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Installation and Operation Manual - SILOTEC 8000

Installation

Doc.-ID: SILOTEC_11022020_EN

11

2.3

Access to the Terminals

Warning

Before removing the terminal covers, switch off the mains voltage to the system. Switch the mains
voltage on only after attaching the terminal cover. After the installation has been completed, live parts
may no longer be accessible.

Figure 6

- Access to the Terminals

2.4

Ferrite Sleeves (EMC)

Caution

In order to avoid cable related disturbances to the electronic unit, the supplied ferrite sleeves must be used.
CE-conformity is invalid if these ferrite sleeves are not fitted!

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Summary of Contents for SILOTEC 8000

Page 1: ...Doc ID SILOTEC_11022020_EN Installation and Operation Manual SILOTEC 8000 O2 COe Analyzer System for Silo Monitoring Version 03 for software version 4 13 ...

Page 2: ...le in other languages Symbols used in this Manual The symbols below are found attached to the system and in this manual They emphasize important information as well as safety instructions for installation operation and maintenance to protect the personnel and the equipment Warning Follow all instructions in this manual Consider Information Points out important information which must be noted befor...

Page 3: ...ystem errors O2 COe 29 4 2 6 COe Measuring Ranges Scaling 30 4 2 7 COe Sensor Calibration values 30 4 2 8 Time per test gas apply 30 4 2 9 Delay time to process 30 4 2 10 Pre purge time 30 4 2 11 Automatic Calibration ACAL 30 4 2 12 ENOTEC REMOTE 31 4 2 13 Measuring units 31 4 2 14 Language 32 4 2 15 Change system code 32 4 2 16 Load factory settings 32 4 2 17 Set COe measurement to off on 32 4 2 ...

Page 4: ...sed air conditioning optional if instrument air is unavailable Dust Ex Zone 22 Max ambient temp 20 C to 55 C 4 F to 131 F Pneumatic cable Coal silo Dust Ex Zone 20 Probe signal cable Manufacturer supply SILOTEC O2 COe probe unit GRP cabinet IP 65 Customer supply Compressed air in 2 10 bar Control line probe Test gas in max 3 bar Optional equipment see offer Counter flange DN65 PN6 customer supply ...

Page 5: ...side which logarithmically depends on the ratio of the oxygen partial pressures of both sides of the sensor The mV signal is converted by the Nernst equation into the oxygen partial pressure in the sample gas which determines the O2 concentration in the sample gas The gas tight separation between the reference air side and the sample gas side of the sensor is of particular importance as otherwise ...

Page 6: ... store the probe in a safe protected place and wait until it has cooled downs below 35 C 95 F 1 5 Disruption of the Process The analyzer system has to be kept in operation also in the event of the process being disrupted or if the plant is powered off temporarily e g at night or during the weekend Frequently cooling down and heating up of the cuvette results in thermal stress of the hot probe part...

Page 7: ...he nominated current frequency protection class year of manufacture serial number order number and system order code The system order code refers to information which is detailed in the system test report and supplied with the system SIL 800000003 electronic unit in field housing SIL 800000004 19 rack housing SIL KES 0001 cuvette Probe in GRP housing Figure 2 Name Plates ...

Page 8: ...20_EN 1 8 System description Contents of GRP housing Abb 3 Contents of the GRP housing Injector 2 2 way solenoid valve for purging Flow meter with alarm module 3 2 way solenoid valve for measuring O2 COe cuvette SIL KES 0001 Throttle valve to fill purge tank Gas sampling probe SIL GSF 8000 ...

Page 9: ...required size All electronic unit terminals are specified from 0 08mm AWG 26 to 2 5mm AWG 14 If wire end ferrules are used the next smaller size is required Before removal of the electronic terminal cover the line voltage must be switched off The line voltage to the electronic unit must be switched on again after the cover is back in position After installation power conducting parts may not be ac...

Page 10: ...on Temp during operation Cross the probe signal cable FEP 0007 8 at right angle to any power supply cables No Function Diameter Colors Notice 1 O2 measuring cell 2 x 0 75 mm 2 white brown brown With shield 2 Thermocouple 1 2 x 0 75 mm 2 green white With shield 3 Thermocouple 2 2 x 0 75 mm 2 green white With shield 4 Probe heater 3 x 1 5 mm 2 black blue green yellow 5 Probe Solenoid valve 2 x 0 75 ...

