glands are suitable for cable diameters from 7 mm to 13 mm The M16 cable glands are used for cable diameters between 4 5 mm and 10 mm The cables for the mains and data cables should be routed separately The mains supply cable should use H 07 RR U 3 G 1 5 or the equivalent The mate rial of the conductors and sheath must be appropriate to the conditions ...

Page 90: ...ouring terminals whilst being disconnected e g using cable ties If monitoring and control of the fail safe shutter is performed via the measuring head the plug end of the 8 core cable already installed should be plugged into the respec tive panel jack in the measuring head The free end of the cable is connected to the respective terminals in the control device of the protective device D SK AE Fig ...

Page 91: ...ter close External shutter close 1 white 24 VDC sensor 2 brown Purge air inlet 3 green S1 inlet SSK open 4 yellow S2 inlet SSK closed 5 grey Outlet SSK open 6 lilac Outlet SSK open 7 blue GND 8 red 24 VDC SSK not needed for D SK AE SSK Fail safe shutter Fig 5 23 Connection of the fail safe shutter to the 8 core plug cable of the measuring head ...

Page 92: ... the connection plug at the measuring head for the fail safe shutter Caution when the connection is broken the fail safe shutter closes very quickly Checking the protective device When the mains power is switched on check the charge status of the supercaps 196 see below and the purge air is present the fail safe shutter automatically switches to the OPEN position If the power supply or the purge a...

Page 93: ...ad D R 290 and the manual test function for the fail safe shutter is tested see also section 8 2 11 Functional test of the fail safe shutter 163 Setting path Functions D R 290 Service Functions Test Functions Test the fail safe shutter 1 Functions D R 290 Service Functions Test Functions Test the fail safe shutter 2 Commissioning the D SK AE Before commissioning the electrical connections must be ...

Page 94: ...afe shutter will open only if the supercaps are fully charged The housing must be opened to set the switching points and the Hysteresis 195 1 Use a screwdriver to turn the twist lock catch on the right side of the housing anti clockwise 2 Then open the assembly frame with the transparent cover which swings open to the left The setting elements are now accessible 3 Set the Air flow potentiometer P1...

Page 95: ...t If the commissioning has been performed correctly but the shutter does not operate the motor current protection switch in the housing of the shutter motor may have trip ped To reactivate the motor current protection switch undo the two socket head screws on the cover of the motor remove the cover and push the actuation button on the motor current protection switch back in If the shutter does not...

Page 96: ...lone device with only one D TB 100 and no control unit Fig 5 28 In this case operation is performed using Modbus or a PC laptop or tablet using the D ESI 100 operating software Fig 5 28 Connecting the D R 290 as an individual sensor to the D TB 100 supply unit Directly supplied by the D ISC 100 control unit at the sensor level Fig 5 29 In this case the D R 290 is supplied with power directly by th...

Page 97: ...URAG Bus Installation of the supply unit The power supply of the D R 290 measuring system is provided by a D TB 100 sup ply unit A blower is also required for the purge air Installation of the D TB 100 supply unit The D TB 100 supply unit is installed close to the measuring point ensure the pre in stalled connection cable reaches it see delivery note The dimensional drawing for the D TB 100 supply...

Page 98: ... unit will no longer satisfy protection type IP 66 NEMA 4 4x Fig 5 32 Attaching the retaining plates If desired the retaining plates can also be attached to the housing in the vertical align ment They then project half way left and right beyond the housing for dimensions see Fig 9 11 Electrical connection to the D TB 100 supply unit The supply unit sends the measurement data prepared by the measur...

Page 99: ...and any supplementary regulations issued by the local power supply companies 1 Loosen the four captive screws and open the supply unit Spring terminals are provided in the supply unit for connecting the data cable screens These terminals can be released using a hexagon socket key moved to the available tapped holes on their rail Fig 5 33 1 if required and also changed to a different direction 1 Ta...

Page 100: ...ovided with end sleeves then inserted into the round opening below as far as the stop 3 Remove the screwdriver and gently tug the core to check it is firmly seated For the customer s connections the terminals X1 X2 and X3 Fig 5 34 and Fig 5 35 are provided Fig 5 35 D TB 100 terminal box connection diagram X1 is used to connect the D TB 100 supply unit to the mains Terminal X3 is used to transmit t...

Page 101: ...of the purge air unit blower The following points must be observed when selecting the installation location Damage as a result of blocked intake openings purge air hoses The inlet opening must not be blocked or covered over by deposits of leaves sand dirt snow or the like It can also make sense to guard against ingress by small animals and insects so as to avoid them causing interruptions in the p...

