P1300 ACU Mk 5 Operating Manual

Transcription

1 P1300 ACU Mk 5 Operating Manual

2 ACU Mk5 Operating Manual Kittiwake Procal Limited Published by Kittiwake Procal Limited. All possible care has been taken in the preparation of this publication, but Kittiwake Procal Ltd its agents and distributors, accept no liability for any inaccuracies that may be found. Kittiwake Procal Limited reserves the right to make changes without notice both to this publication and the products which it describes. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means electronic, mechanical, photocopying, recording or otherwise without the express prior written permission of the copyright holder. Part Number Issue 01 January 2014 Kittiwake Procal Limited Kittiwake Procal Limited 5 Maxwell Road Woodston PETERBOROUGH PE2 7HU United Kingdom PROCAL, PULSI and XSENS are trademarks of Kittiwake Procal Limited. page 2 KITTIWAKE PROCAL LTD Issue 1

3 Contents Contents 1 Introduction... 1 About this manual... 1 About the Procal series... 1 Repair policy... 1 Documentation conventions... 2 Abbreviations... 2 Lists... 2 Figures... 2 LCD screen displays... 2 Italics... 3 Dimensions... 3 Procal Analyser system - an overview... 3 Further information Technical Specification... 1 Introduction... 1 PROCAL 1300 ACU MK 5 specification... 1 PROCAL 1300 ACU MK to AU interconnection cable lengths Installation... 1 Introduction... 1 WARNINGS1 Unpacking the system components... 1 Hardware Layout... 1 Gaining internal access to the ACU... 2 Fitting and preparing the ACU... 2 Preparing cables for the ACU... 4 Feeding cables into the ACU... 6 Connecting the system to the electrical supply... 7 Connecting to Analyser(s)... 8 Connecting to External Communication (Digital)... 9 System configuration Module configuration Operation Connecting the system to the supply The installation is now complete and the system is ready for operation Installing Software Operation... 1 Introduction... 1 ACU display screens... 1 Header area... 2 Instrument Status Area... 2 Primary Data Display Area... 2 Footer buttons area... 3 Starting up the system... 3 Routine operation... 3 Software operation... 5 Setup Key... 5 System Menu Key... 6 Instrument General Key... 8 Procal 2000 Specific Key... 9 Instrument Communications Key Compensations Menu Key Analyser Temperature Control Key Sample Temperature Control Key Auto Verification Menu Key Channel Menu Key Alarm Config Key Issue 1 KITTIWAKE PROCAL LTD page 3

4 ACU Mk5 Operating Manual System Menu Key Instrument General Key Instrument Communications Key Compensations Menu Key Channel Menu Key Config Alarms Key Test Screen Key Inst Status Key Measured Key DC/Derived Key Key Key More Key Test Key Active Alarms Key Actions Key Info Key Alarm Log Key Autocal Log Key Shutdown Key page 4 KITTIWAKE PROCAL LTD Issue 1

5 Introduction About this manual This manual is intended to assist the user in the safe and efficient installation, operation and maintenance of the Procal Analyser series of process gas analysers. It has been written in accordance with the requirements of British Standard BS4884 Technical manuals Part 1: It is split into a number of sections. Introduction (this section) gives a brief overview of both this manual and the systems which it describes, together with sources of further information and product support. Installation gives preinstallation information and goes on to describe how the Control Unit of a Procal Analyser system is installed. Operation gives comprehensive user instructions for the analyser and peripheral devices. Maintenance lists and describes routine maintenance tasks, and provides fault-finding information down to the level of user-replaceable parts. Calibration instructions are given, together with spares lists. Disposal instructions details how the analyser and peripherals may be disposed of safely and without environmental damage. Order-specific information gives additional information specific to the instrument you have purchased. A full Technical specification is provided for the Procal 1300 Analyser Control Unit. Appendices A to G deal with interfaces, the connection of external devices and software variations. About the Procal series The Procal Analyser series is a range of high-performance gas process analyser systems. These systems are intended to be used for measuring gas concentrations, particularly in continuous industrial processes and flue stacks. Every system includes up to four Procal Analysers and a PROCAL Analyser Control Unit. This technical manual describes primarily the Procal 1300 Analyser Control Unit. A separate manual exists for each of the different Analyser Units, eg Procal Four wires are necessary for a connection between an PROCAL 1300 ACU MK 5 and a Procal Analyser. This is because the Analyser has its own power supply and its own connection to mains. The four wires interconnection perform a twoway serial data link and the cable used should be to the specification Belden 9842 or equivalent. The Procal cable specification is on drawing Repair policy Kittiwake Procal recommends that repairs to the Procal Analyser system are only made by its own trained support staff, or by those of its distributors world-wide.

