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Installation and Operation Manual – AQUATEC 1000 

Service and Maintenance

 

Doc.-ID: AQUA_16012020_EN 

33 

5.7 

Replacing the O

2

 Sensor 

 

Warning Hot Surface 

 

 

The probe may only be removed with heat-insulated gloves. Before removing the probe, always switch off the supply 
voltage to the electronic system. After removal, store the probe in a safe, protected place and wait until it has cooled 
down below 35°C/ 95°F. 

 

 

Note  

 
An exchange of the measuring cell is only necessary if the cell is leaking (erratic or incorrect measured values). 

 

 

 

Disconnect the wires in the connection 
head and loosen the 2 torx screws, which 
hold the inner parts of the tube. Pull off 
the thin transparent reference air pipe 
from the entry fitting at the connection 
box.  
Pull out probe internal assembly carefully  
(4-hole ceramic rod with signal measuring 
wire, thermocouple element and heater)  
 
Unscrew the 4 torx screws at the 
measuring cell holder with flange and 
remove the measuring cell. 
 
 

 
Figure 33 

- O

2

 sensor replacement 

 

Clean the flange at the probe tube with fine sandpaper. Tighten the new measuring cell with a new metal gasket  
sealing and four new screws at the measuring cell flange of the probe tube. Insert the probe inner parts and ensure 
that the inner parts do not bind in the probe tube. Press the locking bolt against the spring, so that the inner parts  
assembly is pressed against the measuring cell with enough spring tension. 

Tighten locking bolt and connect wires as follows: 

Terminal  Color 

Description 

Polarity 

Unit 

1 

White/brown 

signal wire, measuring cell 

- 

mV 

2 

Brown 

signal wire, measuring cell 

+ 

mV 

3 Green thermocouple 

element 

+  mV 

4 White thermocouple 

element 

-  mV 

6 

Black 

heating element  

 

 

7 

Blue 

heating element  

 

 

8 green/yellow 

ground/earth 

heater 

   

9 

Grey 

solenoid valve (optional) 

 

 

10 

Grey / blue 

solenoid valve (optional) 

 

 

 

Install the probe; wait for the system to reach its operating temperature. Carry out an O

2

 two point calibration after  

24 hours of operation. 

Содержание AQUATEC 1000

Страница 1: ...Doc ID AQUA_16012020_EN Installation and Operation Manual O2 and water vapor analyzer system AQUATEC 1000 Version 04 for Software Version 4 10 ...

Страница 2: ...UATEC 1000 oxygen and water vapor analyzer system is very easy and user friendly and will provide you with many years of operation with perfect measuring results Symbols used in this Manual All symbols listed beneath attached to the analyzer or noted in this manual show important information as well as safety instructions for installation operation and maintenance to protect the personnel and the ...

Страница 3: ...me to process 24 4 2 8 Automatic Calibration ACAL 24 4 2 9 Automatic Calibration Settings 24 4 2 10 Bluetooth 25 4 2 11 Measuring units 25 4 2 12 Language 25 4 2 13 Change system code 25 4 2 14 Load factory settings 25 4 2 15 Service Factory Service Settings 25 4 3 Calibration Menu 26 4 3 1 Calibration Menu Display Overview 26 4 3 2 1 point calibration manual 27 4 3 3 2 point calibration manual 27...

Страница 4: ...o 55 C 4 F to 131 F In situ measuring probe IP65 Safe Area Max ambient temp 20 C to 80 C 4 F to 167 F Pneumatic cable Process O2 probe signal cable Process gas direction max flue gas temp 200 C 392 F Solenoid valve Optional Manufacturer supply Counter flange Optional Customer supply Isolation Customer Test gas in Duct wall Power supply Instrument air in Reference air in for pump systems Output sig...

Страница 5: ...situ measuring probe IP65 Safe Area Max ambient temp 20 C to 80 C 4 F to 167 F Pneumatic cable Process O2 probe signal cable Process gas direction max flue gas temp 400 C 752 F Solenoid valve Optional Manufacturer supply Counter flange Optional Customer supply Isolation Customer Test gas in Duct wall Power supply Instrument air in Reference air in for pump systems Output signals analog and digital...