Page 102: ...ad and reflector will be damaged if the purge air supply fails If the purge air supply is not running the measuring head and reflector within the duct will be irreversibly damaged within a short time due to excessive heat and dust It is absolutely essential that the measuring head and reflector are removed from the measurement duct before the purge air is switched off Under no circumstances allow ...

Page 103: ...e Risk of fatal injury due to electric shock Touching live parts poses an immediate risk of fatal injury Damage to the insulation or to individual components can lead to fatal injury If there is any damage to the insulation switch off the power supply immediately and have it repaired Permit only qualified electricians to work on electrical equipment Before opening the casing of a device or removin...

Page 104: ...int for the recycling of electrical and electronic devices Your contribution to the correct disposal of this product protects the environment and the health of your fel low man Irresponsible disposal places the environment and our health at risk Materi als recycling helps reduce the consumption of raw materials Current information on the recycling of this product can be obtained from your local au...

Page 105: ...head 6 3 Navigation help for D ESI 100 settings path 6 4 Information on the DURAG Modbus protocol 6 4 1 Basic Modbus information 6 5 Example Save parameters 6 6 Using the PIN lock PIN code 6 6 1 PIN symbol overview 6 6 2 Example Login 6 6 3 Example Change PIN code 6 6 4 Example Logout 6 6 5 Example Deactivate the PIN lock 6 7 Parameter checking or setting overview ...

Page 106: ...106 D R 290 ...

Page 107: ...ess the purge air supply to the flange and dust duct is running If the purge air supply is not running the measuring head and reflector will be irreversibly damaged within a short time due to excessive heat and dust Optical alignment After installation on the stack the measuring system must be optically aligned The measuring system is factory set to the measuring path length specified by the opera...

Page 108: ...in the sighting mechanism moves in the vertical direction Only tighten the self locking nuts to such a degree that the disc springs can still perform their spring action Parameterisation and operation of the measuring head The device is supplied with factory settings The calibration to the dust free measuring path is performed in the factory provided that the operating company has supplied a compl...

Page 109: ...ttings path Navigation help for D ESI 100 If necessary at the start of each description you will find a box D ESI 100 setting path It shows the path to the relevant menu in the setting software where you can perform the listed checks settings see below Setting path Sitemap Device e g D FL 220 Common Parameters Bus In formation Current date and time The device overview page containing the device li...

Page 110: ...about the Modbus RTU 195 Modbus can be obtained from the Internet at the home page of the Modbus Independent User Organisation IDA Modbus Protocol specifications http www modbus org docs Modbus_Application_Proto col_V1_1b pdf Describes the datagrams protocol data units that are exchanged between master and slave Modbus over Serial Line Specification and Implementation Guide http www modbus org doc...

Page 111: ...ers button Using the PIN lock PIN code The measuring head of the D R 290 can be locked with a PIN code against accidental changes to the parameters that affect the measurement see also D ESI 100 Operat ing manual The PIN code is deactivated when the devices are delivered Fig 6 4 PIN lock deactivated Also see about this 2 Example Login 112 PIN symbol overview D ESI 100 uses the following symbols in...

Page 112: ...This calls up the login box for inputting the PIN code Fig 6 5 Login box The login name generally adopted is user The entry is not case sensitive PIN password for a device where the PIN code is deactivated is 0000 four zeros Enter four zeros After entering this login is completed by a left mouse click on the Login button or with the Enter key The Change PIN code button and the symbol with the same...

Page 113: ...N code button assigns a new PIN code to all the devices listed on the device overview page at once for restrictions see below under pre conditions The Change PIN code symbol only assigns a new PIN code to the device listed on the device overview page whose Change PIN code symbol you clicked on for pre conditions see the section Change PIN code in the D ESI 100 manual You logged in with PIN code 00...

Page 114: ... PIN code can only be changed after login with the currently valid PIN code The status of the device PIN code activated is shown on the device details page see also the Device details page section in the D ESI 100 manual by display of a pad lock symbol Fig 6 9 End device locked with a PIN code All the data provided by D ESI 100 also protected can always be read In principle no PIN code entry is ne...

Page 115: ... Code box is displayed Fig 6 10 Deactivate the PIN code Left click on the Deactivate button D ESI 100 Successful completion of the change is reported in a dialogue box Fig 6 11 PIN Code changed successfully In the bottom area under the Protocol heading there is a green tick If you hover the mouse cursor over this tick you are shown the message Quick Info 196 PIN code changed successfully That mean...

