Extractive Beta Gauge Particulate Monitor...

F-904-20 Rev. 32 04/2011

Umwelt- und Prozeßmeßtechnik GmbH

Kollaustraße 105 ⋅ D-22453 Hamburg ⋅ Tel: +49/40/554218-0 ⋅ Fax: +49/40/584154

Extractive Beta Gauge Particulate Monitor F-904-20

Technical Manual

F-904-20 Rev. 31


Table of Contents 1. Design and Function ...................................................................................................... 1 2. Measurement Principal .................................................................................................. 2 3. Determination of Dust Mass .......................................................................................... 2 4. Mounting ......................................................................................................................... 4

4.1. Site Preparation ....................................................................................................... 4 4.2. Mounting Instructions ............................................................................................... 6

4.2.1. Sample gas probe ................................................................................................. 6 4.2.2. Measuring instrument (standard cabinet) ............................................................... 7

5. Start up ........................................................................................................................... 8 6. Operating ...................................................................................................................... 10

6.1. The Terminal .......................................................................................................... 10 6.2. The Main Menu ...................................................................................................... 12 6.3. Manual Mode ......................................................................................................... 13 6.4. Operation ............................................................................................................... 15 6.5. Operation Display ................................................................................................... 16 6.6. Service Menu ......................................................................................................... 17 6.7. Reference Mode..................................................................................................... 22 6.8. Device Interface ..................................................................................................... 23 6.9. Error Messages, possible causes and solutions ..................................................... 24 6.10. Status Messages .................................................................................................... 28 6.11. Analogous Measurement Value Outputs ................................................................ 28 6.12. Inputs ..................................................................................................................... 29 6.13. Option isokinetic sampling ...................................................................................... 32

7. Technical Specifications .............................................................................................. 33 8. Geräteparameter im Auslieferungszustand (Factory Settings) ................................. 34 9. Equipment - Summary ................................................................................................. 35

9.1. Connections (E/A) for the Beta- Dust Monitor (standard cabinet) ........................... 35 9.2. Interface for the Customer ...................................................................................... 36 9.3. Device Views (Standard cabinet) ........................................................................... 39 9.4. Flowchart (standard application) ............................................................................ 43 9.5. Flowchart (BFG application) ................................................................................... 44

10. Service Documents ...................................................................................................... 46 10.1. Some pictures of the measuring instrument ........................................................... 46

10.1.1. Sample probe ...................................................................................................... 46 10.1.2. Measuring instrument .......................................................................................... 52

10.2. Instruction for Changing a Filter Roll ...................................................................... 66 10.3. Wiring Diagrams ..................................................................................................... 73 10.4. Characteristics for dimension of the probe nozzle size ........................................... 74 10.5. Shut-off and Purge Features (Y13)......................................................................... 75 10.6. 2/2- Way- Solenoid Valve Type 404 (Y2, Y14) ....................................................... 82 10.7. Shut off valve exhaust back flow (Y15) ................................................................... 85 10.8. Pressure Transducer P82R (B3, B4) ...................................................................... 87 10.9. Vacuum Pump Specifications (M3) ........................................................................ 96

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10.10. Motor Regulating Valve for bypass control of the vacuum pump (Y3) ................... 103 10.11. Motor Regulating Valve for dilution air control(Y4) ................................................ 104 10.12. Pressure Switch Specifications (S3) ..................................................................... 111 10.13. Electric trace heated sample line .......................................................................... 117

10.13.1. Electric trace heated sample line type 1 ................................................... 117 10.13.2. Electric trace heated sample line type 2 and 3 ......................................... 118 10.13.3. Electric trace heated sample line type 4.0 ................................................ 119 10.13.4. Electric trace heated sample line type 4.1 ................................................ 120 10.13.5. Electric trace heated sample line type 4.2 ................................................ 121 10.13.6. Electric trace heated sample line type 4.3 ................................................ 122 10.13.7. Electric trace heated sample line type 5.0 ................................................ 123 10.13.8. Electric trace heated sample line type 5.1 ................................................ 124 10.13.9. Electric trace heated sample line type 5.2 ................................................ 125 10.13.10. Instructions for installation ........................................................................ 126

10.14. Sample Gas Probe ............................................................................................... 134 10.15. Peristaltic pump for condensate (M7) ................................................................... 138 10.16. Sample gas chiller ................................................................................................ 140 10.17. Maintenance Schedule ......................................................................................... 143 10.18. Calculation of tape consumption in the F-904-20 .................................................. 147

11. German equivalency test published in GMBI ........................................................... 148 12. EC-Declaration of Conformity / EN 50081-1 und EN 50082-2 .................................. 149 13. Order Numbers for Consumables and Spares ......................................................... 150 14. Factory testing Protocol ............................................................................................ 154

Illustrations Illustration 1: Cabinet for the instrument (front view) ............................................................ 39 Illustration 2: Cabinet for the instrument (left side view) ....................................................... 40 Illustration 3: Cabinet for the instrument (top view) .............................................................. 41 Illustration 4: Sample probe, complete ................................................................................. 46 Illustration 5: Nozzle of standard probe ................................................................................ 47 Illustration 6: Nozzle for small hole and BFG applications .................................................... 47 Illustration 7: Mounting position (part inside of the stack) ..................................................... 48 Illustration 8: Mounting of assembly parts (outside of the stack) .......................................... 48 Illustration 9: Connection of lines and wires ......................................................................... 49 Illustration 10: Isolation of upper part ................................................................................... 49 Illustration 11: Isolation of lower part .................................................................................... 50 Illustration 12: Isolation, fixed ............................................................................................... 50 Illustration 13: Extra isolation (for outdoors) ......................................................................... 51 Illustration 14: Complete instrument (standard) .................................................................... 52 Illustration 15: Complete instrument (BFG application) ........................................................ 53 Illustration 16: Display and keyboard ................................................................................... 54 Illustration 17: 3-way-ball-valve (cover removed) ................................................................. 54 Illustration 18: Filter holder, complete .................................................................................. 55 Illustration 19: Side of filter tape supply and deflection ......................................................... 55 Illustration 20: Side of filter tape take-up and transport ........................................................ 56

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Illustration 21: Cabinet with open swinging frame ................................................................ 57 Illustration 22: Cabinet with open swinging frame (BFG application) .................................... 58 Illustration 23: Mounting sheet, top part ............................................................................... 59 Illustration 24: Mounting sheet, lower part ............................................................................ 59 Illustration 25: Bottom part with transformer for the probe, gas chiller and sample pump ..... 60 Illustration 26: Mounting sheet (special application) ............................................................. 61 Illustration 27: Top view with connecting-IN/OUT ................................................................. 62 Illustration 28: Top view with sample gas inlet and cabinet fan ............................................ 62 Illustration 29: Filter-Inlet with cover installed ....................................................................... 63 Illustration 30: Instrument with door closed .......................................................................... 64 Illustration 31: Instrument with door closed (BFG application) .............................................. 65 Illustration 32: Sample gas probe (A up to 1000mm).......................................................... 135 Illustration 33: Sample gas probe (A ≥ 1000mm) ............................................................... 136 Illustration 34: Flange ......................................................................................................... 137 Illustration 35: Sample Gas chiller (front, tube connectors) ................................................ 141 Illustration 36: Sample Gas chiller (top, without cover) ....................................................... 142

Equations and tables (Equation1) Calculation of dust mass ..................................................................................... 3 (Equation 2) Relationship Atomic number to Mass number .................................................... 3 (Table 1) The relationship between Ordinal number/ Mass number ....................................... 3 (Equation 3) Hydraulic diameter ............................................................................................. 4

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1. Design and Function The Beta Dust Monitor F-904-20 consists of a sampling-system and a measurement device.

The sampling-system, with or without the dilution system, consists of a sampler probe (chap-ter 10.14. ) and sampler line. The sampling system is heated to avoid drops in dew point. T he method behind heating the sampling system is the principle of low voltage re-sistance heating. The sampling system presents an ohmic resistance. A low voltage trans-former carries current through the sampler hose and facilitates the warming. There is anoth-er method that heats the sampling hose through an encased heating tube. It is then possible to establish the pipe temperature either with a pre-configured installable regulator or a self-regulated heating system equipped with a pre-set temperature.

The sampler is constructed of titanium because it gets in contact with the gases (stack or exhaust). The heating exclusively follows the principle of low voltage resistance heating.

For the heating of the sampler system, there are the following variations:

- The sampler line will be operated (depending on length) in connection with the sampler probe following the principal of low voltage resistance heating. This allows the sampler probe and the sampler line (lines for total volumetric flow and dilution air volumetric flow) to be joined gas-tight and electrically with each other and form a closed electrical circuit together with the secondary winding of the power transformers. This type of heating is used for very short sampler lengths of about 1 to 2 meters in length.

For lengths up to ca. 5m, the diluted airflow will not be directed in a stainless steel pipe, but rather in a KS – pressure hose (thermally isolated). In order to close the circuit it is necessary to tie together the isolated end of the sampler probe and the secondary wind of the heat transformer with a flexible copper cable.

- The sampler line is designed separately as a heat hose with a heat line, in which two sampler tubes (for total volume flow and dilution air flow) are embedded and electrically isolated. The sampler probe is also aligned and gas-tight with the sampler line, but is heated separately using low voltage resistance heating. This type of combination is adaptable to any allowable line length and the design and dimensions of the components of the sampling system, independent from the length of the line.

- The sampler line is designed separately as a heat hose with a heat line, in which one sampler tube for total volume flow is embedded and electrically isolated. The line for dilu-tion air flow consists of a KS – pressure hose and is embedded and electrically isolated in a heat hose with a heat line. The sampler probe is also aligned and gas-tight with the sampler line, but is heated separately using low voltage resistance heating. This type of combination is also adaptable to any allowable line length and the design and dimensions of the components of the sampling system, independent from the length of the line. Pref-erably, this design of the sampling system should be implemented.

- To prevent soiling and choking the sample system will usually be back flushed with pres-sure air. The numbers of back purge cycles per day will be programmed in the Service Menu and can be up to 24 times per day. The back purge cycle will be activated always during the filter transport. Dependent on the equipment and the cycle of the instrument the filter transport period can be about 21 s econds (single filter transport at a s ingle measurement), 42 seconds (double filter transport at the beginning of a new value) or 63 seconds (treble filter transport at the beginning of a new value and with option filter tape printer). One back purge period consists of a compressed air pulse of 1 second and a stop of 3 seconds. It’s possible that one back purge cycle consists of 5 up to 15 back purge periods. This specification is important for definition of consumption for com-pressed air (see chapter 4. Mounting).

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- The dust emissions gauge includes the function elements for dust collection and valua-tion; sample gas intake and dilution; the drying of the gas; the creation, measurement and the regulation of the volumetric flow; the control of the function cycles; the controls and display and for the collection, calculation and the output of data (9.5. Flowchart).

- A vacuum pump sucks a gas sample (diluted or undiluted) over the sampler probe, the line, through a glass thread filter, over a gas cooler and through the volumetric measure-ment and control equipment.

- The total dust mass, which is contained in the gas sample, is isolated on the filter sur-face. From the radiometric value of the dust filter’s surface the dust mass is calculated.

- This dust mass will be divided by the gas volume, which was sucked up during the sam-pling. S ince the total volume is always calculated during the volumetric measurement, the dilution portion can be determined from the total volume if the gas sample is being di-luted. Consequently only the actual gas volume portion (dry and temperature corrected) is evaluated, which was taken by the sampler spot and is representative for the dust mass trapped on the filter. The result is the dust concentration (mg/Nm3).