6 ACU Mk5 Operating Manual If you have the necessary technical qualifications, training and experience you may wish to make straightforward repairs in-house. A spares list is given for this purpose. However, you should note that if a repair is incorrectly carried out, this may void or limit the warranty on the system. You should also note that this manual is not intended to describe fault-finding or repair down to component level. Documentation conventions Abbreviations Within this manual, the following abbreviations are used: PROCAL 1300 ACU MK 5 Analyser Control Unit IOU Input Output Unit AVU Auto Verification Unit IR Infra red ISH In-Situ Heater LCD Liquid Crystal Display (also referred to as the screen) AU Analyser Unit PSU Power Supply Unit Lists Often in this manual, instructions or information are presented in list form. Use of black squares indicates that there is no special order to the instructions or information. However, when instructions are numbered, it is important that the individual instructions or points are followed sequentially. Figures Figures in the text are always numbered in the form Figure X-Y, where X is the section number, and Y is the sequential figure number within that section. For example, Figure 3-2 is the second figure in section 3. When a figure reference is in brackets (Figure 9-4), this refers you to that figure, usually to confirm the location of a component, control or indicator. LCD screen displays Screen displays on the PROCAL 1300 ACU MK 5 are presented in this manual as approximations. When values are shown on screens, it should be remembered that these appear by way of example only. It is highly unlikely that the values displayed on your screen will be the same as in this manual. Some systems will have different screens because of custom modifications. If so, this will be highlighted in the section of this manual entitled Order-specific information. page 1-2 KITTIWAKE PROCAL LTD issue 1

7 1 Introduction Italics Paragraphs in italics usually indicate background information which may be of benefit to the reader. Groups of words in italics are usually cross-referring the reader to a section or sub-section by name. Dimensions All dimensions in this Operating Manual are in mm (millimetres) unless otherwise indicated. Procal Analyser system - an overview At each Analyser Unit, the concentrations of up to six gases may be measured. In addition, up to four analogue inputs can be accepted as 0-20 ma, 4-20 ma, 0-5 V or 1-5 V signals A schematic diagram of a typical Procal Analyser system appears in Figure 1-1. This shows the various interconnections between different parts of the system, and some of the external devices that may be connected to the Procal 1300 Analyser Control Unit. Each Analyser Unit functions independently but each is controlled by the Procal 1300 Analyser Control Unit, which collects data from all of the Analyser Units. The Analyser Control Unit displays, stores readings and retransmits concentrations obtained from the Analyser Units. issue 1 KITTIWAKE PROCAL LTD page 1-3

8 ACU Mk5 Operating Manual Figure 1-1 Procal Analyser system schematic page 1-4 KITTIWAKE PROCAL LTD issue 1

9 1 Introduction Further information This Operating Manual aims to provide all the information you require to install, operate and dispose of your Procal Analyser system. If you require any further information regarding the system or its use, you should contact Kittiwake Procal Ltd., or your Procal distributor as shown in the panel below: Kittiwake Procal Limited 5 Maxwell Road Woodston PETERBOROUGH PE2 7HU United Kingdom tel: fax: (international) (01733) (within the UK) (international) (01733) (within the UK) sales@procal.com issue 1 KITTIWAKE PROCAL LTD page 1-5