Страница 6: ...r evaluation is represented as follows see chapter 3 9 for details 1 4 Intended use Info The AQUATEC 1000 analyzer system is a system for measuring the oxygen O2 concentration in non combustible process gases and to calculate the water vapor content H2O using the oxygen concentration Warning The system cannot be used to determine the oxygen concentration of combustible gases or in a location where...

Страница 7: ... their product life ENOTEC will not accept any responsibility for resultant damage 1 7 Storage instructions ENOTEC equipment is to be stored in a dry and ventilated environment Paint fumes silicone sprays etc must be avoided in the storage environment 1 8 Name Plates The name plate contains information about the line voltage the nominated current frequency protection class year of manufacture seri...

Страница 8: ...ls are specified from 0 08 mm AWG 26 to 2 5 mm 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 accessible 2 1 Installation Requirements ...

Страница 9: ...ly cables Figure 5 Probe cable FEP 0001 Probe Cable FEP 0001 FEP 0004 armored version No Function Diameter Colors Additional info Measuring cell 2 x 0 75 mm2 white brown brown With shield Thermocouple 2 x 0 75 mm 2 green white With shield Probe heating 3 x 1 5 mm2 black blue green yellow Solenoid valve 2 x 0 75 mm2 grey grey blue Caution The shield of the probe cable must only be connected at the ...

Страница 10: ... 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 ...

Страница 11: ...on contacts 1 3 2 N neutral wire 3 PE grounding conductor 18 A B Maintenance Internal Power supply 1 19 A B System Error 4 L phase 20 A B Output A O2 measuring range 5 N neutral wire 21 A B O2 Limit Alarm 1 6 PE grounding conductor 22 A B O2 Limit Alarm 2 Shielding Probe solenoid valve Power supply probe heater 115V 23 A Internal Power supply for probe solenoid valve 115VAC 8 L black 23 B 9 N blue...

Страница 12: ...Installation Installation and Operation Manual AQUATEC 1000 12 Doc ID AQUA_16012020_EN 2 6 AQUATEC 1000 Wiring diagram Figure 8 Wiring diagram of the AQUATEC 1000 Analyzer system ...

Страница 13: ...or any obstacles are in the way For probe lengths exceeding 2000 mm a support must be mounted inside the duct every 2m to prevent the probe and mounting tube from flexing or bending ENOTEC recommends installing the probe horizontally for the fastest possible response time Maintain the protection class Avoid vibrations greater 2g 2 8 Mounting of the Probe The mating flange must be welded at the spe...

Страница 14: ...his purpose by loosening the counter nut loosening the Allen screw and rotating the filter head V shield to the required position and then tightening the Allen screw and counter nut Flue gas direction V shield KES 132X KES 200X V shield KES500X Screws to secure filter head Filter head Rotation of filter head Probe Figure 11 Adjustment of the V shield Loosen the locknut Loosen the locknut Adjust th...

Страница 15: ...nsor white brown 2 mV O2 sensor brown 3 mV thermocouple 1 green 4 mV thermocouple 1 white 6 L 115VAC heater black 7 N 115VAC heater blue 8 PE Protection earth green yellow 9 L 115VAC solenoid valve grey 10 N115VAC solenoid valve grey blue Figure 13 Electrical Connections of the Probe connections box 2 11 Requirements for Pneumatic Cable FEP 0002 Note the minimum bending radius FEP 0002 Rmin 138 mm...

Страница 16: ...tion of pneumatic tubes 2 13 Gas plans Pneumatic version for Instrument air SME 50000010 Pneumatic version with pumps SME 50000020 Figure 15 Gas plans Pressure control valve Filter Choke non return valve Choke non return valve Solenoid valve 3 2 ways Reference air pump Test air pump Solenoid valve 3 2 ways Solenoid valve 3 2 ways Flow meter Flow meter Instrument air in 4 10 Bar Reference air in Te...