Page 116: ...activated the device is still protec ted against accidental changes The old PIN code for the device remains valid Parameter checking or setting overview The following table shows which parameters must be checked and set The individual operations are listed in functional sequence one after the other The right hand column in the table indicates the section which contains detailed information about t...

Page 117: ...nalogue output fixed value simula tion of the measurement channels simulation of the digital outputs Table 6 2 Checklist for parameter checking general Other entries are device specific Key word Range Component see section 7 Device configuration Device specific settings Device variant fail safe shutter fitted Device configuration 8 Measured values Device specific settings Contamination zero point ...

Page 118: ...ons Calibration to the dust free measuring path test func tion for the fail safe shutters 7 7 8 Calibration on the dust free measuring path 146 only if necessary corresponds to the setting of the signal range of the channel for analogue output Table 6 3 Checklist for parameter checking device specific ...

Page 119: ...over the cursor over a pictogram provided with quick info whose function you would like to get information about see below left hand image All symbols and pictograms are generally provided with quick info of this kind Table 7 1 D ESI 100 quick info Further information on topics such as inputting parameters can also be obtained as quick info if you hover the cursor over an symbol see above right ha...

Page 120: ...e overwritten again by the sys tem time Parameters Description Current date time Standard format 22 08 2011 13 29 28 Set correct the time Left click on device in the site map Left click on for the desired device in the device list Under Common parameters in the list field after Select group set Bus in formation Left click on the Edit symbol in the line for which you wish to change the Cur rent dat...

Page 121: ...e available address range is from 1 to 247 The default address is 25 Comply with the Modbus rules for the use of addresses Setting path Sitemap Device e g D R 290 Common Parameters Bus In formation Modbus Address Value Fig 7 3 Setting DURAG Modbus address Setting DURAG Modbus address in the device Left click on Device in the sitemap Left click on for the desired device in the device list Under Com...

Page 122: ...dbus communication between the device and the PC the new address is at first written only to the register It is not yet brought into use The new address is not transferred to the read only memory of the device EEPROM until it has been saved And only after a restart of the device does the new address also become active i e used see below saving parameters restarting the device Setting path Sitemap ...

Page 123: ...ation If you know the direct input left click on the Edit symbol in the Modbus Com munication Settings line Enter the appropriate code using the keyboard If you do not know the direct input left click on the Binary Table symbol in the Modbus Communication Settings line A window opens Refer only to the first two lines 9600 bd off 9600bd on 19200bd off 38400bd on 57600bd off 9600bd off 19200bd on 38...

Page 124: ... device then reverts to using the old parameters Clicking on the Save parameters button causes the data to be transferred to the read only memory of the device This means the parameters are also retained and continue to be used even the device is restarted The procedure for inputting the DURAG Modbus address and also the baud rate is different from the one used for all other data inputs So as not ...

Page 125: ...Setting variables PARAMETER Fig 7 5 Setting variables for the measurement channels Set variables for the measurement channels general Left click on Device in the sitemap Left click on for the desired device in the device list Under Common parameters in the list field after Select group select Set ting variables Left click on the Edit symbol in the line for which you wish to change the setting Usin...

Page 126: ...utton The new setting is not used permanently until it has been saved Limit values channel 1 channel 4 Each channel can monitor four limit values two upper limit values and two lower limit values The limit values setting for the measurement channels channel 1 channel 4 is performed as follows Setting path Sitemap Device e g D R 290 Common Parameters Setting variables upper lower limit value 1 2 Se...

Page 127: ...ice This means the parameters are also retained and continue to be used even the device is restarted For the new setting to be used permanently left click on the Save parameters button The new setting is not used permanently until it has been saved Type code The Type code selects the output variable for the respective channel The variables setting for the Type code permits a selection based on a c...

Page 128: ...e measuring head and then close the window The new setting will immediately be used until the device is next restarted After a re start the old setting will be used In order to use the new setting permanently even after a restart the settings must be saved before the next restart To do this left click on the Save parameters button The new setting is not used permanently until it has been saved Ava...

Page 129: ...6 Settings 142 Table 7 4 Available type codes for the D R 290 Example Settings for the measured value correction If necessary the real measurement value that was determined can be modified to suit the physical characteristics of the duct in which the measurement is being performed and or to suit the purpose to which the signal is to be put depending on the plant or evaluation process A measured va...