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11 Technical Specification Introduction The PROCAL 1300 ACU MK 5 is a computer-based system, which processes the information collected by Procal Analyser Units. It is designed for both control room and external environments. Connection to the Analyser Unit(s) is by means of a 4 core cable (two twisted pair). PROCAL 1300 ACU MK 5 specification Functions Processing of raw data from Analyser Units to produce concentration readings in the customerspecified units. Input / Output Options The Procal 1300 can support up to 20 I/O devices from the following:- Analogue retransmission in the form of Output 0-20 ma or 4-20 ma signals Analogue Inputs in the form of Output 0-20 ma or 4-20 ma signals Alarm / Control relays (Volt-free switching) Each of the twenty I/O can be assigned to any analyser and any channel. Serial MODBUS Slave interface. Information display Display parameters Integral LCD with LED backlight. MAIN screen displaying gas concentrations with real-time clock/ calendar. TEST screen displaying raw data figures, sample temperature, analyser temperature, optical filter levels, sample pressure and diagnostics. TREND screen displaying 48 hours' history of each component; selectable 'zoom' function. ALARM screen displaying current alarm states. MENUs for adjustable parameters. Controls Outputs Touch Screen. Up to 20 current outputs 0-20 ma or 4-20 ma, each galvanically isolated from ground and from each other. Normally only fitted with the same number as the number of displayed channels. issue 1 KITTIWAKE PROCAL LTD page 2-1

12 ACU Mk5 Operating Manual Outputs (continued) Up to 20 volt-free relay outputs, (n/c or n/o selectable) for channel low/high alarms and various other functions. 24V 1A max. RS232 or RS485 serial MODBUS Slave interface. Inputs Data storage Power down protection Enclosure Operating environment Up to twenty (20) Inputs, either current, voltage or contact inputs, each galvanically isolated from ground and from each other. Not normally fitted. Internal non-volatile FLASH-based logging capability. Non-volatile memory of all configuration parameters, and user adjustments. Storage time with analyser unpowered: indefinite. Mild Steel with high protection finish, sealed to IP65. Cable entry through undrilled gland plate. Operating temperature range: -10 C to +50 C. Non-hazardous area rating. Services required Weight Maximum dimensions V ac; 48 to 62 Hz at up to 150 W 7.8 kg 400 x 300 x 150 mm (H* x W x D). *Excluding Glands page 2-2 KITTIWAKE PROCAL LTD issue 1

13 2 Technical specification PROCAL 1300 ACU MK to AU interconnection cable lengths The PROCAL 1300 ACU MK 5 requires only a 2-pair data cable to connect to the Stack Mounted Analyser, such as Belden Cable lengths can be up to 1,000m, analysers must be connected in a daisy chain format and RS485 connection conventions observed. If in doubt contact your local Procal Disitributor or the factory for advice. issue 1 KITTIWAKE PROCAL LTD page 2-3

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15 3 Installation Introduction This section describes how to install the PROCAL 1300 ACU MK5. Installation procedures for Analysers and other associated equipment are detailed in the technical manuals for those components. WARNINGS YOU MUST NOT ATTEMPT TO INSTALL THIS SYSTEM UNLESS YOU ARE QUALIFIED, COMPETENT AND AUTHORIZED TO WORK ON ELECTRICAL EQUIPMENT OPERATING AT YOUR LOCAL MAINS ELECTRICAL SUPPLY VOLTAGE. READ THIS SECTION IN ITS ENTIRETY BEFORE ATTEMPTING TO INSTALL ANY PART OF THE SYSTEM. IF THERE IS ANYTHING YOU DO NOT UNDERSTAND, OR YOU DO NOT FEEL CONFIDENT OF YOUR ABILITY TO FOLLOW THE INSTALLATION INSTRUCTIONS, DO NOT PROCEED. CONTACT KITTIWAKE PROCAL OR YOUR PROCAL-AUTHORISED DISTRIBUTOR. Unpacking the system components Hardware Layout If this has not already been done, unpack the system components and check that they correspond to the units ordered and listed on the accompanying packing note. If there is any discrepancy, or any damage is apparent, do not attempt to install the system. Contact Kittiwake Procal, or your Procal distributor. The Procal 1300 ACU Mk 5 has a touch screen interface and runs Procal HMI Analyser Control Software, will support up to 4 analysers and is housed in an IP65/NEMA 4X enclosure. Figure 3-1 Issue 1 KITTIWAKE PROCAL LTD Page 3-1