Page 11: ...e system Switch the mains voltage on only after attaching the terminal cover After the installation has been completed live parts may no longer be accessible Figure 6 Access to the Terminals 2 4 Ferrite Sleeves EMC Caution In order to avoid cable related disturbances to the electronic unit the supplied ferrite sleeves must be used CE conformity is invalid if these ferrite sleeves are not fitted ...

Page 12: ... free 2 Potential f 3 18 A B maintenance 2 Functional earth 18 A B 4 19 A B 20 A B 21 A B 20 A B used internal 5 21 A B 6 22 A B limit Alarm 2 COe 3 Shielding 9 Probe solenoid valve 4 Power supply probe heater 48V AC 23 A Internal Power supply for probe solenoid valve 48V AC 8 23 B 23 B 9 24A 24A L 10 24B 24B N 5 O2 sensor signal 10 Measuring range O2 12 24 V DC External supply 12 25A 25A 13 25B 2...

Page 13: ...Installation and Operation Manual SILOTEC 8000 Installation Doc ID SILOTEC_11022020_EN 13 2 6 Wiring Diagram of the SILOTEC 8000 Figure 8 Wiring diagram of the SILOTEC 8000 ...

Page 14: ...Installation Installation and Operation Manual SILOTEC 8000 14 Doc ID SILOTEC_11022020_EN Figure 9 SILOTEC 8000 digital and analog signals ...

Page 15: ...Installation and Operation Manual SILOTEC 8000 Installation Doc ID SILOTEC_11022020_EN 15 Figure 10 SILOTEC 8000 solenoid valves flow meters ...

Page 16: ...Installation Installation and Operation Manual SILOTEC 8000 16 Doc ID SILOTEC_11022020_EN 2 7 Gas Plans Figure 11 SILOTEC 8000 standard gas plan ...

Page 17: ...Installation and Operation Manual SILOTEC 8000 Installation Doc ID SILOTEC_11022020_EN 17 Figure 12 SILOTEC 8000 gas plan with options ...

Page 18: ...guaranteed Before penetrating the silo roof make sure that there is enough space for installation that there are no obstructions nearby and that there are no other obstacles in the way Note the temperature limits Avoid vibrations greater than 2g Mind the IP code 2 9 Mounting the Probe Sampling filter of the analyzer Probe flange gasket Counter flange optional welded gas tight Silo roof Figure 13 M...

Page 19: ...EP 0007 8 has to be connected to the terminal board in the probe terminal box Do not connect the shield here Figure 14 Electrical connections of the probe connection box SIL KES 0001 2 11 Requirements for Pneumatic Cable FEP 0002 Note the minimum bending radius FEP 0002 Rmin 138 mm Temp during installation Temp during operation 5 C Min 50 C Max 40 C Min 90 C Max ...

Page 20: ...e reference air blue and the test gas green have to be prepared with support sleeves clamp rings and nuts Figure 15 Preparation of pneumatic tubes 2 13 Connections at the analyzer Sample gas and injector air out Solenoid valve control cable PE Pneumatic cable FEP 0002 Probe signal cable FEP 0007 Figure 16 Connections at the probe Notice The PE connection on the GFK analyzer must be connected by th...

Page 21: ...ctronic Units Figure 17 Bottom view of SME 53 with pneumatic unit Nr Tube Description 1 4 Testgas in 1 4 Testgas out 1 4 Instrument air in 1 4 Reference air out 1 4 Figure 18 SME 54 pneumatic connections Nr Tube Description 1 4 Testgas in 1 4 Testgas out 1 4 Instrument air in 1 4 Reference air out Test air adjustment valve ...

Page 22: ... tightened sufficiently Are gaskets in use See section 2 8 Installation of the probe Do the conditions at site match the specification in the data sheets See section A Technical Data 3 2 System Power Up Switch on the line voltage to the system After a short power up information the user is prompted to Select language set the System date System time enter a TAG number and ENOTEC REMOTE code only if...

Page 23: ...enu 3 4 Display Measuring Mode Figure 21 Display Measuring mode TAG number Measured values Active measuring range Blinking indicators showing under or over measuring range Last access Measured components Limit alarm indicators min Alarm max Alarm Softkey titles Only if the limit alarms are switched on and the limits are within the set measuring range 3 5 Keypad and Display Figure 22 Keypad and dis...

Page 24: ...essed which may affect the measurement Leave an area Abort a function or entry Error red is lit when a system error has occurred Select or confirm a function value 3 8 System Code Notice The system code on delivery is 0000 In this state entry into the system is granted without having to enter the system code The system code protects the system from unauthorized use Functions which may alter the me...