Page 130: ...device has been restarted i e the device then reverts to using the old parameters Clicking on the Save parameters button causes the data to be transferred to the read only memory of the device This means the parameters are also retained and continue to be used even the device is restarted For the new setting to be used permanently left click on the Save parameters button The new setting is not use...

Page 131: ... for each channel The cor rection is categorised into various steps see the diagram above Integration time Each channel has an integration memory Integration time 195 which can be set to a value between 1 s and 180 s factory default setting 30 s Offset a0 An offset offset or adjustment offset 195 can be added to or subtracted from the measured value see Fig 132 Setting path Site map Device e g D R...

Page 132: ...n factor a0 Offset or adjustment offset 195 Fig 7 7 Diagram Measured value correction by polynomial example a0 a1 a2 a3 K1 0 1 1 0 0 K2 0 0 97 0 0 K3 0 1 0 0012 0 K4 0 1 0 0 00003 K1 K4 Measured values with correction by polynomials Table 7 6 Values table Measured value correction by polynomial example Setting path Site map Device e g D R 290 Common parameters Variables setting Slope a1 3 PARAMETE...

Page 133: ...ring the check measurement the last meas ured value should be retained or the reference check value output Zero range Each channel has a zero range correction function This allows specification that measured values are set to zero range positive active or measured values zero range negative active or measured values zero range equal to zero This function allows suppression of fluctuations around t...

Page 134: ... range C Zero Range Table 7 7 Measured value output channel ZR Zero Range value Variable Zero Range value Example Assignment of the device outputs Current output The measuring head has available a analogue output 0 4 20mA with live zero The setting is performed as follows Setting path Sitemap Device e g D R 290 Common Parameters analogue output and relay settings PARAMETER Fig 7 9 Setting the anal...

Page 135: ...ch variable whose value you wish to change Setting path Sitemap Device e g D R 290 Save Parameters For security reasons parameters that are changed e g specific parameters such as data for gravimetric calibration are initially written only to the working memory of the device This means these data are currently used or referenced but are no longer available after the device has been restarted i e t...

Page 136: ...ange value manually Select settings from binary table Fig 7 10 Setting relay setup The relays switch when triggered by the events assigned to them Close abort and close window Send load temporarily Table 7 8 Relays configuration of the outputs Setting the relay outputs Left click on Device in the sitemap Left click on for the desired device in the device list Step 1 Step 2 ...

Page 137: ...ters For security reasons parameters that are changed e g specific parameters such as data for gravimetric calibration are initially written only to the working memory of the device This means these data are currently used or referenced but are no longer available after the device has been restarted i e the device then reverts to using the old parameters Clicking on the Save parameters button caus...

Page 138: ...window Send load temporarily Table 7 9 Relays configuration of the switching logic Setting the relay outputs Left click on Device in the sitemap Left click on for the desired device in the device list Under Common parameters in the list field after Select group enter the an alogue output and relay settings If you know the direct input left click on the Edit symbol in one of the lines un der Relay ...

Page 139: ...d parameters Clicking on the Save parameters button causes the data to be transferred to the read only memory of the device This means the parameters are also retained and continue to be used even the device is restarted For the new setting to be used permanently left click on the Save parameters button The new setting is not used permanently until it has been saved Maintenance setup Maintenance s...

Page 140: ...ured value is divided by the setpoint calibrate in the factory 12 OP SP and scaled according to the prevailing setpoint see above Tab Ref erence point check setpoint R generally 70 Signal range start Signal range Signal range end see section 7 5 3 5 Signal range 133 The zero point setpoint is 0 zero This value is fixed and cannot be adjusted or changed Control cycle step duration and control cycle...

Page 141: ...e D R 290 Setting path Device D R 290 Specific Parameters D R 290 Configuration PARAMETER Change val ues manually This communicates to the system whether purge air sensors and or fail safe shutters are fitted After installation and connection of the protective device at the measuring head at the reflector see section 5 5 4 D SK AE electrical connection 88 the corre sponding entry must be made at t...

Page 142: ...case If there is a check measurement actually in progress it shows the continuously upda ted value In the example illustration above the measured values relating to contamination zero point value and reference point value are shown as 0 since no control cycle has yet been performed If necessary a contamination warning threshold may be set here Note If contamination 10 the device outputs an error m...

Page 143: ...ical density extinction 48 The values for the flange flange distance LFF and the flange length LF can also be saved for reference If these values are input the active measurement path length is calculated automatically using the formula LA LFF 2 LF The stack correction factor can be input for an opacity evaluation according to US EPA regulations see section 4 2 5 Calculation of the opacity at the ...