2. Measurement Principal The measurement principle of the dust emissions meter F-904-20 is based on the absorption of Beta radiation (electrons) emitted from a radioactive source through the mass that is sam-pled from the exhaust stream. Dependent on their energy, the electrons are absorbed by each material (solid materials, liquids, gas). The absorption constant (effectively and absorp-tion) based on the energy (in MeV) of the emitted electrons as well as on the chemical com-position of the absorbing materials. In simplified terms, the lower the energy of the electrons, the less substance dependence of the absorption.

A C-14 emitter is installed in the Verewa F-904-20. The use of these isotopes presents some advantages over other isotopes used for analysis. A half-life of 5,730 years, the little energy of the electrons from only 0,156 MeV and the decay in a non -radioactive element. With the use of a C-14 source, the beta absorption measurement of the dust content nearly independent from the chemical composition of the dust particles.

Further details on the theory of C-14 radiation and the beta absorption are available in the theory fundamentals.

In contrast with the optical dust meters (especially scattered light photo meters), the meas-urement with the F-904-20 is independent from particle size, cooler and specific weight. The Verewa F-904-20 is specifically designed for use with wet scrubbers and is not affected by the presence of water drops or water vapour in the gas. Because of the difference in the size of grain, a place-specific calibration, such as with photometers is not necessary. The F-904-20 will be fully calibrated before delivery. It can also be installed on changing locations.

3. Determination of Dust Mass The Beta Dust Monitor F-904-20 belongs to a group of radiometric meters.

The Beta Dust Monitor F-904-20 measures the dust concentration in mg dust/cubic meter of dry gas (mg/Nm3). In order to detect the dust concentration, the partial exhaust flow must be measured and the dust mass established.

First a fresh filter surface is radio metrically evaluated. Beta radiation is emitted through the filter band and is scanned for 120 seconds. The decay process is gauged in the form of indi-vidual impulses. After the filter surface is exposed to the dust, it is revaluated in the same

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manner as the fresh filter surface. The absorption of the radiation by the dust is measured by the reduction of the Beta radiation from the C-14 source and saved as a sum of the indi-vidual impulses. The difference between both scans is directly proportional to the accrual of the dust mass on the filter tape.

This radiometric procedure can be applied universally since it allows the analysis of the dust mass in wide boundaries (independent from the chemical and physical composition of the dust and the carrier gases).

If the dust condensate is distributed evenly in the form of mass m on the filter surface A, the following relationship applies.

ln(n0/n) = (µ/p)xd

(Equation1) Calculation of dust mass

The following apply:

d the surface concentration m/A of the dust (mg/cm2) at a concentration m (mg) on the constant condensation surface A (cm2).

µ/p the mass attenuation coefficient (cm2/g), which is practically independent from the composition of the dust.

µ The linear attenuation coefficient (cm-1) of the applied Beta radiation.

p the density of the absorbing material.

no, n Beta particles measured with or without the dust density per minute, which are elec-tronically registered as voltage impulses

The impulse rate is a measure for the radioactive intensity. With the use of a filter area of A=2.54 cm2, the dust monitor can still detect a dust mass of 0.03 mg.

The mass attenuation coefficient µ/p of the applied Beta radiation is dependent on the elec-tron density of the absorber and proportional to the following relationship:

OZ (Atomic number) / A (Mass number)

(Equation 2) Relationship Atomic number to Mass number

However for the most commonly occurring dusts to which this relationship is constant ((see (Table 1) The relationship between Ordinal number/ Mass number) it can be said that the attenuation of the Beta Radiation is virtually independent from the grain size and the chemi-cal composition of the dust.

Element Al C Ca Fe K Mg Na O S Si H

AN/MN 0.428 0.50 0.49 0.466 0.486 0.494 0.48 0.50 0.499 0.489 1

(Table 1) The relationship between Ordinal number/ Mass number

An exception to this is hydrogen. But the proportion of hydrogen in dust is relatively small so that its different behaviour does not disturb the measurement principle.

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With a filter surface that remains constant, where µ/p is also constant, the mass sampled on the filter can be calculated from the attenuation of the Beta Radiation with

ln(n0/n) = (µ/p)xd.

When the mass absorption coefficient with reduced Beta maximum energy increases, the mass reading becomes more sensitive due t o the Beta absorption measurement with the energy reduction of the applied radiation. Partially through its large half-life of T/2 = 5,730 years, the C-14 isotope with a maximum energy of WMAX = 0.156 is especially suited.

4. Mounting

4.1. Site Preparation In order to determine the sampling location, several conditions must be met to ensure that the partial flow sample is representative of the entire gas flow. Localized fluctuations in dust loading can occur temporarily in the main stream, as can variable dust strains. Tests are required to locate sampling points in the stack that would provide dust concentration meas-urements representative of conditions present throughout the cross section of the stack.

The length of the flow path prior to sampling should be at least three times the hydraulic di-ameter.

UFDHD *4=

DHD = hydraulic diameter F = area of cross section measured U = circumference of cross section measured

(Equation 3) Hydraulic diameter

The working area of the monitoring location must be adequately sized (approx. 3 to 4 times the floor space occupied by the monitor), taking into account the reference measurements performed during calibration of the monitoring system, from the sampling through to the measured value output. Monitoring locations for reference measurements should be a r-ranged such that they lie in immediate proximity to the sampling point of the monitor, but do not influence one anot her. It is fundamentally important that any gas analyzer sample probes are installed behind the sample probe for the dust measurement. I f the system is installed outdoors, covers must be provided for the sample line, and weather hoods provided for the monitor.

The sample probe is typically installed horizontally with a gentle slope in the direction of the sample flow. The opening of the sample nozzle should be oriented exactly opposite the flow. The sample line should be as short as possible. Ideally the sample line should be straight. However if curves are unavoidable, they should be as slight as possible (300mm at least).

It is recommended that the exhaust be r eleased back into the stack if there is either high negative pressure at the sampling point or if the flue gas is toxic. This is also advisable to reduce noise. It may be necessary, on a site-specific basis, to install shut-off equipment on the probe and in the gas return line, as well as equipment for reducing toxic emissions when the filter holder opens.

To speed the installation, the customer can make the following preparations in advance.

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Power Supply: - Voltage 230V/50Hz, +10/-15%; 220V/60Hz (optional), other with a pre- transformer - Power rating at 230V AC (measuring instrument about 1300W, option

heated sample probe about 1700W, heated sample line including dilu-tion line about 130W/m, option cooling unit and/or heater for cabinet about 1000W, depending on equipment (see technical specification)

- Customer provided a 50 A fuse, trigger complies with VDE 0660, Siemens ”D”

- Connecting cable 3 x 10 mm2 (Note: when used outdoors, use a waterproof design)

- Cable length ca. 4m of free cable end when installed near ground, 2m of free cable end when installed at top of housing, for the installation in the housing to the terminal.

Flushing gas - Nominal pressure of 6 … 8 bar

- Quality instrument air, free of oil, condensation and dust

- Option Nitrogen for dust monitoring of blast furnace gas

- Consumption per back flush period

∅i of inlet nozzle (mm)

Consumption of pressure air per back flush pulse of 1 second at 6 … 8 bar (litre) of about

5 3

7 6

10 11

- Example: maximum pressure consumption (at 6 ... 8 bar) with 7mm- nozzle for 1 flush cycle per hour (5 back flush periods/cycle) is about 720 l/day, please note that time distance between the back flush pulses has to take into consideration

- PVC pipe connection 10 x 3 TX (ca. 2 m excess hose end at the device side connection)

System Location: - Equipment is designed, made and tested for application in not explosive zones

- Climate-controlled Control shelter or measurement container. (If installed outdoors, the system should be equipped with the optional air- conditioned or heated cabinet.)

- Please note: For installation of the instrument please hold a distance of 150…200 mm between cabinet side walls, rear and top parts of the instrument and the neighbouring markings, ceiling or walls! Weight: - ca. 200 – 250 kg, depending on model

Space needed for maintenance:

- in front of the monitor so that the front door and the swinging frame can be swung open fully (1 m2 for the entire height of the monitor)

Sampling System: - Information from customer to Verewa, based on the questionnaire

- Information from Verewa to the customer for the flange type (”A”), Flange nipple (dimensions C, F: see following table!)

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(see 10.14. Sample Gas Probe)

- At time of installation, flange nipple and flange A are welded to stack wall at the predetermined sampling point; flange gasket included

Flange type / size = f (pipe socket length C)

C ( mm) F (∅ mm) Flange A (type) Flange B (type)

≤ 200 108,0x2,6 100/108,0 DIN 2573/76 PN 6/10 100 DIN 2527 PN 6/16

≤ 270 133,0x2,6 125/133,0 DIN 2573/76 PN 6/10 125 DIN 2527 PN 6/16

≤ 400 159,0x3 150/159,0 DIN 2573/76 PN 6/10 150 DIN 2527 PN 6/16

(Please note: - tabular summary only for steel flanges and steel pipe sockets!) - table for standard probe only (Illustration 8: Nozzle)

4.2. Mounting Instructions

4.2.1. Sample gas probe - Mounting of the sample gas probe according to 10.1.1. Sample probe mounting

(fig.7,…, 11) and drawing Illustration 35: Sample gas probe (installation of the probe in the flange, mounting of all accessories and fittings, after the right position fixing of all parts)

- Assembly of the complete sample gas probe (flange position according Illustration 37: Flange) on the sampling point (insert the probe in the pipe socket (7) and connect both flanges (11, 12) with hexagon bolts, plain washers and hex-nuts

- Connection of the sample line (end without cables) with straight coupling (22, 23, 24) on the tube (3), cut the steel tube if necessary (short connection distances for no h eated parts of the line)

- Connection of dilution air line (end without cable) on the hose nozzle (21, 25) of the tube (2) or depending on the dilution line type substitute the position 25 for a stiffener sleve

- Connection of heating cable 1 on the binding post (20) of the tube (3) with accessories (16 – 19)

- Connection of heating cable 2 on the binding post (20) of the tube (2) with accessories (16 – 19)

- See also picture Illustration 12: Connection of lines and wires

- During the mounting or in case of maintenance on the probe pay attention to fas-tening the heating cable connections on the probe pipes carefully and the acces-sories (16 – 19) between cable connectors and binding posts (20) has to be fixed correct and very strong. The probe will be heated by a very high current of about 100A depending on the actual working situation. If the connections are not good fixed (are loose) the connecting parts will be extremely hot in a very short time and can be destroyed!!

- Installation bundle of all parts for sample line system (sample line, dilution air tube, heat-ing cable 1, heating cable 2, Pt100-connection cable from the probe) arranged on a cable bridge to the location of the measuring instrument

- Careful thermal isolation of both sample probe tubes behind the flange with the red sili-cone tube (as shown in pictures Illustration 13: Isolation of upper part up to Illustration 15: Isolation, fixed)

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- According to the situation for installation at the measuring point preparation of a weather protection for the parts of the sample probe outside of the duct beginning at the flange (see Illustration 16: extra isolation (for outdoors)) or use the weather shield included in the scope of delivery

4.2.2. Measuring instrument (standard cabinet) - Site preparation to install and operate, in consideration of enough ventilation inside and

around the instrument, for accessibility in case of installation, maintenance and services see drawing: Illustration 1: Cabinet for the instrument (front view), Illustration 2: Cabinet for the instrument (left side view) and explanation, for connections see drawings 10.3. Wiring Diagrams regarding the following steps

- Please hold distance of 150…200 mm between top part of the instrument, left and right instrument side walls, rear part of the instrument and neighbouring obsta-cles, housing walls, ceilings and other equipments, don’t block the outlet and inlet filters and filter-and fan units

- Please note about 1 m2 on the front side of the cabinet for opening the front door and swinging frame of the instrument cabinet

- Open the cabinet door, the swinging frame and switch off the residual current operated device F1 (delivery condition)

- Interface signal cable lead through the screwed cable gland (18/2) up to the terminal strip for the user interface X3 and connect the single wires according your wishes and list for the interface X3/1 – 22, X2/33, 34 (see 9.2. Interface for the Customer)

- Signal wires from the switch contact for the two flow rates or the flow rate signal for con-tinuously isokinetic sampling (options) lead through the screwed cable gland (18/1) too up to the terminal strip X2 and connect it to pins 33, 34

- Power cable lead through the screwed cable gland (20) up to the terminal strip X0 and connect the single wires on X0/1, 2, 3 (L, N, PE

- Pt100-connecting cable for the sample line control and the power cable for the sample line on the end of the sample line above the connection (25) lead through the screwed cable gland (17/1 and 19/1) up to the terminal strips , Pt100-connecting wires connect on X4/7,8 and the power cable connect on X1/7, 8, 9 (L, N, PE)

- Heating cable 1 from the probe lead through screwed cable gland 21/1 and connect it on one of the both free contacts U1, V2 of the heating transformer T4 and isolate it (in this case already connected !)