Page 25: ...e heater power Thermocouple input mV COe sensor temperature COe heater power mW COe heater resistance Ω COe heater voltage mV COe heater current mA Terminal temperature C F Internal temperature C F O2 sensor life Calibration results e g 2012 04 20 Choose date time Executed at Calibration method O2 sensor calibration COe sensor calibration Calibration results O2 value at test air 20 95 O2 calibrate...

Page 26: ...test gas s O2 sensor life COe voltage at test air mV COe voltage at test gas mV Device operating data Powers on counter Hours in operation Min internal temperature Max internal temperature Software version and options Software SILOTEC 8000 Options SYS MENU System configuration O2 Measuring ranges Meas range 1 from O2 Meas range 1 to O2 Meas range 2 from O2 Meas range 2 to O2 Meas range select by d...

Page 27: ...n system errors mA COe sensor calibration values COe cal value offset COe cal value alpha COe cal value beta COe cal value gamma COe cal value delta COe cal value SO2 correction value Calibration settings Time per test gas apply Min Delay time to process Min Pre purge time Min Measurement value hold on calibration ON OFF Auto calibration ON OFF Calibration method 1 Point 2 Point O2 COe visible whe...

Page 28: ...ible when ENOTEC REMOTE interface is activated ENOTEC REMOTE ON OFF Passkey 8 digit code Visible when ENOTEC REMOTE is ON Range Short Medium Maximum Measuring units Temperature C F Pressure mbar psi COe value ppm mg m 3 Probe type and cable length Probe type cable length m Language Choose language Deutsch English Spanish Polish French Russian Change system code Load factory settings Set COe measur...

Page 29: ...defines a value by which the limit alarm is activated if the measured value falls below the limit If the hysteresis is set to greater than 0 00 the limit alarm is reset when the measured value rises above the limit plus the hysteresis value The limit alarm function max defines a value by which the limit alarm is activated if the measured value rises above the limit If the hysteresis is set to grea...

Page 30: ... signal instable resp COe Sensor calibration failed COe sensor signal instable This problem can be offset by setting a longer duration The factory setting for maximal duration is 10 Minutes If necessary the time can be adjusted between 5 minutes and 30 minutes Delay time to process 4 2 9 Here the delay time showing the last measured value from the data storage is frozen after test air or test gas ...

Page 31: ...t is requested during the remote connection setup must be assigned The ENOTEC REMOTE password is used for authentication and pairing with a smartphone tablet laptop pc authentication login after every connection Without Authentication login device data cannot be read or modified The device configuration can also not be altered Range limits the transmission power of the ENOTEC REMOTE module Maximum...

Page 32: ... be set to OFF to prevent the probe from being destroyed After the replacement the COe measurement has to be switched back on manually Once the COe measurement is switched ON the user is queried whether or not the COe sensor has been exchanged If this is confirmed the user is then prompted to enter the following sensor calibration values which can be found on the COe sensor test certificate COe RH...

Page 33: ... sensor mV COe sensor mV ppm Flow rate 3 bar max l h Source Process O2 sensor mV COe sensor mV ppm Check mA outputs Set mA output 17A B mA Set mA output 34A B mA Check relay outputs Relay contact at 18A B opened closed Relay contact at 19A B opened closed Relay contact at 20A B opened closed Relay contact at 21A B opened closed Relay contact at 22A B opened closed Check digital inputs Input status...

Page 34: ...lay overview Here an O2 COe 1 point calibration Maximum measuring range is depicted display jumps between O2 and COe Representation of measured O2 value Representation of measured COe value Time scale showing the elapsed time of the current calibration process The amount in seconds here 240 s refers to the end of the time scale The flow rate currently measured Current measured value of O2 and COe ...

Page 35: ... in the process and the O2 concentration with test air is more than 3 00 7 Prompt to enter test gas concentration does not apply to test air 8 Display of the calibration results max 1 minute 9 Maintenance LED switches off is delayed by the set value in Delay time to process if Meas Value hold on cal is set ON 10 Revert to main display 2 point calibration O2 and or COe manual 4 4 3 During the 2 poi...

Page 36: ... 5 A 250 V AC T L 5x20 mm F5 115 230 V AC 1 0 A 250 V AC M L 5x20 mm F1 230 V AC 2 0 A 250 V AC T H 5x20 mm F1 115 V AC 4 0 A 250 V AC T H 5x20 mm F2 115 230 V AC 4 0 A 250 V AC M H 5x20 mm 5 2 Pressure and flow rates The systems are factory set to the correct flow rate for test air and or reference air The instrument air versions are designed for an inlet pressure of 2 10 bars With a higher inlet...