16 ACU Mk5 Operating Manual Gaining internal access to the ACU Unlock the main hinged door using the key provided. A view of the terminals and main components is shown in Figures 3-2 & 3-4 Figure 3-2 Fitting and preparing the ACU The ACU is designed to be wall mounted in the control room, shelter or other designated location. The wall mounting brackets are supplied with the ACU and the mounting details are shown in Figure 3-3. WARNING DO NOT CONNECT THE MAINS CABLE (POWER CORD) TO THE ELECTRICAL SUPPLY UNTIL ALL CONNECTIONS WITHIN THE ACU HAVE BEEN MADE. FAILURE TO FOLLOW THIS WARNING MAY RESULT IN SERIOUS OR FATAL INJURY FROM ELECTRIC SHOCK. Page 3-2 KITTIWAKE PROCAL LTD Issue 1

17 3 Installation Figure 3-3 Mounting details for the ACU Cables will need to be fed in through glands mounted in the base of the ACU. Note the gland plate is supplied blank (undrilled) issue 1 KITTIWAKE PROCAL LTD page 3-3

18 ACU Mk5 Operating Manual Figure 3.4 Main ACU components Preparing cables for the ACU During preparation of the ACU, you may need to refer to the relevant installation drawing in the ACUMk5 Drawing Pack, particularly if you will be making up your own interconnecting cables. The cables used to connect other system components to the ACU are shown in Figure 3-5. Specifications for the cables are as follows: Page 3-4 KITTIWAKE PROCAL LTD Issue 1

19 3 Installation Data cable to Analyser. 2 twisted pairs, impedance 120 ohms, size 24 AWG. Suitable cable is Belden 9842, wire ends crimped for screw terminal connection. Functions are: RS485 transmit, RS485 receive. Mains supply cable. 3 core cable, rated for the local supply, 1 mm 2 cross section min, wire ends crimped for screw terminal connection. Customer connections Unscreened circular cross-section cable with the to relays and required number of cores, outside diameter ma outputs. mm max. Note that while both the relays and the current outputs are galvanically isolated from ground, the voltage superimposed on them should not exceed 50 V dc with respect to ground. Optional RS485 data cable. Screened circular cross-section cable, 1or2 twisted pairs depending if half or full duplex, of outside diameter 15 mm max, Belden 9841 or 9842 is suitable. Wire ends crimped for screw terminal connection. issue 1 KITTIWAKE PROCAL LTD page 3-5

20 ACU Mk5 Operating Manual Figure 3-5 Analyser system interconnections Feeding cables into the ACU The gland plate mounted in the bottom of the ACU enclosure must be removed before gland holes are drilled, Before drilling it is important to determine the number of glands required. The gland for the power cable / lead should be located on the left hand side of the gland plate to line up with terminal block 1. Connect the cables to the ACU as follows: Data cable (ACU Analyser) See Analyser to ACU Mains supply cable Wire to Terminal Block TB1. Connections to relay Connect to terminal TS2, TS4, TS8 or TS10 as shown in Figure ma outputs or inputs. Connect to terminal TS1, TS3, TS7 or TS9 as shown in Figure 3.5. External Comms (ACU DCS) See Page 3-6 KITTIWAKE PROCAL LTD Issue 1