Page 144: ...ed temperature undershoots the respective temperature setting a heating element is activated for the respective component The D R 290 has combined analogue digital inputs for purge air monitoring The de vice connected between pins 1 and 2 of the respective plug see 144 can option ally be a 4 20 mA analogue transmitter for purge air measurement or a NO contact for purge air monitoring In this case ...

Page 145: ...fail safe shutters is Sensor 1 shutter 1 measuring head connection 4 in Fig 7 18 Sensor 2 shutter 2 reflector connection 5 in Fig 7 18 The status of both fail safe shutters can be interrogated here An explanation of the status codes can be displayed as Quick Info 196 hover the mouse cursor over the start of the line Fig 7 19 Quick Info explanation of the shutter status Activation of the fail safe ...

Page 146: ...tion display The contamination must not be greater than 2 Setting path Device D R 290 Specific Parameters D R 290 Measured values contamination 1 First the measuring head has to be aligned optically see section 6 1 Optical align ment 107 If the measuring head and the reflector have been mounted as shown in figure Fig 5 10 or Fig 5 18 the 3 nuts on the reflector flange can be tightened First tighte...

Page 147: ...sed simply restart the device or perform the follow ing function Setting path device D R 290 Functions Maintenance Service Functions Restore the saved parameters If the measurement shall be taken over after the calibration has terminated automati cally or manually click on the Save parameters button or perform the follow ing function Setting path device D R 290 Functions Maintenance Service Functi...

Page 148: ...onfiguration it is advisable to order two optional additional purge air flanges and to mount them on the flanges of the measurement tube For measurement only the reflector and measuring head need then be installed there This means the measurement configuration requires optical alignment only the first time it is installed For every further measurement the devices are then need only be mounted on t...

Page 149: ...Media conditions by using a D ISC 100 analogue input module and the Media conditions software module in the D ISC 100 in a special variant of the D R 290 via the optional 4 20 mA temperature input see section 7 7 10 2 Temperature compensation via an external temperature trans mitter special variant 149 Temperature compensation via an external temperature transmitter special variant The necessary d...

Page 150: ...esignations shown in Fig 7 24 for the device socket 1 4 match those for the Fig 7 25 and Fig 7 26 D R 290 TC inlet temperature 4 20 mA Transducer 4 20 mA max 20V max 30 mA 1 2 4 Fig 7 25 Electrical connection of a 2 wire transducer without its own power supply D R 290 TC inlet temperature 4 20 mA Transducer 4 20 mA max 20V max 30 mA 1 2 4 Power supply Fig 7 26 Electrical connection of a 4 wire tra...

Page 151: ...ions for leaks and secure fitting 8 2 3 Checking and changing the filter 8 2 4 Cleaning the outer glass and the zero point reflector 8 2 5 Removing deposits from the welded in pipes 8 2 6 Checking the linearity 8 2 7 Zero point check 8 2 8 Contamination check 8 2 9 Reference point check 8 2 10 Control cycle 8 2 11 Functional test of the fail safe shutter 8 2 12 Checking the battery in the measurin...

Page 152: ...152 D R 290 ...

Page 153: ...illed electricians to work on electrical equipment Before starting work switch off the power supply and secure it against restoration Before removing the casing or guard check that the devices are deenergised Keep moisture away from live components Moisture can lead to short circuits WARNING Danger of burns due to hot surfaces Contact with hot components can cause serious burns Suitable heat resis...

Page 154: ...l Ensure compliance with the skills and knowledge described in section 2 4 1 Personnel skills 22 WARNING Risk of injury due to incorrect spare parts Incorrect or defective spare parts can lead to damage malfunctions or total failure and may also impair safety Only use genuine spare parts supplied by the manufacturer Spare parts can be obtained from an authorised agent or directly from the manu fac...

Page 155: ...hose connections for leaks and secure fitting Operating personnel every four weeks b Remove deposits on and within the welded in pipe Operating personnel every four weeks b Purge air blower Checking the filter Changing the filter see also Checking changing the filter Specialised staff every four weeks typically every 3 months b Cleaning the purge air hoses Specialised staff Typically every 3 month...

Page 156: ... for external changes such as corrosion faulty seals colour changes on the housing etc There is also a check that all screw connections clo sures and devices are tightly secured Use oil free compressed air or a soft lint free cloth moistened with water and Isopro panol 195 if necessary to remove any deposits Check the purge air unit and the hose connections for leaks and secure fitting Check the p...