Страница 17: ...EP 0002 green tube Figure 16 Pneumatic connections of the probe 2 15 Pneumatic Connections of the Electronic Unit Figure 17 Bottom view of SME 53 with integrated pneumatic unit Nr Tube Pump version Instrument air version 1 4 Testgas in Testgas in 1 4 Testgas out Testgas out 1 4 Reference air input Instrument air in 1 4 Reference air output Reference air out 1 4 Test air input ...

Страница 18: ...on in the data sheets See section A Technical Data Has the O2 reference value been entered into the system See section 3 9 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 and System time The probe heating phase now begins which is followed by the measuring mode Figure 18 System Power up Note...

Страница 19: ...Select or confirm a function value 3 8 System Code Info 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 measurement of O2 are therefore also protected Caution If the system code has been altered it must be kept in a safe place 3 9 Adjust...

Страница 20: ...temperature C F Process pressure rel mbar psi O2 sensor life Lambda Calibration results e g 2012 05 11 Choose date time Executed at Calibration method O2 sensor calibration Calibration results O2 value at test air 20 95 O2 calibrated to O2 O2 value at test gas O2 only if determined calibrated to O2 Calibration data O2 sensor offset mV O2 sensor slope mV dec only 2 point calibration Test gas data T...

Страница 21: ...pm O2 Meas range 2 from O2 ppm O2 Meas range 2 to O2 ppm O2 Meas range select by dig input keypad Meas value averaging for s Conversion wet dry H2O mA output type 0 20 mA 4 20 mA mA output on system error mA O2 limit alarms O2 limit alarm 1 OFF ON at visible when set to ON hysteresis O2 limit alarm 2 OFF ON at visible when set to ON hysteresis O2 sensor calibration values O2 cal value offset mV O2...

Страница 22: ...g Input both visible when set to ON Interval days not applicable with dig input next ACAL at set date Pressure compensation Pressure input from mbar Pressure input to mbar Location altitude m System date time System date jjjj mm tt System time hh mm ss TAG ENOTEC REMOTE settings optional Visible when ENOTEC REMOTE interface is activated ENOTEC REMOTE ON OFF Passkey 8 digit code Visible when ENOTEC...

Страница 23: ...entry sets the duration for the continuous average measurement flowing average During a calibration or sensor verification the measurement average is not shown though still active for the analogue output 4 2 3 mA output on system errors The mA output value for a system error is specified in range of 0 3 55 mA or 20 41 to 20 80 mA The mA output value for a system error cannot be set in the mA measu...

Страница 24: ...olled calibration using the digital input of the O2 sensor The ACAL can be globally switched on or off and can only be started from the main screen of the display When a 2 Point ACAL is set a test gas bottle must be permanently connected and turned on Info Make sure that the test air and test gas volume and flow settings needed for calibration are correct For systems with flow monitoring The flow ...

Страница 25: ...again SYS MENU System configuration ENOTEC REMOTE Settings which will reset the module All previously paired users will need to delete their saved connection to the analyzer and re pair their devices 4 2 11 Measuring units Measuring units can be set for temperature C F and pressure mbar psi 4 2 12 Language Set the language for all text shown on the display One can choose between English German Spa...

Страница 26: ...f a 2 point calibration Test Gas apply Test Air apply and Return to Process gas The max adjustable measuring range Trend representation of measured O2 value and O2 target value The target value is determined by the O2 concentration in the test gas test air Time scale showing the elapsed time of the current calibration process The amount in seconds here 120 s refers to the end of the time scale The...

Страница 27: ... 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 4 3 3 2 point calibration manual During the 2 point calibration of the sensor the calibration offset and slope is determined Hereby two gases are applied to the sensor test air and test gas In systems without inte...

Страница 28: ...ensor mV Flow rate 3 bar max l h Source Process O2 sensor mV Flow rate l h 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 at 25A B Input status a...

Страница 29: ...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 Flow rates for Test Air and Reference Air The systems are factory set to the correct amounts of test air and or reference air The instrument air versions are designed for an inlet pressure of 1 10 bar With a higher inlet pressure of 6 bar it i...

Страница 30: ...p and instrument air versions are different In the pump version ambient air is used Only the flow rate of test air can be adjusted The instrument air version requires an external supply of clean dry and oil free air instrument air Both flow rates test air and reference air can be adjusted In systems with integrated pneumatics unit the flow rate of reference air can be seen in the menu actual measu...