- Heating cable 2 from the probe lead through screwed cable gland 21/2 and connects it on one of the free contacts U1, V2 of the heating transformer T4 and isolates it (in this case already connected !)

- Pt100-connecting cable from the probe lead through screwed cable gland 17/2 to the terminal strip and connect it to X4/5, 6 (socket area below cabinet)

- If still not connected, pay attention to fastening the heating cable connections on the contacts U1 and V2 and fix it very strong.

- On the transformer T4 are one or two cable bridges depending on the output voltage 6 or 12 VAC (please don’t change or remove it!)

- Connect the dilution air line with straight coupling (22), the power cable lead through the screwed cable gland (19/2) and connect on X1/10, 11, 12 (L, N, PE)

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- Connect an exhaust hose on the straight coupling (23) according to the requirements, the hose is already internal connected, its overhang is about 1m below the socket

- Connect a pressure hose on the straight coupling (24) for compressed air 6 ... 8 bar to the pressure source, the hose is already internal connected, its overhang is about 1m be-low the socket and has to be connected to the source pipe/hose

- Connect the condensate outlet hose to a proper drain, avoiding anything that could dis-turb the flow, the hose is already internal connected, its overhang is about 1m below the socket

- Switch on the F1

- Close the swinging frame

- Lead the sample line through the hole near the front on the top of the cabinet (big bend-ing radius)

- Connection of the sample line with fitting for the sample gas input (25) on top of 3-way-ball-valve (see Illustration 17: Complete instrument and Illustration 20: 3-way-ball-valve (cover removed)), cut the steel tube if necessary (short connection distance for the no heated part of the sample line)

- Preparation for starting the measuring system (see Technical Manual / mounting, start up!)

5. Start up Start up can take place once the installation of the sampling system and analyzer has been inspected, the filter tape loaded (see point 10.2. Instruction for Changing a Filter Roll), and the pressure roller fitted on the filter tape. All safety devices, the Fi-safety switch and motor safety switch for the vacuum pump can be activated if the door has been opened (right-hand wall). The S0 power switch is then activated (see: Cabinet for the instrument (front view)). After approx. 30 minutes, the sampling system (probe and sample line), filter holder and gas sample chiller will have all reached their required temperatures.

Once the S0 switch has been activated, the following message will appear in the display (see chapter 6. Operating):

DURAG F-904K V1.0

Dust monitor

select mode

↓

(If the message is displayed in German, press F1 to switch to English.)

The system will then await the input of the desired mode of operation. Normally, the user begins by pressing the ”down” button twice and then ‘F1’ to go to ‘SERVICE’. After entering a password, the user gains access to the service menu and can edit all relevant parameters, while adjusting the monitoring system to local conditions (i.e. at the sampling point).

Assuming that a s et of parameters has been pr ogrammed in prior to shipment, based on known process data (see point 8. Geräteparameter im Auslieferungszustand (Factory Set-tings), the user can immediately begin in the monitoring mode. The monitor begins by run-ning through the first measurement cycle. During this phase, a zero test is performed, in which a clean section of filter tape is transported into position 1 (and 2 for an option with two measurement systems, which means two C14 sources and two GM tubes) and the beta at-tenuation is measured. The test for position 1 concludes after 120 seconds. The filter holder

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then opens and this same section of filter tape is positioned to collect a dust sample. The filter holder closes automatically.

If the instrument has been on for less than 30 to 60 minutes, it will go into a delay for some time to prepare the internal parameters, showing “prepare”. This should automatically be finished after 30 to 60 minutes. (If not all temperature-parameters reach the set range within one hour, the signal ‘general fault’ is set.)

Then the vacuum pump is activated and a gas sample is drawn through the filter tape. The cycle phase, ”Sampling”, is shown in the display. The intake time is determined by subtract-ing the time required for the zero test, measuring phases (120 seconds each) and transport phases for the filter tape from the programmed cycle time. At the beginning of the suck cycle 1 the zero test on filter tape position 2 will be executed.

When the suck cycle of the first filter tape position has been finished the filter tape then is transported to the measurement position, the section of filter tape with the dust sample is evaluated, and a measured value is displayed after 120 seconds. The difference between the measurements obtained for the clean and dirty filter tape is a measure for the absolute dust mass 1.

Once the cycle has concluded, this result appears at the right of the first line in the display (x.xxx mg). The amount of gas sampled during cycle 1 is also calculated. Dust concentration 1 is derived from the absolute dust mass 1 and s tandardized sample gas volume 1. This is given in mg/Nm3 and appears in the display under the value for the absolute dust mass (1).

At the beginning of the measurement cycle 1 the suck phase for filter tape position 2 is stared for dust sampling. After the suck phase 2 the filter will be transported for measuring phase to the measuring position 2. Once this cycle 2 has concluded the result 2 appears as the new value 2 on t he same line in the display the value 1. A long filter tape transport is starting now for new clean filter tape positions.

Please notice that the parameters dust mass (displayed at the right of the first line), dust concentration (displayed at the right of the second line) and the gas volume sucked during the suck phase (displayed at the right of the third line) are displayed until the next cycle is completed. They are then replaced by new values (see point 6. Operating).

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6. Operating

6.1. The Terminal The F-904-20 Dust monitor is operated by a control panel on the front side of the device.

Essential functions of the keypad:

Edit keys

The plus key is for entering positive values. By pressing this key, the selected value will increase by increments of 1. It this key is held, the function automatically repeats.

The minus key is for entering negative values. By pressing this key, the selected value is reduced by increments of 1. If this key is held, the function automatically repeats.

Direction Keys

The left cursor button selects previous menu, ends the operation, or positions the cursor left one position in a variable selection.

The down cursor button selects following menu, changes the screen during operation to the message screen, or positions the cursor on the next editable variable below.

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Special Keys

The help key displays the current help text or error messages. The blinking of the help key LED signals that there are messages waiting to be checked. To view it, press and hold this key.

The data edit key switches from the menu to the editor. By pressing this key again, the editor is cancelled.

The enter key is pressed to confirm a selection or enter variable data.

Function Keys

Function keys F1 – F4 are used to select functions or notifications of operating parameters during operation. F1 i s also used to exit the message list.

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6.2. The Main Menu

The Main Menu allows access the sub-menus “Manual Mode“, “Service“ or “Reference Mode“. It also provides to start operation.

Sub-menu “Manual Mode“ Allows individual components to be accessed by hand, for ex-ample, when a Filter roll is changed.

Sub-menu “Service” All operation parameters can be viewed or changed with the entry of a pas sword. T here are both a us er password and a service password to avoid inadvertent changes to critical opera-tion parameters.

Sub-menu “Reference Check“ The process of a reference measurement is done with a ref-erence foil.

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6.3. Manual Mode

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Menu option Adapter

The menu option „Adapter“ allows the manual adjustment of the filter tape adapter. Upon opening, the Filter tape is released. T his menu point can only be left if the adapter is closed.

Menu option “Filter Tape”

The menu point „Filter“ allows manual filter tape transport in either direction.

Menu option ”Pump“

The Menu point „Exhaust pump“ allows the manual operation of the exhaust pump. This menu point can only be left if the pump is turned off.

Menu option “Pulses/Min“

The menu point „Pulses/Min“ serves as a check of the decay process recorded by the Geiger-Müller tubes.

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6.4. Operation

“Operation”

Important operation parameters can be c alled up during operation with the help of the function keys. As long as that certain function key is held, the message shows in the display. The running of the measurements will not be interrupted. The release of the key brings back the operation display.

Pressing the Down Cursor key brings you to the message list. The last 500 messages are saved here with date and time.

Note! If necessary, the messages can be deleted by pressing the function keys F2 and F3 on the control panel.

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6.5. Operation Display

During operation, the concentration of the last measurement is shown in the upper right hand of the display. Furthermore the absolute mass and volume can be read, which were used to calculate the concentration. The bottom line shows one of the current events:

Tape zero: The zero-rate of the filter tape is being measured.

Transport: The filter tape is being transported.

Prepare: The internal parameters are prepared. This may take 30 to 60 minutes.

Sampling: The air is being sampled.

Sample measure: The sampled dust is being measured.

Flush rest gas: System is flushed (for toxic or explosive gases).

Stop: Cycle is stopped (caused by signal from monitor for toxic or explosive gases). In this case we recommend to interrupt the cycle by pressing the key [<<] and then check and fix leakage of gas. Apply safety measures (such as ventilation of the room).

On the left side are the statistics of the current measurement. A countdown tracks the pro-gress of individual periods of the current measurement. Under that, the length of the sam-pling period is shown. One can assess whether the sampling system is functioning properly with the aid of the sample gas volumetric flow.

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6.6. Service Menu

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Sub Menu “Cycle time“

The cycle time is the time for the sequence where after a new measured value is available. I t contains the time for all of the filter transports, M- and O-rate measure-ments as well as the sampling time. If the entered cycle time is lower then possible, the cycle time is automatically corrected to the minimum. It gets longer also by the lengthening of the measurement time or if a filter band printer is in use.

Sub Menu “Impulse-Reading-Time“

The impulse-reading-time limits the duration of the recording of impulses for both the M- and O-rate. The minimum is 120s.

Hint! A rise in the measurement time causes either (if possible) a shorter sampling period or a lengthening of the cycle duration.

Sub Menu “Measurement range“

The measurement range is completely selectable. The entering of 15mg/Nm³ con-tains an aut omatic changeover, with an ov erflow, to the measurement range of 45mg/Nm³ and 225mg/Nm³. Any other entry will be interpreted as an absolute Meas-urement range. A change or an overflow of the measurement range will be signalled by status relays.

Sub Menu “FB-Cycles“

The FB-Number (Forward-Back Number) indicates how often a s pot on the filter is allocated and measured (multiple applications). A multiple application cycle means a lengthened sampling time, because a new O rate measurement is not necessary.

Sub menu “Steps“

The step numbers are entered before delivery. They determine the length of the filter band transport and facilitate an exact positioning of the filter spots under the meas-urement equipment.

Sub Menus “Filter Adapter Temperature“, “Probe temperature“, “Line temperature“, “Filter inlet temperature” and “Chiller temperature”

The temperatures are regulated by the set reference value. The allowed deviation (e.g. +/- 20°C) sets the range the temperature has to be in for sampling. If a higher deviation occurs, sampling is paused and the message "Temperature-fail" is created for the respective temperature.

The setting for the chiller is for monitoring only and must match the adjustment made on the chiller itself.

Sub Menu “Standard Density“

The standard density is used in the calculation of the standard volumetric flow.

Sub Menu “Dilution Ratio“

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The dilution ratio is regulated by the set value. It’s the ratio of sampled volume to total volume. (Wherein the total volume is the sum of sampled volume plus dilution vol-ume.)