Page 157: ...asive particles If necessary then carefully clean them off with a soft non linting cloth wetted as necessary with water and alcohol To prevent displacement of the zero point reflector by an automatic contamination measurement whilst work is being performed on the screws first bring the device into zero point measurement mode Setting path Device D R 290 Functions Maintenance Service Functions Maint...

Page 158: ...ctions Maintenance Functions Stop zero point test Removing deposits from the welded in pipes Remove any deposits in and also on the welded in pipes Never touch parts which could be hot without temperature resistant equipment or pro tective gloves Depending on the characteristics pressure and temperature of the gases in the duct it may be that the inside of the welded in pipes can be cleaned only w...

Page 159: ...e measured values is performed directly in the function menu Setting path Device D R 290 Functions D R 290 Linearity test Linearity test measured value OP SP The type of output of the linearity values on the four measurement channels can be set by the parameter Setting path Device D R 290 Functions D R 290 Linearity test Scaling the linearity values If this parameter is set to 0 the device measure...

Page 160: ...test with scaling The linearity measurement is started and a test filter with an opacity of approx 15 4 is inserted The scaling is set to 1 The channels are set to the following signal ranges see also section 7 5 3 5 Signal range 133 and 7 5 2 1 Available type codes for the D R 290 128 Channel 1 Optical density double path 0 to 2 Channel 2 Opacity PLCF 1 0 to 20 OP Channel 3 Opacity SP 0 to 100 OP...

Page 161: ...m the measuring channels is dependent in every case on the settings for the channel see section 7 5 3 6 Settings 133 Direct output of the opacity measured during the current measurement and during the last zero point measurement can be found under Setting path Device D R 290 Specific parameters D R 290 Measured values Zero point value OP SP Contamination check The D R 290 automatically performs a ...

Page 162: ...to position and mesh filter swung into position and compares it with the factory reference value The output from the measuring channels is dependent in every case on the settings for the channel see section 7 5 3 6 Settings 133 Direct output of the opacity measured during the current measurement and during the last reference value measurement can be found under Setting path Device D R 290 Specific...

Page 163: ...ecessary undo the connections between the measuring head and control unit between the fail safe shutters and control device for the fail safe shutters including the connecting cables to the measuring head 2 By undoing the quick release clamps release the measuring head or reflector from the purge air flange 3 If necessary disconnect the measuring head or reflector as from the purge air sup ply 4 P...

Page 164: ...Checking the battery in the measuring head The battery in the measuring head buffers the power supply for the internal clock with in the measuring head This clock provides system messages with timestamp After a long time in storage without a power supply this battery can become dis charged Frequent occurrence of the warning 81 see 168 Clock not set may also indicate a discharged battery To change ...

Page 165: ...eplace the old battery type CR 2032 3V with a new one Closing the housing 1 Carefully place the housing cover back over the electronics The handle at the bot tom Insert the screws and tighten them equally in the opposite sequence to re moving them see Fig on the left Fig 8 10 Undo ...

Page 166: ...ance 166 D R 290 2 Swing the measuring unit shut and close the four quick release clamps Setting the system time See section 7 2 Example Settings for checking synchronising Date and time 120 Fig 8 12 Tightening ...

Page 167: ...rmed The system is performing zero point measurement No action necessary 007 Reference point measurement is being performed The system is performing reference point measure ment No action necessary 008 Contamination measurement is being performed The system is performing contamination measure ment No action necessary 009 Parameter change saved Changed parameter have been saved No action necessary ...

Page 168: ...essary 024 Device outputting PLCF The device is outputting the scaled stack factor PLCF for devices according to the US EPA No action necessary Table 8 2 List of messages for D R 290 Se qu no Warning Cause available actions by whom 064 Measured value 1 Upper limit value 1 active The upper limit value 1 of measurement channel 1 has been exceeded 065 Measured value 1 Lower limit value 1 active The l...

Page 169: ...perature of the electronics is above 80 C 176 F Protect the device against exposure to solar ra diation and or sources of heat Operating person nel 083 Device temperature too low The temperature of the electronics is below 40 C 40 F Insulate the device against cold Operating person nel 084 Initial contamination measure ment could not be performed This message is intended only for the manufactur in...

Page 170: ...ck the purge air flow restore the flow or re move the device from the flue stack Specialised person nel 094 Purge air flow 1 measuring head too high Purge air flow above the warning threshold If the purge air flow is too high depending on the flue stack temperature and flue gas velocity there may be an effect on the measured values Check the effect of the purge air on the meas ured values Speciali...