21 3 Installation Connecting the system to the electrical supply Ensure that a 2.5 A, 20 mm slow blow fuse is fitted in both terminal mounted fuses (located on TB1, see Figure 3-4). Figure 3.4 ACU mains connector and fuse location (Extract from Drawing sheet 1 of 4) 1. Connect mains Cable / Lead to TB1 Live TB1-2 Neutral TB1-3 Earth TB1-1 (Earth must be connected) issue 1 KITTIWAKE PROCAL LTD page 3-7

22 ACU Mk5 Operating Manual Connecting to Analyser(s) Figure 3-5 ACU Connection to Analyser (Extract from drawing sheet 2 of 4) The connection from the ACU to the first analyser using J5 will be as follows:- CABLE TYPE 13 ACU Mk5 ANALYSER (AU) INTERCONNECTION (PROCAL INSTRUMENT BUS) SPECIFICATION ACU FUNCTION ACU MK5 AU OR AU WITH COVER HMI MASTER ISSUE 3 P100 P600 P100 P600 COVER TWO TWISTED PAIR CORES WITH SCREENS. NOMINAL CHARACTERISTIC IMPEDANCE = 120 OHMS, BELDEN 9842 OR EQUIVALENT ONWARDS AU DATA RETURN R- J5-1 TS1-1 TB1-1B DATA RETURN R+ J5-2 TS1-2 TB1-2B DATA OUT T- J5-3 TS1-3 TB1-3B DATA OUT T+ J5-4 TS1-4 TB1-4B SCREEN J5-7 JUNCTION BOX (Extract from drawing sheet 4 of 4) Page 3-8 KITTIWAKE PROCAL LTD Issue 1

23 3 Installation Connecting to External Communication (Digital) ACU MK5 EXTERNAL RS485 MODBUS SLAVE CONNECTIONS (EXTERNAL DATA INTERFACE) CABLE TYPE 13 SPECIFICATION 4 WIRE RS485 2 WIRE RS485 ONE (2 WIRE) OR TWO (4 WIRE) TWISTED PAIR CORES WITH SCREENS. NOMINAL CHARACTERISTIC IMPEDANCE = 120 OHMS BELDEN 9842 OR EQUIVALENT EXTERNAL MASTER FUNCTION SLAVE (ACU Mk5) LABEL J34 SLAVE/MASTER FUNCTION ACU EXTERNAL COMMS J34 (LABEL) Tx+ R+ PIN-4 DATA + PIN-2 (T+) Tx- R- PIN-3 Rx+ T+ PIN-2 DATA - PIN1-1 (T-) Rx- T- PIN-1 SCREEN 0V PIN-5 SCREEN PIN-5 MODBUS SLAVE - LINK CONNECTIONS LINK 16 & 17 PINS 1 TO 2 4-WIRE LINK 16 & 17 PINS 2 TO 3 2-WIRE MODBUS SLAVE BAUD RATE LK25 IN x1, OUT x3 DEFAULT IN 19k2 LK26 19k2 (38k4) DEFAULT IN 19k2 LK27 9k6 (28k8) DEFAULT OUT OUT=O LK28 38k4 (115k2) DEFAULT OUT OUT=O MODBUS SLAVE TERMINATION LK18 Rx TERMINATOR DEFAULT IN LK19 Tx TERMINATOR DEFAULT IN 2 WIRE NOT CONNECTED LK21 Tx- PULL DOWN DEFAULT OUT LK20 Rx- PULL DOWN DEFAULT OUT 2 WIRE NOT CONNECTED LK22 Rx+ PULL UP DEFAULT OUT LK23 Tx+ PULL UP DEFAULT OUT 2 WIRE NOT CONNECTED Figure 3-6 ACU Connection to external communications for example plant DCS (Extracts from Drawing sheets 4 &2 of 4) issue 1 KITTIWAKE PROCAL LTD page 3-9