Sub Menu “Calibration“

Through the entry of offset and slope, the measured dust concentration is adjusted to the dust concentration measured by the testing agency.

Sub Menu “Sample Flow Factor“

Through the entry of a sample flow factor, the measured flow is adjusted to the flow measured by the testing agency.

Sub Menu “Temperature Gas”

The gas temperature is used for the calculation of the standard volumetric flow. The display is for information only. There is no need to edit anything here.

Sub Menu “Sample Flow“

The operating volumetric flow is adjusted to the set value. During operation the actu-al measured standard volumetric flow is also shown.

Sub Menu “Date/Time/Purge”

The date and time of the system are displayed and can be edited. The number of purge cycles per day can be set up to 24. The purge is always started during the first filter tape transport after initialization. A manual purge can be triggered by pressing and holding the F2 key. If the optional purge of rest gas is installed, the duration can be changed after pressing F4.

Sub Menu “Filter printer“

The filter printer is optional and can be activated, deactivated and tested with the help of this sub menu. When activated, the printer documents each sampling with its sample time, sample volume and abs olute mass. The most recent status is dis-played.

Sub Menu “Change Password“

The user or service password is changeable through the dual entry of the old and new passwords. (Changing is not recommended.)

Sub Menu “Auto start“

The activation of the auto start function initializes the automatic start of the device when powered on. The most recent status is displayed. We recommend to set this to ‘yes’.

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6.7. Reference Mode

Sub Menu “Reference Mode“

In this selection a reference measurement with the aid of a reference foil can be initi-ate by using the F1-Key.

The filter tape is then advanced twice. Following the tape advance, an O-rate meas-urement is taken. After that is finished, a request is displayed to insert the reference foil. When the foil is inserted, an M-rate measurement is taken and the measurement values are displayed.

The F3-Key allows to toggle between the values of Tube 1 and optional Tube 2.

The foil must then be removed. This allows the return to the main menu.

F3 and F4 will start zero point- and reference point measurement.

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6.8. Device Interface All of the status signals, error messages (except for the temperature-fails) and analogue out-puts can be found on the device interface (X3). Additionally the interface allows a zero point and/or a reference point measurement.

Status signals and error messages are used as dry relay contacts with the same reference point. They are opened if the device is switched off.

The analogue outputs deliver the measurement values as 4 to 20mA. The allowable, outer output resistance has a maximum of 520Ω (including lead impedance).

Zero-point and reference point controls are triggered by bridges with dry contacts.

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6.9. Error Messages, possible causes and solutions -Vacuum Errors

A vacuum error is triggered if the intake of the sample has a vacuum pressure of more than 0.5 bar If triggered, the sampling process is ended and the cycle continues at M-rate measurement. With multiple sampling, a new filter spot is drawn and an O-measurement is taken. If the error occurs four times in succession, the device auto-matically switches to stand-by mode.

The error message remains until a complete and successful cycle with valid meas-urements has been completed.

Possible causes for a vacuum error are:

* Exceedingly high dust concentration on the filter tape

* Impurities on the nozzle

* Impurities in the intake

* Pressured air missing

Solutions:

* Reduce FB-Number or sampling time

* Remove impurities

* Raise number of purge cycles (Service Menu)

* Check pressured air

-Filter tear A filter tear is recognized if the pulse rate of the GM-tubes is more than 80000 Pulse/Min. The device switches to stand-by and requests the removal of the cause of the error. After successful removal of the error, the system resumes operation and the error message is removed.

Possible causes of a filter tear are:

* Multiple sampling too high (FB-Number)

* Condensation on the filter tape

* End of the filter tape has been reached

* Defective GM-Tube

Solutions:

* Reduce FB-Number (Service Menu)

* Raise dilution-ratio (Service Menu)

* Replace filter tape

* Replace GM-Tube

-Volume errors Volume errors arise if the total volume flow deviates more than 150 l /h from the set value. The error message is active for the duration of the deviation. The occurrence of a volume error has no influence on the continuation of the measurement cycle.

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Possible causes of a volume error are:

* Impurities on the nozzle

* Impurities on the intake

* Multiple sampling too high (FB-Number)

* Previous vacuum error

* Pump defective

Solution to frequent errors:

* Examine sampling system for impurities

* Reduce FB-Number (Service Menu)

* Check pump

-Measuring Range Error The measuring range error is triggered if the biggest or only measurement range of the concentration measurement is exceeded. The error message remains until a new, valid measurement value is produced.

Possible causes for a measuring range error are:

* Increased dust concentration

* Defective GM-Tube

Solutions:

* Select a larger measuring range

* Check the filter spots

* Check the Pulse/Min (F1 when machine is running)

* Replace GM-Tube

-Uptake full (option) The end of filter tape will be detected by an optional micro switch on the uptake roll.

Solutions:

• Replace filter tape

-Condensate (option) This error message appears when condensate is detected in the condensate trap.

Possible causes for a “Condensate error”:

• Chiller-temperature is set too high

• Chiller is defective

• Condensate-pump at the chiller is broken

• Something avoids rinse of condensate

• Total flow to high

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Solutions:

• Adjust chiller-temperature

• Replace chiller

• Replace transportation hose or peristaltic pump

• Reduce total flow

- Probe temperature fail The deviation of the temperature of the probe is higher than the allowed deviation set in the menu ‘Probe temperature’.

Possible causes for a “Probe temperature fail”:

• Setting of Probe temperature or deviation wrong

• Probe-heating or temperature measurement (Pt100) defective

• Safety circuit detected malfunction (more than 4 m inutes of uncontrolled heating)

Solutions:

• Check setting for Probe temperature, lower setting, increase allowed devia-tion

• Check Probe-heating and temperature measurement (Pt100)

• Turn device off and on again and monitor heating-cycles (K8, K11)

- Line temperature fail The deviation of temperature of the sample line is higher than the allowed deviation set in the menu ‘Line temperature’.

Possible causes for a “Line temperature fail”:

• Line-heating defective

• Setting of Line temperature or deviation wrong

Solutions:

• Check Line-heating

• Check / lower setting for Line temperature

• Increase allowed deviation

- Inlet temperature fail The deviation of the temperature of the Filter-Inlet is higher than the allowed deviation set in the menu ‘Inlet temperature’.

Possible causes for an “Inlet temperature Fail”:

• Inlet-heating defective

• Setting of Inlet temperature or deviation wrong

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Solutions:

• Check Inlet-heating

• Check setting for Inlet temperature


- Adapter temperature fail The deviation of the temperature of the Filter-Adapter is higher than the allowed devi-ation set in the menu ‘Adapter temperature’.

Possible causes for a “Adapter temperature fail”:

• Adapter-heating defective

• Setting of Adapter temperature or deviation wrong

Solutions:

• Check Adapter-heating

• Check setting for Adapter temperature


- Chiller temperature fail The deviation of the temperature of the Chiller is higher than the allowed deviation set in the menu ‘Chiller temperature’.

Possible causes for a “Chiller temperature Fail”:

• Chiller defective

• Setting of Chiller temperature or deviation wrong

Solutions:

• Check Chiller

• Check setting for Chiller temperature

• Increase allowed deviation (by e.g. 1 or 2°C)

- General fault The „General fault“ error message appears as soon as one o f the previously de-scribed errors arises or the preparation is not completed after one hour. It is removed if all errors are rectified.

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6.10. Status Messages -Zero Signal

The Zero Signal status message shows that the results of a previously re-quested zero control are still on t he analogue outputs. It is active for 2 minutes. The last measurement values are then output again. (This only ap-plies to zero started by contact, not manually from the menu.)

-Reference Signal

The status message „Reference Signal“ shows that the results of a previously requested reference control are still on the analogue outputs. It is active for 2 minutes. The last measurement values are then output again. (This only ap-plies to reference started by contact, not manually from the menu.)

- Measuring range > 15mg/Sm3

This signal is on i f the actual value 4 … 20 mA corresponds to 0 … 45 mg/Nm3

- Measuring range > 45mg/Sm3

This signal is on i f the actual value 4 … 20 m A corresponds to 0 … 225 mg/Nm3

- Operation

This signal is on if the device is in operation. That is, all internal parameters are in range and the cycle has been started.

6.11. Analogous Measurement Value Outputs - Dust Concentration

After the measuring phase output signal will be bet ween 4 … 20 mA corre-sponding to the active range indicated by the status (for ranges 0 … 15 mg/Nm3, 0 … 45 mg/Nm3 or 0 … 225 mg/Nm3).

- Dust Mass

After the measuring phase output signal will be between 4 … 20 mA repre-senting the recent sampling of dust on one filter spot corresponding to the range of 0 … 10 mgabs.

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6.12. Inputs -Start Zero Control

The triggering of a zero control does not cause a di sturbance in the current measurement cycle. A fter the ending of the M-Rate measurement and the display of the measurement values of the last measurement, the device goes to Zero Control and begins with a long filter transport. It follows the recording of the O-Rate (120s) and also that of the M-Rate (120s). Measurement value and status signal are registered for 2 minutes.

-Start Reference Control

The triggering of a reference control does not cause a disturbance in the cur-rent measurement cycle. After the ending of the M-Rate measurement and the display of the measurement values of the last measurement, the device goes to Reference Control and begins with a long filter transport. It follows the re-cording of the O-Rate (240s) and also that of the M-Rate (120s). Measurement value and status signal are registered for 2 minutes. The measuring-range for this output is always 20mg/Nm3.

Note! The zero and reference controls can be started at the same time. The zero control is run first. The reference control is then shortened by about 160s since the filter transport and the M-Rate recording is saved.

- Flow rate change-over (option)

In dependence on the position of the contact (S5, digital input) the instrument is switching the programmed flow rate between two values (Switch open: high flow rate, switch closed: low flow rate). Regarding the stack gas conditions the parameters of the instrument (for example the sample flow rate and the dilu-tion ratio) are programmed. Important is that the calculated high flow rate is programmed. If the switch contact is open, the programmed high flow rate is on. If the contact is closed, the instrument reduced the flow rate to the half of the programmed high value.

- Stack gas velocity (option)

By providing a velocity-proportional current on this analog input an automatic adaptation of the sample-volume to the stack-gas-velocity is possible.

The current of 4 to 20 mA, which represents the stack-gas-velocity at stand-ard-conditions, has to be connected to the input on X3.

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The diagrams approximately show the display of a line recorder after the initiation of the con-trol cycles individually or together.

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6.13. Option isokinetic sampling By providing a velocity-proportional current, an automatic adaptation of the sample-volume to the stack-gas-velocity is possible.

The current of 4 to 20 mA, which represents the stack-gas-velocity at standard-conditions, has to be connected to the input on X3.

For setup, go to menu SAMPLEFLOW a press F1.

In this mask, the following values have to be entered:

I1, I2 and v1, v2. These define two points of the linear relation between the current (in mA) and the velocity (in m/s). They depend on t he device used for velocity-measuring. Please refer to the respective manuals.

d is the diameter of the nozzle used (in mm), up to 12 mm.

T is the temperature (in degrees centigrade) the velocity is compensated to, usually 0. If un-compensated, enter the average temperature in the stack.

For information, the minimal and maximal possible velocity are also shown. They depend on the nozzle used.

Whenever the current is lower than 4 mA, the device will switch to the sample-volume set in the menu SAMPLEFLOW.

The velocity-measuring itself is not included.

You can use the DURAG products D-FL100 or D-FL200.

If no velocity-measuring is possible, a fixed volume is used based on the average velocity in the stack.