Page 171: ... Receiver overrun Electronics fault Service technician 134 Receiver overrun Electronics fault Service technician 135 Contamination error The contamination is greater than 10 Clean the device plate zero point reflector and reflector unit Specialised personnel 136 LED undertemperature shut down The LED was shut down because the LED temper ature was too low If the device is started up at a very low t...

Page 172: ... too low Purge air flow is below the fault threshold Possible causes Blower defective filter clogged purge air hose split parameterisation of the purge air inlet defective It can be expected that the measurement func tion may be impaired by dust in the welded in pipes by a rapid increase in contamination or damage to the device due to high temperatures Check the purge air flow restore the flow or ...

Page 173: ...ct fault at the fail safe shutter protect ing the measuring head Check the connections for the fail safe shutter protecting the measuring head and check the control device Specialised personnel 200 Fault fail safe shutter 2 reflector Switch contact fault at the fail safe shutter protect ing the reflector Check the connections for the fail safe shutter protecting the measuring head and check the co...

Page 174: ...8 Maintenance 174 D R 290 ...

Page 175: ...it terminal box 9 2 6 D BL XXX purge air unit 9 3 Dimensional diagrams 9 3 1 Dimensional diagram of the measuring head reflector 9 3 2 Dimensional diagram of the measuring head reflector with fail safe shutter 9 3 3 Dimensional diagram of the welded in pipe with adjustment flange 9 3 4 Dimensional diagram of the control electronics D SK AE 9 3 5 Dimensional diagram fail safe shutter D SK MA 9 3 6 ...

Page 176: ...176 D R 290 ...

Page 177: ...9 Appendix D R 290 177 Appendix Measurement point questionnaire Fig 9 1 Measurement point questionnaire 1 9 9 1 ...

Page 178: ...9 Appendix 178 D R 290 Fig 9 2 Measurement point questionnaire 2 ...

Page 179: ...put range opacity Freely configurable within the measuring range Measuring range extinction 0 0 1 0 2 Output range extinction Freely configurable within the measuring range Measuring range dust concentration 0 80 mg m3 0 4000 mg m3 dependent on the calibration Output range dust concentration Freely configurable within the measuring range Lowest detection limit 0 75 for measuring range 0 0 1 extinc...

Page 180: ...ve msl Dimensions HxWxD Approx 370 x 190 x 270 mm Weight Approx 7 kg Material Aluminium painted blue RAL 5017 Table 9 3 Technical data D R 290 reflector D SK AE control electronics protective device Digital outputs 1 contact fail safe shutter CLOSED 1 contact fail safe shutter OPEN 1 changeover contact Purge air available failed contact rating 48 V 0 5 A Power supply 25 264 V 47 440 Hz 10 VA Overv...

Page 181: ...ox 160 x 230 x 105 mm or 180 x 230 x 105 mm Tests for Flammability of Plastic Materials for Parts in Devices and Applications to IEC DIN EN 60695 11 10 and 20 UL 94 V0 Weight Approx 1 5 kg Material Polycarbonate light grey RAL 7035 Table 9 6 Technical data D TB 100 supply unit terminal box D BL XXX purge air unit Power supply 115 230 V 50 60 Hz 0 4 kW 0 5 kW Overvoltage category CAT II Purge air q...

Page 182: ...9 Appendix 182 D R 290 Dimensional diagrams Dimensional diagram of the measuring head reflector Fig 9 3 Dimensional diagram of the measuring head reflector D1 D4 see Table 9 8 9 3 9 3 1 ...

Page 183: ...h other within 1 2 Duct wall 3 Welded in pipe with adjustment flange 4 Red dot 6 Rubber sleeve 7 12 disc springs 8 1 spherical washer 9 1 self locking nut 10a Measuring head MK 10b Reflector R per threaded stud Fig 9 4 Installation example on a horizontal duct ...

Page 184: ... Appendix 184 D R 290 Dimensional diagram of the measuring head reflector with fail safe shutter Fig 9 5 Dimensional diagram of the measuring head reflector with fail safe shutter D1 see Table 9 8 9 3 2 ...

Page 185: ... 9 6 Installation example on a horizontal duct Dimensional diagram of the welded in pipe with adjustment flange Fig 9 7 Dimensional diagram D R 290 standard welded in pipe with adjustment flange red dot D1 Pitch circle diameter Ø mm D2 Tube outside Ø mm D3 Tube inside Ø mm D4 Flange outside Ø mm L1 max permis sible length mm L2 Stud length mm 100 65 59 130 200 73 100 89 83 130 600 73 150 89 83 190...