24 ACU Mk5 Operating Manual Connecting - Lan Ethernet/USB Device/Flash Drive Ethernet and USB Ports Figure 3-7 ACU showing Lan Ethernet and USB Ports (Image of back of front panel) Only the USB Host port is to be used, for a FLASH Drive. Connecting - Analogue / Digital I/O The optional Input Output Units is mounted in the ACU enclosure to provide addition inputs, current outputs and relay outputs to any system. Each unit can provide up to 20 Input or Output Modules or Relay Modules(mixed allocation). The controller software can allocate any channel to any output, any alarm to any relay and configure any input as an additional channel. All Input Modules and Output Modules are fully isolated. The Relay outputs are voltage free. The addressing of the units by the controller does not affect the system ability to address Analysers. Page 3-10 KITTIWAKE PROCAL LTD Issue 1

25 3 Installation Memory Modules and I/O Terminals Figure 3-8 ACU showing Module Locations and I/O Terminations issue 1 KITTIWAKE PROCAL LTD page 3-11

26 ACU Mk5 Operating Manual Figure 3.9 IOM PCB During preparation of the ACUMk5 IOM connections, you should refer to the ACU Mk5 Drawing Pack if you will be making up your own interconnecting cables. The typical cables used to connect other system components to the IOM are shown in Figure 3.10 and Page 3-12 KITTIWAKE PROCAL LTD Issue 1

27 3 Installation Figure 3.10 Interconnection Cables issue 1 KITTIWAKE PROCAL LTD page 3-13

28 ACU Mk5 Operating Manual Figure 3.11 Interconnection Cables Page 3-14 KITTIWAKE PROCAL LTD Issue 1

29 3 Installation System configuration The System Database provided will be configured to suit the Inputs,Outputs and Relays configurations ordered. If changes need to be made, consult the relevant section in this manual. To add additional Modules refer to Procal for an updated configuration. Module configuration See IOM Configuration Sheet form entries for this delivery identifies the Module setup details. See IOM Customer Connections drawing for Module and Relay locations. Output Modules Link LK1 UP for 0-24mA range. Link LK1 DOWN for 0-20mA range (Default) Input Modules Link selection for three modes. J2 in, J1 out for 0-20mA or 4-20mA range. J2 and J1 out for 5V range. J1 and J2 in for Switch detection. Approx 10mA. Relay Outputs Link selection for NO (Normally Open) and NC (Normally Closed) operation. When powered off the relays will be in the Normal position. By default the error condition is this power off condition. An LED indicates Relay powered ON. Relay Rating - 28V dc max, 1A max. Not suitable for mains switching nor signal switching. issue 1 KITTIWAKE PROCAL LTD page 3-15

30 ACU Mk5 Operating Manual Operation NOTE: If the IOM is powered without communications from the Control Software then all relays will be in their alarm state and all current transmitters will output 2mA. A timeout is provided after communications is established to ensure the above occurs only in the case of a communications fault. The Output Modules have an LED on the module which is illuminated in an Error condition. This error is the result of the Module being unable to create any current output. This will be normally be because the output for this module is open circuit. Hence these LEDs can be used to check the system wiring. Note this requires operating the ACU with the door open. This should only be done by a qualified service engineer and the earlier warning as to operation on Mains Voltage applies. Connecting the system to the supply The ACU has been designed to operate on either of two power supplies: 110 V ac nominal (low limit 85 V, high limit 130 V), Hz. 230 V ac nominal (low limit 190 V, high limit 264 V), Hz. No user adjustment is necessary as the ACU automatically detects the input voltage. The procedure to connect the system to the mains supply is: 1. Ensure that all wiring between the ACU, Analysers(s) (AU)s and ancillary equipment is correct. 2. Connect the free end of the mains cable to a suitable ac supply. Follow local regulations for permanently installed equipment. It is recommended as good practice that a means of disconnection is provided within 2 meters and an RCD or ELB is also fitted. The installation is now complete and the system is ready for operation. The electrical connections are detailed on drawing Page 3-16 KITTIWAKE PROCAL LTD Issue 1