I1= 4.0mA d= 7.5mm I2=20.0mA T= 45.7°C v1= 4 vmin= 4.29m/s v2= 20 vmax=22.45m/s

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7. Technical Specifications Ranges selectable between 0 - 5 and 0 - 2000 mg/Nm3

Lower Detectable Limit < 0,1 mg/Nm3

Error Limit < +/- 5% from range

Zero drift automatic zero-point correction

Span drift < 1% from range / week

System Availability > 95 %

Warm-up time 30 Minutes

Start time 2 Minutes

Power Supply 230 V, 50 H z (instrument: 1300W, sample probe: 1700, sample line: 130W/m, cooling unit and/or heater: 1000W)

Pressurized air 6 .. 8 bar, Instrument air

Ambient Temp. Range -10 °C … +40 °C (cooling unit, heater as option)

Meas. Value output 4 - 20 mA (Dust massabs, Dust concentration)

Status signals Dry switch contact with a common Reference point

Emitter C-14 Flat-top emitter(s), Half-life of 5,730 Years Activity < 500 kBq

Detector Geiger- Müller- Counter- Tube(s)

Filter material Glass thread filter, Degree of separation: 99.95% At > 0,3 µm, Measurements: L = 150 m, B = 45 mm Filter feed: 43 mm or 36 mm

Filter Adapter 25 - 80 °C temperature control and user adjustable

Filter surface 7,07 cm2 or 2,54 cm2

Total volumetric flow < 3 m3/h

Dilution ratio adjustable 1:1,0 … 1:4,0 (by default 1:2,0)

Measurement cycle adjustable (> 5 Minutes)

F/B Operation max. 8 cycles

Dimensions 1600 mm x 800 mm x 800 mm (H x W x D)

Weight ca. 200 ... 250 kg

Housing Sheet cabinet with front glass door

Protection IP20, IP50, IP55 depending on project

Colour RAL 7035 (grey)

Sampling system acc. VDI 2066, nozzle ∅ 4 - 12 mm, Heated probe, Isoki-netic sampling, dilution, back flush, automatic shot-off, Ma-terial: Titanium for sample probe and

Stainless steel for Sample line

Pump Disk Vacuum Pump, Flow controlled

Sample gas cooler Compressor cooling system

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8. Geräteparameter im Auslieferungszustand (Factory Settings) (see specific sheets in dependence on the customer project) Gerätetyp (Instrument type) : F-904-20 Software SPS (PLC) : …

Auftragsnummer (O/C no.) : … Software Display : …

S/N : … Settings Updating : …

PASSWORT (PASSWORD) : 1111

ZYKLUSZEIT (MAIN CYCLE) : …s

MESSZEIT (IMPULS-READING-TIME) : 120 s

MESSBEREICH (RANGE) : 0 – 15/45/225 mg/Nm3 oder ein fester Messbereich: … mg/Nm3 (or one fixed range: … mg/Nm3)

VZ-ZAHL (FB-CYCLES) : …

SCHRITTZAHL / VOR (STEPS / FORWARD) : … / ZURÜCK (STEPS / BACKWARD) : …

FILTERADAPTER TEMPERATUR (FILTER ADAPTER TEMPERATURE) : … °C +/- 20 °C

TEMPERATUR SONDE (PROBE TEMPERATURE) : … °C +/- 30 °C

TEMPERATUR LEITUNG (LINE TEMPERATURE) : … °C +/- 30 °C

TEMPERATUR EINLASS (Filter inlet TEMPERATURE) : … °C +/- 30 °C

TEMPERATUR KÜHLER (Chiller TEMPERATURE) : 7 °C +/- 7 °C (adjustment on chiller 4 °C)

NORMDICHTE (STANDARD DENSITY, SAMPLE GAS) : 1.293 kg/Nm3 (Sample gas)

VERD. VERHÄLTNIS (DILUTION RATIO) : 1:…

KALIBRIERUNG / KONSTANTE (CALIBRATION / OFFSET) : 0 µg/Nm3

/ STEIGUNG (CALIBRATION / SPAN) : 1,000

TEILVOL.STROM FAKTOR (SAMPLE FLOW FACTOR) : …

GASTEMPERATUR (TEMPERATURE GAS) : aktuelle Anzeige (current display value)

TEILGASVOL.STROM 1 (SAMPLE FLOW 1) : 787 Nl/h, trocken (dry based) TEILGASVOL.STROM 2 (SAMPLE FLOW 2) : - Nl/h, trocken (Option) dry based (option)

ISOKINETIK-PARAMETER (option) Strom 1 (current 1) : I1= 4,0 mA nicht aktiviert (not activated) Strom 2 (current 2) : I2= 20,0 mA nicht aktiviert(not activated) Geschwindigkeit 1 (velocity 1) : v1= 0 m/s nicht aktiviert (not activated) Geschwindigkeit 2 (velocity 2) : v2= 25 m/s nicht aktiviert (not activated) Düsendurchmesser (nozzle diameter) : d= … mm nicht aktiviert (not activated) Normierungstemperatur (normalized temperature) : T= 0,0 °C nicht aktiviert (not activated)

DATUM (DATE) : aktuelle Anzeige (current display value)

UHRZEIT (TIME) : aktuelle Anzeige (current display value)

SPÜLZYKL. / TAG (BACKFL.PURGE CYCLES / DAY) : …

Dauer opt. Restgasspülung (Duration of purges for rest gas) : … s

FILTERDRUCKER (TAPE-PRINTER) : AN/Aus (Option) (ON/OFF)(option)

PASSWORT ÄNDERN (CHANGE PASSWORD) : -

AUTOSTART (AUTOSTART) : AN/AUS (ON/OFF)

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9. Equipment - Summary

9.1. Connections (E/A) for the Beta- Dust Monitor (standard cabinet) Component Location, type Interface (status and measuring signals)

Measuring signal - outputs, analogue:

- Measuring signal, analogue (Dust mass)

- Measuring signal, analogue (Dust concentr.)

Status signal - outputs, digital:

- General fault

- Range 0 … 45 mg/Nm3

- Range 0 … 225 mg/Nm3

- Range errors

- Volume faults

- Filter tear

- Vacuum error

- Zero signal

- Reference signal

- Condensate

- in operation

Status signal - inputs

- Start Zero control

- Start Reference point measurement

Roof insert (18/2), cable gland M20 for (shielded) multi-wire control line

Control signal for isokinetic sampling (option)

Measuring signal stack flow rate

Roof insert (18/1), cable gland M16

Power Supply (instrument) Roof insert (20), cable gland M25, to X0/1,2,3

Cable 3x10mm2 (waterproof for outdoor applica-tion)

Dilution air connection

- Hose-/Pipe connection

- Isolated case implementation

Roof insert (22), 12 mm pipe fitting and stiff-ener sleeve for PTFE-hose

Exhaust

- Hose connection with inserted trim nozzle

Roof insert (23), Stainless steel hose nozzle ∅12x2

Compressed Air

- Hose connection

Roof insert (24), Stainless steel hose nozzle ∅12x2

Diluted sample gas

- pipe connection

- isolated case implementation

Roof insert (25), cable gland M63 or other solution depending on the type of sample line, 12 mm pipe fitting for connecting inside

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Condensate

- Hose connection

Socket area, left side, hose installation (26), about 1m tube end overhang, hose type: PVC-hose 4x1

Probe heating

- 2x heating cable

Roof inserts (21/1, 21/2), cable glands M25

Cable 35 mm2

Pt100 for heated sample probe

- Connecting cable to the sample probe

Roof inserts (17/2), cable glands M12, to X4/5,6

Power supply for heated sample line

- Power cable from the sample line

Roof inserts (19/1), cable glands M20, to X1/7,8,9

Pt100 for heated sample line

- Connecting cable from the sample line

Roof inserts (17/1), cable glands M12, to X4/7,8

Power supply for heated dilution line

- Power cable from the dilution line

Roof inserts (19/2), cable glands M20, to X1/10,11,12

9.2. Interface for the Customer Terminal X03/01, 12: - General Fault (Error status)

- Switch contact (output, digital)

- Message inactive : switch closed

- Message active : switch open

- Technical specs. : max. switch cap. 2A,250VAC,cosϕ=1 (=0,4); 1A,250VAC,8A / Module min. switch cap. 10mA, 5VDC

X03/02, 12: - Vacuum error (Error status)


- Messages, technical specs: refer to X03/01, 12

X03/03, 12: - Filter tear (Error status)



X03/04, 12: - Volume error (Error status)

- Switch contact (Output, digital)


X03/05, 12: - Range error (Error status)

- Switch contact (Output, digital)


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X03/06, 12: - Range > 15 mg/ Nm3 (Function status)


- Message inactive : switch open

- Message active : switch closed

- Technical specs. : max. switch cap. 2A,250VAC,cosϕ=1 (=0,4); 1A,250VAC,8A / Module min. switch cap. 10mA,5VDC

X03/07, 12: - Range > 45 mg/ Nm3 (Function status)



X03/08, 12: - Zero point value (Function status)




- Technical specs: refer to X03/06, 12

X03/09, 12: - Reference point value (Function Status)





X03/10, 12: - Condensate (Error status)


- Message active : switch open

- Message inactive : switch closed


X03/11, 12: - Operation (Function Status)





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X03/13, 14: - Start Zero control (input, digital) (option)

- Connection of a dry switch contact

- Switch open : No Start initiated

- Switch closed : Start initiated (≥ 20ms)

X03/15, 16: - Start Reference measurement (input, digital) (option)

- Connection of a dry switch contact

- Switch open : No Start initiated

- Switch closed : Start initiated (≥ 20ms)

X03/17, 18: - Value output, analog (Dust concentration)

- Results of a measurement cycle: 4...20 mA for each programmed measurement range

- Results of a zero or reference point control: 4...20 mA for 0 ... 15 mg/Nm3 (virtual volume 0,5 Nm3)

- X03/17 (+)

- X03/18 (−)

X03/19, 20: - Measurement value output, analogue (dust mass abs.)

- Results of a measurement cycle: 4 ... 20 mA for 0 ... 10 mgabs

- Results of a zero- or reference point control: 4 ... 20 mA for 0 ... 10 mgabs

- X03/19 (+)

- X03/20 (−)

X03/21, 22: - Isokinetic sampling (adjustment of sampling velocity on the input nozzle of the sample probe to the gas velocity in the stack (option)

- Gas velocity (input, analogue) as result of a flow meter 4 ... 20 mA for 0 ... 25 m/s

- X03/21 (+)

- X03/22 (−)

X02/33,34: - Flow rate change-over between two fixed gas velocities (option)

- Connection of a dry switch contact (input, digital)

- Sample Flow 1: (High flow rate) : Switch open

- Sample Flow 2: (Low flow rate) : Switch closed

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9.3. Device Views (Standard cabinet)

Illustration 1: Cabinet for the instrument (front view)

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Illustration 2: Cabinet for the instrument (left side view)

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Illustration 3: Cabinet for the instrument (top view)

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Explanations 01 Tube connection for purge interval sample line

02 GM-counter tube

03 Filter tape

04 Filter tape transport roll including stepping motor (M6)

05 Pad roll

06 Filter tape take-up reel and motor (M5)

07 Temperature switch for filter fan

08

09 3-way ball valve (Y13.1) with connection for sample line

10 Display-and control unit (A5)

11 Filter adapter, solenoid mechanism and C14-flat top source

12 Main switch (S0)

13 Filter tape turning roll

14 Filter tape source reel and motor (M4)

15

16

17/1 Pt100 (heated sample line)

17/2 Pt100 (heated sample probe)

18/1 Cable measuring signal from flow sensor (option)

18/2 Cable (status and measuring signals)

19/1 Power cable (heated sample line)

19/2 Power cable (heated dilution line)

20 Power cable (instrument)

21/1 Heating cable 1 (heated sample probe)

21/2 Heating cable 2 (heated sample probe)