Страница 31: ...may only be removed with heat insulated gloves Before removing the probe always switch off the supply voltage to the electronic system After removal store the probe in a safe protected place and wait until it has cooled down below 35 C 95 F Note Only cemented ceramic basalt and sintered metal filters can be replaced 5 5 1 Remove old Filter Loosen the holding screws Clamp the filter head in a vice ...

Страница 32: ...d metal filters supplied by can be inserted and fixated 5 6 Replacing the probe Warning Hot Surface The probe may only be removed with heat insulated gloves Before removing the probe always switch off the supply voltage to the electronic system 1 Disconnect the wires at the probe connection box 2 Loosen the bolts connecting the probe to the counter flange and remove the probe 3 Insert the replacem...

Страница 33: ...torx screws at the measuring cell holder with flange and remove the measuring cell Figure 33 O2 sensor replacement Clean the flange at the probe tube with fine sandpaper Tighten the new measuring cell with a new metal gasket sealing and four new screws at the measuring cell flange of the probe tube Insert the probe inner parts and ensure that the inner parts do not bind in the probe tube Press the...

Страница 34: ...sconnect the wires in the connection box and loosen the 2 allen screws which hold the inner parts of the probe Pull off the thin transparent reference air pipe from the entry fitting at the connection box Pull out probe internal assembly carefully 4 hole ceramic rod with signal measuring wire thermocouple element and heater 5 9 Exchange of Thermocouple Element The thermocouple element is a covered...

Страница 35: ...t this hole will be sealed with cement This avoids the thermocouple touching the signal wire and causing a short circuit If the heater support is changed the hole of the thermocouple in the heater support has to be sealed with cement after the insertion of the thermocouple as well 5 11 Exchange of Signal Measuring Wire The signal measuring wire has a specially shaped contact for taking the mV valu...

Страница 36: ... B Probe valve Normally open 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 Relay outputs and functions 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 36 Relay pla...

Страница 37: ...ria The last measured value is always temporarily saved When the next value is outside the tolerance the internal timer is reset and the new value temporarily saved This means that if the timer was not reset the value is stable In this way the last measured value after the timer has elapsed 2 min is used to calculate the cell constant or slope 5 16 Reaction Time of the mA Output The reaction time ...

Страница 38: ...ow 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 car...

Страница 39: ...EMOTE module System error open Indicates a hardware error of the REMOTE module Possible cause the REMOTE module is defective Unlisted errors Other errors cannot be remedied by the customer Please contact a service point 6 2 Alarm Messages Error Message Relay contact Description Reference air flow too low Possible Cause reference air flow set incorrectly instrument air supply is inadequate referenc...

Страница 40: ...eck measuring range Check whether the current value is outside the 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...

Страница 41: ... measured value Response time Change of 100mV at sensor input 200ms Manual or ACAL Automatic calibration 1 or 2 point automatic calibration Mains Voltage 230V 10 50 to 60 Hz 115V 10 50 to 60 Hz see Name Plate Power consumption 400 VA heating phase 200 VA typical measuring mode Recommended fuse 10A Output signal O2 Active 0 4 to 20 mA max load 500 Ω Galvanically isolated Relay contact 24 V AC DC 1 ...

Страница 42: ...ciple Zirconium oxide Operating temperature O2 sensor 800 C Raw signals from O2 sensor Air 20 95 O2 0 mV 1mV 2 1 O2 50 mV 1 mV O2 Sensor Reference Air Instrument air 40 l h Adjustment at SME 53 Process gas pressure 50 to 50mbar Flow Velocity 0 to 50m s Ambient temperature 40 C to 80 C Reaction Time 0 5s Process flow velocity 10m sec T90 5s Process flow velocity 10m sec Probe material V4A DIN 1 457...