Page 37: ...ectronic unit showing the position of the test air valve 5 4 Adjusting Flow Rate SME 54 19 rack With systems in 19 racks the test air quantity can be adjusted at the back of the electronic unit In systems with integrated pneumatics unit the flow rate can be seen in the menu Actual measured values Test air adjustment valve Figure 31 SME 54 19 rack analyzer Adjusting the flow rate ...

Page 38: ...king on the Measuring Cuvette Warning hot Surface During operation the test gas inlet and outlet are directly connected to the heated cuvette The surface temperature of the sample gas inlet and outlet connections may exceed 100 C Direct contact with the hot parts for dismantling or maintenance will cause severe burns The cuvette may only be removed with heat insulated gloves Before removing the cu...

Page 39: ...gure 33 Loosen the cuvette mounting Remove the cuvette Figure 34 Remove the cuvette Loosen the pipe clamps and remove the insulation from the cuvette Abb 35 Remove the cuvette insulation Replace the cuvette inner part 5 6 1 Carry out the procedures as described in chapter 5 6 to remove the measuring cuvette Remove the 2 screws of the retaining bolt Carefully pull out inner part of probe Abb 36 Rep...

Page 40: ... remove the cap nut Loosen the clamping ring the O ring and the retainer ring Pull the COe sensor out of the probe Take care The COe sensor may be hot Figure 38 Remove the COe sensor Figure 39 Prepare the new COe sensor Prepare the new COe sensor as follows Take the clamping ring the O ring retainer ring and the cap nut and cover them over the COe sensor Note Mind the position of the bevel Bevel m...

Page 41: ...rs have to be checked according to the process specific time intervalls At filter check and filter change check the filter tightness and the lock nut Tightening torque 250 Nm 5 8 Blow back optional The SILOTEC 8000 system has an optional blow back module The option includes a 4 l purge tank filled with instrument air at operating pressure two timer relays controlling the purge process and a soleno...

Page 42: ... 2 i X5 20A B Probe valve Normally closed Triggering of the probe valve X5 24A B Limit value 1 Normally closed Signals a violation of limit value 1 X5 21A B Limit value 2 Normally closed Signals a violation of limit value 2 X5 22A B The relay system error is active also during the heating phase The relay contact for the probe valve is designed for max 230V and 1A Figure 41 Relay plate with marked ...

Page 43: ...flow greater than 60 l h power supply too low flow rate too high and or temperature in the process too low electronic failure O2 probe temperature too high System error open 2 00 mA when not set differently The error can occur during measurement indicating that the O2 sensor temperature has risen 20 C 68 F above the set point temperature The O2 sensor heater is switched off An error reset can be c...

Page 44: ...f COe sensor heater A reset can be carried out by the user once the fault has been remedied Possible causes contact problems between COe sensor cable and terminal points of the electronics respectively the probe probe cable is damaged defective COe sensor Open circuit COe sensor heating 20 80mA unless set otherwise The error can occur at any time and signals a break in the circuit of COe sensor A ...

Page 45: ...mperature of the transmitter is higher than the specified upper limit The specified measurement tolerances are no longer guaranteed Clock battery low The alarm can only be reset by the user after replacing the clock battery Lithium type 2032 As long as the system is connected to AC power the alarm has no impact Only after restarting system will the time date be incorrect A possible timed automatic...

Page 46: ...e measuring range Measure the mA output on the strip terminal O2 Display Indicates 0 although the Process Operation Mode expects a higher O2 Value Possible reasons Procedure Measuring probe heater defective resistance must be approx 37 5 47 5 Ohm disconnect probe and check Check the measuring cell temperature set value 800 C 1472 F A lower temperature could have the effect of showing a value of 0 ...

Page 47: ...n the terminal box housing If the stainless steel nut is not tight enough the O ring seal allows ambient air to enter into the COe senor mounting tube which influences the sensors readings Tighten or replace the COe sensor coupling assembly No COe Measuring Value Arrow instead of a value Possible reasons Procedure The physical measuring range has been exceeded Perform a O2 COe sensor check An erro...

Page 48: ...ed value or 0 02 Vol O2 higher value valid COe measuring range 1 range from 0 to 5000 ppm COe others on request Mains Voltage 230 V AC 10 50 Hz to 60 Hz 115 V AC 10 50 Hz to 60 Hz Power consumption 425 VA heating phase 225 VA typical measuring mode Recommended fuse 10 A Output signal O2 active 0 4 mA to 20 mA max load 500 Ω galvanically isolated Output signal COe active 4 mA to 20 mA max load 500 ...