22 Hose (Dilution)

23 Hose with inserted trim nozzle (Exhaust)

24 Hose (Compressed air)

25 Passage for sample line

26 Condensate

27 Cabinet fan (M1)

28 Inlet filter

29 Ring bolts for transport

30 Swinging frame

31 Front glass door

F904-20 Rev. 31 Page 43


9.4. Flowchart (standard application)

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F904-20 Rev. 31 Page 44


9.5. Flowchart (BFG application)

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Explanation of flow chart F-904-20 1 Sample Point

2 Sample Probe

3 Sample Line

4 3-Way Ball valve for dilution medium (Y13.2)

5 3-Way Ball valve for Total Volume (Y13.1)

6 Pneumatic pivoting drive for 4 and 5 (Y13.0)

7 Pilot valve for 6 (Y13)

8 Pilot valve for purge interval sample system (Y2)

9 Control system for the Dust Meter (PLC) (A2)

10 Display- and Control Unit (A5)

11 Filter fan (M1) or cooling unit (M2) for cabinet ventilation and cooling including temperature switches for the fan (B1) or cooling unit

12 Measuring amplifier for GM-Tube (A4)

13 GM-counter tubes

14 Heater for Filter holder

15 Filter holder top with 13

16 Filter tape- Transport roll including stepping motor (M6)

17 C-14-Flat Top Source

18 Filter tape- Take- up Reel including Motor (M5)

19 Filter holder- Temperature measurement

20 Filter tape- Turning roll

21 Filter tape- Source Reel including Motor (M4)

22 Pressure switch (-1 ... 0 bar) (S3)

23 Motor control valve for Vacuum pump (Y3)

24 Vacuum pump (M3)

26 Venturi nozzle for Total gas flow

27 Venturi nozzle for dilution gas flow

28 Moisture indicators for dilution gas before the Pressure Differential Meas.

29 Moisture indicators for total gas before the Pressure Differential Meas.

30 Pressure transducer for Gas Probe Flow (B4)

31 Pressure transducer for Total gas flow (B3)

32 Temperature measurement within the gas flow

33 Motor control valve for dilution gas flow (Y4)

34 Sample gas chiller incl. peristaltic pump (E1, M7)

35 Condensate-trap (A6)

36 Shut off valve exhaust back flow (Y15) (option BFG)

37 Pilot valve rest gas flushing (Y14) (option BFG)

38 Throttle valve rest gas flushing (Y16) (option BFG)

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10. Service Documents

10.1. Some pictures of the measuring instrument

10.1.1. Sample probe

Illustration 4: Sample probe, complete

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Illustration 5: Nozzle of standard probe

Illustration 6: Nozzle for small hole and BFG applications

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Illustration 7: Mounting position (part inside of the stack)

Illustration 8: Mounting of assembly parts (outside of the stack)

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Illustration 9: Connection of lines and wires

Illustration 10: Isolation of upper part

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Illustration 11: Isolation of lower part

Illustration 12: Isolation, fixed

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Il- lus-tra- tion 13: Ex-tra iso-la- tion (for

outdoors)

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10.1.2. Measuring instrument

Illustration 14: Complete instrument (standard)

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Illustration 15: Complete instrument (BFG application)

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Illustration 16: Display and keyboard

Illustration 17: 3-way-ball-valve (cover removed)

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Illustration 18: Filter holder, complete

Illustration 19: Side of filter tape supply and deflection

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Illustration 20: Side of filter tape take-up and transport

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Illustration 21: Cabinet with open swinging frame

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Illustration 22: Cabinet with open swinging frame (BFG application)

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Illustration 23: Mounting sheet, top part

Illustration 24: Mounting sheet, lower part

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Illustration 25: Bottom part with transformer for the probe, gas chiller and sample

pump

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Illustration 26: Mounting sheet (special application)

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Illustration 27: Top view with connecting-IN/OUT

Illustration 28: Top view with sample gas inlet and cabinet fan

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Illustration 29: Filter-Inlet with cover installed

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Illustra- tion 30: Instru- ment with door

closed

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Illustration 31: Instrument with door closed (BFG application)

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10.2. Instruction for Changing a Filter Roll

Opening the supply filter reel:

Remove the front part of the supply filter reel by turning it while holding the back part.

Opening the uptake filter reel: Remove the front part of the uptake filter reel by turning the centre part while holding the back part.

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Place on the filter roll in the shown direction.

In menu manual mode go to adapter and press F1 to open.

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Lift the pad roll and lock it in the intended hole in the panel.

Push the tape through the filter adapter.

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Lead the tape by the transport roll.

Fix the Tape on the cardboard roll with an adhesive tape.

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Turn the uptake reel 2 to 3 times to the left to fix the tape some more.

Release the pad roll onto the transport roll, so the tape is pressed on the roll.

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Close the adapter by pressing F2.

Fix the front part of the uptake reel by turning it while holding the back part.

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Fix the front part of the supply reel by turning the front part while holding the back part.

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10.3. Wiring Diagrams and terminal connection table (see specific sheets in dependence on the customer project)

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10.4. Characteristics for dimension of the probe nozzle size

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10.5. Shut-off and Purge Features (Y13)

Function

- Gas direction for diluted gas probe or back purging for the sample gas line

- Gas direction for dilution gas or back purging for the dilution gas hose

3- Way ball valve with a top-mounting flange (Y13.2) - W 160 1 / 2 ‘’ with T- Holes

- sealed on all sides

- Brass

- Sealed with PTFE

Pneumatic ¼ turn drive (Y13.0) - GTE-083-090-10-F05 / F07-Z10A

3 / 2- way solenoid valve S8-M32G-C2-24V (Y13)

Electromechanical stop switch (S2) - TI-SU 1W

Sleeves- 3-way ball valve with mounting holes M5 (Y13.1) - W 430 1 / 2 ‘’ with T- Hole

- sealed on all sides

- W-Nr. 1.4408/1.4401

- Sealed with PTFE

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10.6. 2/2- Way- Solenoid Valve Type 404 (Y2, Y14)

Function : Control valve for the back purge cycles (one pack purge

period consists of a compressed air pulse of 1 second

and a stop of 3 seconds)

Model : 0404

Operating mode : 2 / 2- Way, closed in normal position

Nominal width : 12 mm

Dense materials : NBR

Lead connection : G 1 / 2 Sleeve

Voltage : 024 V

Frequency : DC

Input : 8 Watt

Special Configuration : Standard cable head, SEV- Approval

Pressure Range : 1 - 16 bar

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10.7. Shut off valve exhaust back flow (Y15)

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10.8. Pressure Transducer P82R (B3, B4)

Function: Differential pressure measurement on venturi nozzles

(Total volume flow, partial volume flow) for measuring

and control of volume flows

Type: Root Extracting Pressure Transducer P 82 R

Range: 0 - 60 mbar

Output signal: 0 - 10 V DC

Supply Voltage: 24 V DC

Housing: 120 mm x 122 mm x 75 mm

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10.9. Vacuum Pump Specifications (M3)

Function: Dry running rotary van vacuum pump sucks a gas sample

(diluted or undiluted) through a filter tape. The gas flow through

the pump will be controlled by a bypass valve.

Type: Disk Vacuum Pump Pico VLT 10 (0)

Motor: EW- Motor 0,37 / 0,45 KW 1450 / 1700 / MIN

230 V +/-10 % 50 / 60 Hz

Isolation class: F

Protection: IP 54

Equipment: Suction side Micro-fine filter

Vacuum safety valve

Acoustic jacket

Exhaust silencer

Built-in Plastic/Metal buffer

Pump speed: 11,7 / 13,5 m3/h

Max. Pressure: 150 mbar (abs.)

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10.10. Motor Regulating Valve for bypass control of the vacuum pump (Y3)

Function (Y3): Volume flow control in bypass of the vacuum pump for total flow

Type: MKEN-0227

Description: 2 / 2- way, I

Size: 20 mm

Sealed with: EPDM

Material: Plastic

Connection size: TU28

Voltage: 24 V DC

Power consumption: 10 Watt

Pressure range: 0 - 6 bar

F904-20 Rev. 31 Page 104


10.11. Motor Regulating Valve for dilution air control(Y4)

Function (Y4): Volume flow control of the gas probe, undiluted (measured on

the exhaust output)

Type: 2- Way Motor Regulating Valve

Connection size: G 1 / 2”

Pressure range: - 0,9 … 10 bar

Voltage: 24 V DC

DC Motor: Running time 90 Degree entering angle : 10 - 14 seconds

mechanical strike

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10.12. Pressure Switch Specifications (S3)

Type: VH 0880100 (F-904K)

Range: 1 ... 0 bar

V max: 250 VAC

W max: 400 VA

P max: 80 bar

I max: 3 A

T max: 80 °C

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Type: 625 (option for F-904)

Pressure range: -100 ... –900 mbar

Voltage max: 250 VAC

Current max: 6 A at load resistance, ohmic

3 A at load resistance, inductive

Temperature max: 65 °C

Membrane Type A (NBR)

Protection: IP 54 (incl. plastic cap with direction upwards)

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10.13. Electric trace heated sample line (see specific sheets in dependence on the customer project)

10.13.1. Electric trace heated sample line type 1 (one line for the diluted sample gas and one line for the dilution gas, total length ≤ 20m, for weather protected installation only) Instrument type : F-904-20 O/C no. : … S/N : … Componen t “heated and temperature adjusted line for diluted sample gas” Type: - Electric trace heated sample line for stack gas sampling

Construction: - Process tube inside as stainless steel 1x12x1 mm

- Resistance heating cable 100 W/m

- Thermal insulation by multilayer thermo sheet material

- Coating made by polyamide wave, black

- Pt100 for temperature measurement and control 2-wires cable, 3 m long

- Limiter for 200 °C switch off (up to 20 m length of line)

- Power cable 3-wires, 3 m long

- Flexibility (minimum radius) 300mm

- Hard cap on both sides

Specifications: - Temperature up to 200 °C

- Electrical heating 230 V AC

- Length … m (total power consumption … W)

Component 2 “heated and temperature self-limited line for dilution gas” Type - Electric heated and temperature self regulated dilution gas hose

Construction - Process hose inside as PVC-fabric hose 10x3

- Resistance heating and temperature self-adjusting cable about 15 W/m

- Thermal insulation and protection by multilayer thermo sheet Material, diameter outside about 50mm



Specification - Temperature up to 35 °C


- Length equal to the length of the component 1 (total power consumption … W)

F904-20 Rev. 31 Page 118


10.13.2. Electric trace heated sample line type 2 and 3 (all in one protection, total length ≤ 20m, line type 2 for weather protected installation only, line type 3 sampling side outdoor, instrument side for weather protected installation only) Instrument type : F-904-20 O/C no. : … S/N : … Component “heated and temperature adjusted line for diluted sample gas”

Type: - Electric trace heated sample line for stack gas sampling

Construction: - Process tube as stainless steel (1.4571) 1x12x1 mm

- Resistance heating cable about 120 W/m


- Protection for -Line type 2 through a coating made by polyamide weave, black -Line type 3 through a coating made by Polyamide wave, black

- Diameter outside for line type 2 about 55mm for line type 3 about 79mm



- Flexibility (minimum radius) 450mm for type 2 600mm for type 3

- Hard- / Teflon cap on both sides




Component “heated line for dilution gas”

Type - Electric heated dilution gas line parallel to the component “heated and temperature adjusted line for diluted sample gas”

Construction - Process tubing inside as PTFE-hose 1x12x1

- Heated from the resistance heating cable for the component “heated and temperature adjusted line for diluted sample gas”


Specification - Temperature up to 60-80 °C

- Length equal to the length of the component “heated and temperature adjusted line for diluted sample gas”

F904-20 Rev. 31 Page 119


10.13.3. Electric trace heated sample line type 4.0 (one line for the diluted sample gas and one line for the dilution gas, total length ≤ 40m, for weather protected installation only) Instrument type : F-904-20 O/C no. : … S/N : … Component 1 “heated and temperature adjusted line for diluted sample gas”