Страница 43: ...8573 1 class 2 Particle size max 1 m Particle density max 1mg m Oil content max 0 1mg m Pressure dew point max 20 C Constant 20 95 Vol O2 Input pressure 2 10 bar Flow rate continuously maximum 40 l h for reference air supply 180 l h during calibration Test gas test gas bottle for calibration system test Input pressure max 3 bar Specification test gas 1 optional 21 Vol O2 in N2 synthetic air in cas...

Страница 44: ...d Operation Manual AQUATEC 1000 44 Doc ID AQUA_16012020_EN B Dimensional drawings B 1 Dimensions of Electronic Unit Housing versions Figure 36 Dimensions in mm of the SME 53 B 2 Probe Dimensions Figure 37 Dimensions of the KES 132X probes ...

Страница 45: ...l AQUATEC 1000 Dimensional drawings Doc ID AQUA_16012020_EN 45 Figure 39 Dimensions in mm of the KES 132X probes with KES 1320600AK active carbon filter B 3 Counter Flange Dimensions Figure 38 Dimensions of counter flange for KES 132X ...

Страница 46: ...Dimensional drawings Installation and Operation Manual AQUATEC 1000 46 Doc ID AQUA_16012020_EN B 4 Dimensions of protection tube flanges Figure 39 Dimensions of protection tube flanges ...

Страница 47: ...s KES 132X Figure 40 KES 132X Probe Components No Part Part No 1 Connection Box ASK 1001 2 Measuring probe tube MSR 132X 2a Probe flange gasket FLD 132X 3 Probe inner part SIK 132X 4 Oxygen measuring cell ZO2 00 0 1 1 4a Measuring cell gasket MZD 0001 5 Filter head KES 1320X00 6 Test gas valve Solenoid valve KES 13200X0 ...

Страница 48: ...depends on probe type KES 1321 2 KES 1323 1 Heater support tube HZH 00002 HZH 00002 2 Heater HEI 132X HEI 2001 3 heater clamp 0 R 000474 0 R 000474 4 Distance sleeve 0 R 000201 5 Ceramic rod KER 132X KER 2001 6 Tube clamp 0 R 000500 0 R 000500 7 Spring 0 R 000044 0 R 000044 8 Thermocouple MT2 132X MT2 2001 9 Reference air hose RLS 0001 RLS 0001 10 Signal wire MSD 132X MSD 2001 11 Reinforcement pro...

Страница 49: ... Restrictor one way DFM 00001 Internal flow meter for reference air and test gas SME5 PLU 0025 Reference air pump for SME5 30l h Figure 43 Mounting plate 1 version with pumps Parts List Test gas and reference air unit for instrument air TRA 0017 Transformer primary 2 115V sec 115V PGM 0001 Test gas solenoid valve P01 for SME53 with pneumatic unit and fittings PGM 0002 Test gas solenoid valve P02 f...

Страница 50: ...d PLF 0003 Filter for reference air and test air for version with internal pumps Figure 45 Mounting plate 2 C 4 Display Board Figure 46 Display board Parts List Display Board 0 L 000035 SME5 display board without pneumatic 0 L 000036 SME5 display board with pneumatic 0 L 000108 SME5 display board with CSP with pneumatic 0 L 000110 SME5 display board with RS232 with pneumatic ...

Страница 51: ...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 equipme...

Страница 52: ...uing this declaration Manufacturer ENOTEC GmbH Höher Birken 6 51709 Marienheide Germany Tel 49 2264 45 78 0 Product model System OXITEC 5000 OXITEC Economy Electronic units SME 53 SME 54 Probe types KES 1000 KES 132X KES KIS 200X KES 500X Description InSitu oxygen analyzer system Relevant EC directives 2014 30 EU electromagnetic compatibility EMC 2014 35 EU low voltage directive 2014 53 EU radio a...

Страница 53: ...ange of Probe Inner Parts 34 F Ferrite Sleeves 10 I Installation Electronic Unit 8 Probe signal cable 9 Installation of the probe 13 L Language settings 25 M Mounting Plates of the Electronic Unit 49 N Name Plate 7 Name Plates 7 P Pneumatic Connections Probe 17 Position of the adjustment valves 31 Pressure and Flow rates 30 Probe Components 47 Probe inner parts 48 probe tube 33 R Relay outputs 36 ...

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