Page 186: ...9 Appendix 186 D R 290 Dimensional diagram of the control electronics D SK AE Fig 9 8 Housing D SK AE dimensional diagram space required 9 3 4 ...

Page 187: ... fail safe shutter D SK MA Fig 9 9 Dimensional diagram housing D SK 290 MA D1 diameter 100 mm Fig 9 10 Dimensional diagram housing D SK 280 MA D1 diameter 150 mm D1 see Table 9 8 Dimensional diagram supply unit terminal box D TB 100 9 3 5 9 3 6 ...

Page 188: ...9 Appendix 188 D R 290 Fig 9 11 Dimensional diagram D TB 100 supply unit Dimensional diagram purge air unit D BL 9 3 7 ...

Page 189: ...9 Appendix D R 290 189 WSH Weather protection cover optional FR Clear space for changing the filter Fig 9 12 Dimensional diagram purge air unit D1 diameter 100 mm D1 see Table 9 8 ...

Page 190: ...9 Appendix 190 D R 290 WSH Weather protection cover optional FR Clear space for changing the filter Fig 9 13 Dimensional diagram purge air unit D1 diameter 150 mm D1 see Table 9 8 ...

Page 191: ...tional weather protection covers Fig 9 14 Dimensional diagram weather protection cover measuring head D1 pitch circle diameter 100 Fig 9 15 Dimensional diagram weather protection cover reflector D1 pitch circle diameter 100 D1 see Table 9 8 9 3 8 ...

Page 192: ... D R 290 Fig 9 16 Dimensional diagram weather protection cover measuring head D1 pitch circle diameter 150 Fig 9 17 Dimensional diagram weather protection cover reflector D1 pitch circle diameter 150 D1 see Table 9 8 ...

Page 193: ...9 Appendix D R 290 193 Fig 9 18 Dimensional diagram weather protection cover control electronics protective device ...

Page 194: ...9 Appendix 194 D R 290 ...

Page 195: ...eference variables T P RF for dust concentrations this result is given in mg Nm Gravimetry lat including chem Measurement analysis procedure for quantitative determination of ele ments and groups in substance mixtures Hysteresis Greek hysteros afterwards refers to the con tinuation of an effect after the removal of its cause This phenomenon occurs in a wide range of scientific fields For the fail ...

Page 196: ...e g over a button a symbol or even a text to which quick info is associated RoHS compliance The EC Directive restricting the use of hazard ous substances in electrical and electronic devi ces governs the use of hazardous substances in devices and components This EC Directive to gether with the necessary implementation into national law is denoted by the abbreviation RoHS Restriction of the use of ...

Page 197: ... Control measurements 140 Fault indication suppression 141 Reference value 140 Designated use 53 Designation of system components 55 Device components Designation 55 Devices settings additional 141 143 Dimensional diagram measuring head and reflector 78 85 Dismantling 103 Disposal 104 double walled ducts 75 Drilling template 186 D SK 290 MA fail safe shutter 83 D SK AE control electronics 83 E Eme...

Page 198: ...ide 110 Protocol specifications 110 Setting the address 121 Setting the Baud rate 123 Motor current protection switch D SK 290 MA 95 Fail safe shutters 95 Motor current protection switch purge air unit 102 Mounting Purge Air Unit 147 N Navigation help 109 119 O Operation 103 Operators definition 23 Output variable 128 P Parameters Analogue output 134 Fault indication suppression 141 Integration ti...

Page 199: ...51002 51 Storage conditions 32 Supercaps 92 Symbols Further 15 System components 51 System components Designation 55 T Technical data D BL xxx purge air unit 181 D R 290 application data 179 D R 290 measuring head 180 D R 290 reflector 180 D R 290 system 179 D SK 290 MA fail safe shutter protective device 181 D SK 290 AE control electronics protective de vice 180 Temperature compensation 149 Tempe...

Page 200: ...11 Index 200 D R 290 ...

Page 201: ...urag durag com DURAG India Instrumentation Private Limited 27 30 2nd Main Road Industrial Town Rajajinagar Bengaluru 560 044 India Tel 91 80 2314 5626 2301 1700 Fax 91 80 2314 5627 E Mail info duragindia com DURAG Instrumentation Shanghai Co Ltd Room 706 Dibao Plaza No 3998 Hongxin Rd Minhang District Shanghai 201103 PR China Tel 86 21 60732979 200 Fax 86 21 60732980 205 E Mail info durag cn com D...

Page 202: ...GmbH Kollaustraße 105 22453 Hamburg Germany www durag com ...

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