- Diameter outside about 43mm








Component 2 “heated and temperature adjusted line for dilution gas”

Type - Electric trace heated dilution gas line

Construction - Process tubing inside as PTFE tubing 1x12x1

- Self-adjusting heating cable about 30W/m





- Hard caps on both sides





F904-20 Rev. 31 Page 120


10.13.4. Electric trace heated sample line type 4.1 (one line for the diluted sample gas and one line for the dilution gas, total length ≤ 40m, lines for out-door installation, connecting side for the instrument for weather protected installation only) Instrument type : F-904-20 O/C no. : … S/N : … Component 1 “heated and temperature adjusted line for diluted sample gas”
















Construction - Process tubing inside as PTFE-hose 1x12x1



- Coating made by PVC YM4, black








F904-20 Rev. 31 Page 121


10.13.5. Electric trace heated sample line type 4.2 (one line for the diluted sample gas and one line for the dilution gas, total length ≤ 40m, for outdoor installation) Instrument type : F-904-20 O/C no. : … S/N : … Component 1 “heated and temperature adjusted line for diluted sample gas”






- Diameter outside about 43 mm





















F904-20 Rev. 31 Page 122


10.13.6. Electric trace heated sample line type 4.3 (one line for the diluted sample gas and one line for the dilution gas, total length ≤ 40m, for outdoor installation)

Instrument type : F-904-20 O/C no. : … S/N : … Component 1 “heated and temperature adjusted line for diluted sample gas”



























F904-20 Rev. 31 Page 123


10.13.7. Electric trace heated sample line type 5.0 (one line for the diluted sample gas and one line for the dilution gas, including explosion-proof acces-sories, total length ≤ 20m, sampling point side in explosion hazardous area and F-904-20 side in safe area, for weather protected installation only) Instrument type : F-904-20 O/C no. : … S/N : … Component 1 “heated and temperature adjusted line for diluted sample gas”

Type: - Electric trace heated (Ex)-sample line for stack gas sampling






- 3x Pt100 for temperature measurement, control and limiting for 180°C including control and isolation module, 2-wires cable, 3 m long







Component 2 “heated and temperature self-limited line for dilution gas”

Type - Electric heated and temperature self regulated dilution gas hose

Construction - Process hose inside as PVC-fabric hose 10x3

- Resistance heating and temperature self-adjusting cable about 15 W/m

- Thermal insulation and protection by multilayer thermo sheet Material, diameter outside about 50mm






F904-20 Rev. 31 Page 124


10.13.8. Electric trace heated sample line type 5.1 (one line for the diluted sample gas and one line for the dilution gas, including explosion-proof acces-sories, total length ≤ 40m, sampling point side in explosion hazardous area and F-904-20 side in safe area, for outdoor installation) Instrument type : F-904-20 O/C no. : … S/N : … Component 1 “heated and temperature adjusted line for diluted sample gas”



























F904-20 Rev. 31 Page 125


10.13.9. Electric trace heated sample line type 5.2 (one line for the diluted sample gas and one line for the dilution gas, including explosion-proof acces-sories, total length ≤ 40m, sampling point side in explosion hazardous area and F-904-20 side in safe area, for outdoor installation)

Instrument type : F-904-20 O/C no. : … S/N : … Component 1 “heated and temperature adjusted line for diluted sample gas”



























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10.13.10. Instructions for installation

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10.14. Sample Gas Probe (see specific sheets in dependence on the customer project)

Instrument type : F-904-20

O/C no. : …

S/N : …

Welding flange (pos.11): Customer side, equal type like pos.12 (100/108,0 DIN 2573) (alternative: type FL100MF3, length … mm

Flange (pos.12): NW100 ND 6 DIN 2527 (blind flange, included in VEREWA delivery)

Cable connection for Resistance heating: 2 wires heating cables 16 (35) mm2 between heating transformer and tubes for diluted sample gas and tube for dilution gas (without heating for BFG application and high temperature sampling)

Probe length: Dimension A = … mm Dimension B = … mm Dimension C ≤ … mm Total length = … mm

Probe nozzle ∅middle: … mm

Dimension C about … mm because no pipe socket is used (for mounting of sample gas probe especially for small holes and for BFG applications see modified nozzle on drawing below)

Boxed execution: Flange (Pos.11) welded to the pipe socket on the duct wall (please note: flange position / technical manual, att. 2.2, upper / lower drawing, flange type can be different !)

Modified nozzle: used for this application!

Please note: sampling nozzle is welded! not screwed!

F904-20 Rev. 31 Page 135


176

F

Illustration 32: Sample gas probe (A up to 1000mm)

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F

Illustration 33: Sample gas probe (A ≥ 1000mm)

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Illustration 34: Flange

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10.15. Peristaltic pump for condensate (M7)

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10.16. Sample gas chiller Function

The gas chiller (cooler) is a special equipment and modified for the Extractive Beta Gauge Particulate Monitor. For the modification of the gas chiller (gas dryer) the special characteris-tics of the plant have to take into consideration like:

- The high water content in the sample gas

- The aggressive and strong corrosive components in the sample especially dur-ing condensation of moisture (demand of resistant material for all parts staying in contact with the sample)

- The high sample gas flow

- The continuous working condition with internal system pressure (up to about -0.5 bar)

- Transport of condensate with a peristaltic pump regarding the low pressure in the gas canal in comparison with the ambient pressure

Technical data

Dew point on gas output: +2°C ... 11,5°C adjustable

Stability of dew point: lower limit +2 +/- 1°C

upper limit +11,5 +/- 2°C

Temperature gas input: max. +50°C

Dew point on gas input: max. +60°C

Performance max. 3 m3/h

Ambient temperature +5°C ... 40°C

Pressure of sample gas: -0,5 ... 1,2 bar

Power supply: 230 V / 50 Hz – 1/N/PE; 430VA

Warm-up time: < 15 minutes

Protection: IP22

Dimensions: D = 415 mm, W = 315 mm, H = 400 mm

Weight: 45 kg

Cooling capacity: ca. 600kcal/h (700 W)

Condensate drain: Titanium tubing ∅ 12 x 1, reduced to tube connection DN 4 x 1

Sample gas connections: Titanium tubing ∅ 12 x 1 for gas IN/OUT

Condensate container: ca.1175 cm3

Cooling unit material: Titanium

Refrigerant: Design.: R134a, capacity: 170 g

Compressor: Danfoss FR 11 GX (alternative: GL 90 TG, Elektrolux)

Liquefying equipment: GT 3R208D59360 (special unit)

Fan: 2 pieces flat fan 13 W

Thermostat: K50-1122

F904-20 Rev. 31 Page 141


Illustration 35: Sample Gas chiller (front, tube connectors)

Gaseingang Gas inlet

Gasausgang Gas outlet

Kondensatausgang Condensate outlet

Lüftungsöffnungseinlass Ventilation inlet

Kühlerdeckel Cover sheet

F904-20 Rev. 31 Page 142


Illustration 36: Sample Gas chiller (top, without cover)

Rohrstutzen für Schlauch-Anschluss Gaseingang Tube connector for gas inlet

Rohrstutzen für Schlauch-Anschluss Gasausgang Tube connector for gas outlet

Thermostatregler für Kühlertemperatur (Werkseinstellung!!) Control for cooler temperature (Factory setting!!)

Wärmetauscher mit Lüfterblock für Kom-pressoreinheit Air cooler and fan modul for compres-sor unit

F904-20 Rev. 31 Page 143


10.17. Maintenance Schedule

Maintenance Schedule for F-904 (PLC) / w: weekly, m: monthly, t: three monthly, h: half-yearly, y: yearly

Activity w m t h y

Check the sample gas probe 2

. Remove the probe; visual inspection inlet nozzle, probe pipe, PTFE-insulating

shells; cleaning of the probe x

. Check of probe heater incl. fittings x

. Removal of sediments, incrustations, especially on the input of the nozzle

and within the probe pipe; replacement of damaged parts, if

necessary x

Check of the sample gas line 3

. Visual inspection, condition of the insulation x

. Fixed seat of pipe fittings between sample gas probe and

the instrument x

. Cleaning and removal of blockages, if necessary x

Check the shut-off and purge features of the sample gas way 4, 5, 6, 7, 8

. During the operation check the mechanical change over and turn drive functions

of solenoid valves and ball valves x

. Check the tightness; fixed seat of all fittings for pipes and tubes x

Check the shut-off and purge features for BFG application 36, 37, 38 (option)

. During the operation check the mechanical change over and turn drive functions

of solenoid valves x

. Check the tightness; fixed seat of all fittings for pipes and tubes x

Check of the control system, Display and keyboard 9, 10

. Visual check of all components; fixed seat of boards and

connectors x

. Function check of display and keyboard x

Function check of cooling unit 11 (option)

Check of cooling function (see assembly instructions) x

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Check of the programmed temperature within the cabinet, correction if necessary x

Cleaning of the heat exchanger x

Function check of fan-and-filter-unit incl. temperature regulator 11 (option)

. Cleaning or exchange of the filter (air-in and air-out) x

. Function check of the temperature regulator and the fan x

Check of the mechanical components on the front side of the

instrument 15, 16, 18, 20, 21

. Position of all mechanical components x

. Check of the filter holder (condition, cleaning of the

gas flow components and these parts are contacting with filter tape) x

. Function check during the instrument is working (filter holder,

filter tape) x

. Check of the filter tape transport x

. Exchange of the filter tape if necessary x x x x x

. Exchange of the cover foil if necessary (option) x x x x x

. Exchange of the ribbon for tape printer if necessary (option) x x x x x

Check of the radiometric measuring system 12, 13, 17

. Fixed seat of GM-counter tube and connectors x

. Display count rate (Technical manual,

Service menu !) x

Check of the filter holder heating 14, 19

. Simple check - touch the filter holder and you feel the temperature x

. Display filter temperature (Technical manual, Service menu!)

and measurement of the temperature in comparison with the display

value x

Function check of the vacuum switch 22

. During the suck cycle close hermetically the input for gas probe

(at about - 0,5 bar the switch is on) x

Check tightness of the whole system

. During the display flow (Service menu)

connect a manometer (0 ... -1 bar) on the input for the gas probe

(the pressure / vacuum of the system decreases to about - 0,8 bar) x

F904-20 Rev. 31 Page 145


Vacuum pump with bypass controller 23, 24

. Exchange of the filter inside the pump (Manual for the pump,

Service manual !) x

. Exchange of the carbon vanes, always the complete set (Manual for the pump,

Service manual !) x

. Exchange of the GF- or textile fibre filter on the output of the

vacuum pump x

. Check/adjustment of the volume flow display (total flow, sample flow) x

. Gas counter and thermometer on the exhaust (sample flow), on the sample

inlet (total flow)

. Note the counter results (lgc: litre gas counter) after the suck cycle is finished

and the middle of the gas temperature (tgc) during the suck cycle

. Standard condition: Nlgc/h = lgc/suck cycle (minutes) x 60 x 273/(273+tgc)

. Comparison the display value of the volume flow with the measured gas coun-ter

result (standard condition)

Check of components for volume flow measurement 26, 27, 28, 29, 30, 31

. Visual check of moisture indicators (28, 29) x

If colour changes from blue to pink than exchange the moisture indicators

and remove the cause for the moisture x x x x x

with the gas volume in the display, alignment board A8 if necessary)

. Check the tube connections between silicagel vessels (28, 29),

venturi nozzles (26, 27) and pressure transducers (30, 31) (fixed seat, tightness) x