Page 49: ...Oe Process gas pressure 50 mbar 0 725 PSIG to atmospheric pressure Ambient temperature 20 C to 55 C 4 F to 131 F other on request Reaction time O2 1 s with test gas T90 O2 5 s with test gas Probe material stainless steel SS316 GRP transmitter with reduced surface resistance enclosure according to EN 60079 0 Protection class SIL KES 0001 IP65 for installation in Zone 22 Power supply Through electro...

Page 50: ...0 1 mg m3 Oil content Max 0 1 mg m3 Pressure dew point 20 C Inlet pressure 4 8 bar Instrument air as reference air supply test air supply Quality ISO 8573 1 Class 2 O2 content 20 95 vol Test gas 1 instrument air synthetic air Quality ISO 8573 1 Class 2 O2 content 20 95 Vol 2 Balance N2 Test gas 2 O2 Inlet pressure max 3 bar Flow rate 40 80 l h at 1 1 bar 0 1 Quality ISO 8573 1 Class 2 O2 content 2...

Page 51: ...ngs Doc ID SILOTEC_11022020_EN 51 B Dimensional drawings B 1 Electronic units dimensions Figure 42 Dimensions mm of the electronic unit SME 53 Figure 43 Dimensions mm of the electronic unit in 19 rack SME 54 Figure 44 Dimensions mm of the Optional SME 56 GRP Cabinet ...

Page 52: ...Dimensional drawings Installation and Operation Manual SILOTEC 8000 52 Doc ID SILOTEC_11022020_EN B 2 Probe dimensions B 3 Probe inner part SIK 5001 Figure 45 SIK 0501 probe inner part ...

Page 53: ... 0 P 001350 3 Flow Meter 0 P 001349 4 Non return valve throttle optional 0 P 001508 5 Air Injector 0 P 001374 6 3 2 way solenoid seat valve 0 P 001934 7 2 2 way solenoid valve optional 0 P 001947 8 Compressed air tank optional 0 P 001946 9 Gas sampling probe SIL GSF 8000 10 Pressure regulator 0 P 000752 11 Measuring cuvette SIL KES 0001 NM activated carbon filter optional 0 P 001956 12 exhaust sil...

Page 54: ...Test gas solenoid valve P01 for SME53 with pneumatic unit and fittings PGM 0002 Test gas solenoid valve P02 for SME5 with instrument air unit and fittings DFM 0001 Internal flow meter 0 P 000752 Pressure regulator Figure 47 Mounting plate 1 version with instrument air Mounting Plate 2 instrument air version ENOTEC Part No Description 0 L 000107 COe sensor board 0 L 000180 Power board Figure 48 Mou...

Page 55: ...TRA 00017 Toroid transformer 2x115V sec 115V 330VA DFM 0001 Internal flow meter for reference air and test gas SME5 PGM 0001 Solenoid valve for test gas P01 0 L 000180 Power board 0 L 000100 COe sensor board PGM 0002 Solenoid valve for test gas P02 Figure 49 Mounting plate with instrument air Version A and Version 1 C 4 Display Board ENOTECPart No Description 0 L 000169 SILOTEC 8000 display board ...

Page 56: ... inadequate maintenance and non compliance with the operating instructions All ENOTEC products and systems which incorporate a heated sensor must be operated under continuous conditions If the heater power is switched off and on regularly the resultant thermal stress for the probe heater probe thermocouple and sensor will cause a shorter life span If it is not possible to operate the heated equipm...

Page 57: ...system zur Siloüberwachung Relevant EU directives relevante EU Richtlinien 2014 34 EU ATEX directive ATEX Richtlinie 2014 30 EU electromagnetic compatibility EMC EMV Richtlinie 2014 35 EU low voltage directive Niederspannungsrichtlinie 2014 53 EU radio and telecommunications terminal equipment directive 1985 374 EWG product liability directive Produkthaftungsrichtlinie 2011 65 EU RoHS directive Ro...

Page 58: ...ue 2 41 M Mains voltage 47 Measuring Principle 5 Menu Explanations Time per test gas apply 29 N Name Plates 9 P Position of the adjustment valves 36 Power consumption 47 Pressure and Flow rates 36 probe valve 41 R Recommended fuse 47 Relay outputs 41 Remove the cuvette 38 S Safety Hazards 6 Sondeninnenteile 51 Spare Parts Display Board 54 Mounting Plates of 19 Rack 54 Mounting Plates of SME 53 Ele...

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