Check the temperature measurement within the flow of gas 32

. Visual check x

. Measurement of the gas temperature and comparison with the temperature value

shown on the display x

Dilution flow measurement and control 33

. Visual check x

Check of sample gas chiller incl. Peristaltic pump 34

. Check the function of the chiller during the suck cycle, feel the different

temperatures on the tube connections for input (warm) and output (cold) of the

of the gas probe x

F904-20 Rev. 31 Page 146


. Measurement of the temperature for the gas input and the gas output,

correction on the chiller thermostat if necessary x

. Visual check of the peristaltic pump during operation (fixed seat of x

cartridge with rolls and the press clamp, tubing will be pressed completely in this

position, if peristaltic pump is on you should visit condensate and air bubbles

within the tubing, during operating condensate is not allowed to run back

to the chiller)

. Exchange of tubing for peristaltic pump x

. Exchange of cartridge with rolls, press clamp and clip x

Check of piping and wiring

. Visual check (condition of tubing - holes and fractures - , fixed seat of

tubing connections and hose band clamps) x

. Exchange of piping x

Check of the internal gas canal

. Cleaning of pipe fittings if necessary x

. Cleaning of venturi tubes if necessary x

. Maintenance of the valves if necessary x

Function check of measuring signals, status signals and other

functions and parameters of the instrument

. Check of analogous measuring signal outputs x

. Dust Concentration 0 ... X mg/Nm3 = 4 ... 20 mA,

. Dust Mass 0 ... 10 mg = 4 ... 20 mA option

. Function check for status signals (error) x

. Collection fault

. Vacuum error

. Filter tear

. Volume error

. Measuring range error

. Condensate

. Uptake full (option)

. Function check for status signals (function)

. Range status signal for 0 ... 45 mg/Nm3

. Range status signal for 0 ... 225 mg/Nm3

. Zero signal

. Reference signal

F904-20 Rev. 31 Page 147


. Zero Test cycle

. Reference Test cycle

. Check of the Error messages memory if the help key LED is blinking x

. Check the instrument with x

. Reference foil

. Zero signal

. Reference signal

Note: (number) = position in the flow diagram

10.18. Calculation of tape consumption in the F-904-20

Formula N = L[m] * tcycle[s] * FB * k / d[mm]

Comments N: tape consumption in “days/filter tape”

L: length of filter tape in “mm”

d: distance between consecutive filter spot in “mm”

tcycle: total cycle time for generation of one measuring result in “s”

FB: number of single samples on one filter spot

k: constant for correction of dimension units with 0,0115 for N[days/tape]

Worked sample N = ?

L = 150m

d = 43mm (for F-904-20)

tcycle = 900s

FB = 1

K = 0,0115

N = 150m * 900s * 1 * 0,0115 / 43mm = 36,1

Tape consumption with the selected parameters is 36 days / tape of 150m length.

F904-20 Rev. 31 Page 148


11. German equivalency test published in GMBI

F904-20 Rev. 31 Page 149


12. EC-Declaration of Conformity / EN 50081-1 und EN 50082-2

F904-20 Rev. 31 Page 150


13. Order Numbers for Consumables and Spares

Art.-Code Art.-Code Description included

in per year

for 2 years

(new) (old) CK SK CS1 CS2

Heated sampling System

FVF904010206# Insulating Husk (PTFE) (flange bushing)

nmuM18-L/V4A Cap nut (flange bushing)

mdiS-RINGS18-L Cutting ring (flange bushing)

FVF904010209# Setting element, part 1 for sample probe tubes

FVF904010210# Setting element, part 2 for sample probe tubes

FVF904010214# Binding Post for heating cable 1 1 2

BF904-20/SA 904-CONNECT Fitting between probe and heated sample line 1 1 1

mdiSO51021-12 Straight coupling (sample tube/tube dilution gas)

FVF904010211# Hose nozzle (sample tube/tube dilution gas)

904-2244 PTFE-gasket for probe flange size:

mdi100ND16D2527 100 ND16 DIN 2527

mdi125ND16D2527 125 ND16 DIN 2527

mdi150ND16D2527 150 ND16 DIN 2527

wdisilschl50/rb Silicone foam hose Do=50mm, Di=30mm red and brown per m 2 1 2

wdisilschl30/rb Silicone foam hose Do=30mm, Di=15mm red and brown per m 1 0,5 1

wdiSO223 Shut-off and Purge Features

wdiSO223353T 3-Way Ball valve for Total Flow SO 223 353T

wdiSO2233/2KuVe 3-Way Ball valve for Dilution Gas Flow SO 223 3/2 KuVent

wdiSO223EScha. Electromechanical End position Switch SO 223 E Scha.

wdiSO223Ant Pneumatic Pivoting Drive

wdiSO2233/2Vent Pilot Valve SO 223 3/2 Vent

wdiSO2231/4"DRO Choke Silencer SO 223 1/4" DRO

wdiventil0404 904-0034K Back flush Valve

BFG-dust monitoring (option)

wdiventil0404 904-0034K Flush Valve Remnant Gas

mdiSO46221L-6 Flush Gas Choke Valve

mdi00022504 Block Valve Exhaust Gas Backflow

Filter holder-and transport option

FVF904--170207# Inlet

F904-20 Rev. 31 Page 151



in per year

for 2 years


FVF904--170210# Filter holder (top part)

FVF904--170211# Filter holder (bottom part)

FVF904--170204# Insert

wdiheizpatrone1 Heating Cartridge (Inlet)

wdiheizpatrone 904-0158 Heating Cartridge (Filter Holder)

wdithermoPT100 904-0258 Resistance thermometer Pt100 (inlet, filter adapter, Gas temperature on Differential pressure Tube)

pdiTWÄCHTER Temperature limiter

BF904-20/GF 904-227150 Glass-Fibre Tape 150m, low heavy metal content 5 12 24

wdimotorM4E060 703-M4E060230 Tape Reel Motor (230V, 50/60Hz)

pko000100/400v Motor Capacitor 1μF/400V (for 230V-Motor)

wdimoM4E060CA05 703-M4E060115 Tape Reel Motor (115V, 50/60Hz)

pkom000400e400v Motor Capacitor 4μF/400V (for 115V-Motor)

wdimotorUFB2 904-0027UFB2 Stepping Motor

mreWAB312/24V 904-1031 Solenoid 24V, 50Hz

mreWAB312/24V60 904-4031 Solenoid 24V, 60Hz

Heavy Metal Sampling

BF904/AFB 904-111150 Cover Foil 150m 5 12 24

BF904-20/FR Cover Foil roll

wdoCQM1H-SCB41 Communication Module 1xRS232, 1xRS422/485

wdiminidrucker 703-160160 Tape Printer (mechanic)

wdifarbbDPN-190 904-0180 Ribbon for Tape Printer (1 per Box) 1 4 8

wdisteuerplatte 703-000160 Tape Printer (Controller)

FVF904030201# Mounting Angle 1

FVF904030202# Mounting Angle 2

Signal processing, Control

wdiCQM1-0C222 Contact Output Unit

wdiCQM1-0D214 Transistor Output Unit

wdiCQM1-PA203 AC Power Supply Unit

wdiCQM1-TC102 Temperature Control Unit

wdiCQM1H-CPU51 CPU Unit

wdiCQUM1H-MAB42 Analog I/O Board

wdiNT4S-SF121B Interactive Display

wdiCQM1-AD042 A/D-Converter

F904-20 Rev. 31 Page 152



in per year

for 2 years


wdiCQM1-DA022 D/A-Converter

wdiCQM1H-PLB21 Impulse I/O-Board

Components, Sensors

BSM-57 904-SM5700 GM-Counter Tube Signal Amplifier

mscdruckschalte 904-0039K Vacuum Switch

BF904-20/ST 703-000C14 Source

BF904-20/GZ 904-0059 GMC (Geiger-Müller Counter Tube) 1 1 1

mreSRGY22593 Electron. Load Relays (for probe K8, for line K9)

mdikapSSR900000 Cover for Load Relays

mre0-24VDCSolid Solid-State-Relay 0V-24DC/60DC/2

mreV23107-S4042 Solid-State-Relay 0V-24DC/280AC/5

mla35vL3/2S14 Replacement insert for cabinet lamp 230V 35W L3, 2S14 1 1 2

Gas-Volume Flow-Measurement and- Control

FVF904--040200# Differential Pressure Tube

wdimeßumformer 904-1006 Differential Pressure Transducer

FVF904--160207# Dry Cartridge for Difference Pressure Measurement 1 1 2

mor25x1,5 O-ring NBR 70 25x1,5 4 4 8

wdisilica/or Silicagel w/ indicator 1-3 mm, per 1kg 1 1 1

wdipumpeVLT10/d Sample Gas Pump for Total Gas Flow, tight (BFG option)

wdivakuumpumpe Sample Gas Pump for Total Gas Flow

wdipatroneVLT10 904-2123 Filter Cartridge (11) for Sample Gas Pump 4 4 8

wdilamelleVLT10 904-2223 Carbon Blade (set of 6) for Sample Gas Pump 1 1 1

mor526331 Sealing ring (31) 1

mor517087 Supporting ring (32) 1

mor704024 Sealing ring (91) (set of 3) 1

mor704545 Sealing ring (93) (set of 2) 1

wdiventilMKEN Motor Control Valve type MKEN for Sample Gas Pump

BF904-20/VG Control Board for Motor Control Valve type MKEN

wdidruckfilter 904-0055 Filter Case for Sample Gas Pump

wdifilt/element 904-0154 Glass Fibre Filter Cartridge for Filter Case 4 4 8

mor/EAF4000-F03 904-0355 O-Ring 111636 for Filter Cartridge 1 1 2

BF904-20/MR Motor Control Valve and Control Board for Dilution Gas Flow

F904-20 Rev. 31 Page 153



in per year

for 2 years


Sample Gas Dryer, Condensate Transport

wdimeßgaskühler Sample Gas Chiller

mdifeuchtwvar2 Moisture Watchdog

wdiSR25-15UPM 904-0057 Peristaltic Pump

wdischlauch4,8 904-0157 Tubing for Peristaltic Pump, per m 1 1 2

SETCONSR25 904-0657 Repair-Kit for Peristaltic Pump (Tubing Set, Cartridge with Rolls, Press Clamp, Clip) 1 1

wdipumpeDSP9911 Peristaltic Pump DSP 9911,1l/h,230V,50/60Hz,100%ED

Tubes

wdipvcschlD10 904-0073 Plastic-Textile-Tubing 10x3 (per m) 10 10 20

wdimetschlP10 904-0072 Plastic-Steel spiral-Tubing 10x3 (per m) 2 2 4

wdischlDN10x4 904-0358 Silicone-Tubing 10x4 (per m) 2 2 4

wdischlDN4x1 Plastic-Tubing 4x1 (3m for peristaltic pump DSP) per m 2 2 4

wdischlauchPVC Plastic-Tubing 4x1,5 (3m for peristaltic pump DSP) per m 3 3 6

wdischlauchPVC Plastic-Tubing 4x1,5 (5m for peristaltic pump SR25) per m 5 5 10

wdisk5200158 Hose Clamps for Net-Pump-/Spiral-Pump-Tubing 20 10 20

wdisk5200182 Hose Clamps for Silicone Tubing 4 2 4

wdisk5200081 Hose Clamps for Venturi-Nozzle, Differential Pressure Transducer, Cartridge for Silicagel, Peristaltic Pump 20 10 20

F-904-20/CK Consumable Kit

F-904-20/SK Spare Parts Kit

F-904-20/CS1 Consumables and spares for 1 year operation

F-904-20/CS2 Consumables and spares for 2 years operation

(For completion of "CK" and "SK" regarding type and options of devices see list "Consumables and Spare Parts", last column!)

F904-20 Rev. 31 Page 154


14. Factory testing Protocol (see specific sheets in dependence on the customer project)

Date post:	06-Mar-2018
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