31 3 Installation Installing Software. The ACU Mk5 may have the operating software and Configuration files pre-installed, and will hence boot up immediately on power up. See the Operations Section of this Manual. If installation or update of the operating software or the Configuration Database is required see the Guide to Installation as below. issue 1 KITTIWAKE PROCAL LTD page 3-17

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33 Operation Introduction A PROCAL analyser system is controlled from the Procal 1300 (ACU Mk 5) Signal Processor Unit, and has been designed to be as straightforward as possible. The Procal Analyser Units (AU) have no operator controls. The system processes data from each Analyser Unit (AU) by allocating channels to different data types: Up to 8 channels can be allocated for gas concentration data 3 channels are allocated to internal analog inputs: Analyser Temperature, Sample Temperature and Sample Pressure. Up to 3 channels can be allocated for external analog inputs connected via the AU. Up to 32 channels can be allocated for derived channels; these produce readings that are calculated from data on other channels according to relationships defined during system setup - for more information contact Procal. The Home display of the Procal 1300 ACU is shown in Figure 4-1. The unit has a built in HMI which incorporates a touch screen backlit graphics liquid crystal display (LCD). This provides all the information about the instrument and its performance, and any faults. The software utilises touch screen buttons. The function of some of these buttons vary between screens with the function indicated on each button. THIS MANUAL VERSION APPLIES TO ACU PROGRAM V1.0.4 ACU display screens Figure 4-1 The operational LCD screen displays are divided into four areas, as shown below: issue 1 KITTIWAKE PROCAL LTD page 4-1

34 ACU Mk5 Operating Manual These areas are: the header area the instrument status area the primary data display area (for the selected input) the footer buttons area Header area The header area, shown below, is common to almost every screen. This area contains Time and Date and an identifier indicating the Analyser or Input to which the screen data refers. The example above is the header area which appears on start-up whereas the example below indentifies the Main Menu screen for a specific Analyser. Instrument Status Area The instrument status area, shown below, appears on the Home screen after startup and identifies the status of each of the inputs (up to six) to the ACU. Subsequent screens, specific to one particular input, will show the same information in the header area of each screen. Each of the inputs is selectable via the touchscreen and will cause the data display area (see next secion) to change accordingly. Figure 4-2 Primary Data Display Area This is the screen area that contains key information for the selected AU/input. page 4-2 KITTIWAKE PROCAL LTD issue 1

35 4 Operation Figure 4-3 Footer buttons area This is the screen area showing the functions of the four pushbuttons. These functions are fixed, irrespective of the displayed screen. Starting up the system Connect the ACU to the electrical supply, and switch on. After the ACU has been switched on, the display screen will display an operating system loading page for approximately 20 seconds then blank for a further 10 seconds. The ACU application software will then load taking approximately 20 seconds. After a successful start up, the Home system screen is displayed. This is described under the heading Introduction above An autozero cycle will be started at switch on as part of the system initialisation. Readings should not be considered valid until: each AU has reached thermal equilibrium by being in the process environment for at least 30 minutes and an autozero cycle has been completed following the 30 minute stabilisation period. It is normal to leave the Procal Analyser running continuously, with scheduled breaks only for routine maintenance of the analyser and/or the plant to which the system is connected. Routine operation Normally you will see the Home screen on the LCD of the AU. A typical primary information display for the Home screen is shown in Figure 4-1. issue 1 KITTIWAKE PROCAL LTD page 4-3

36 ACU Mk5 Operating Manual The Home screen shows the measured value of each component of the sample for each AU which your Procal Analyser has been configured to measure. Concentrations are shown for one AU at a time, with identification details shown at the top of the screen. You can select a different AU or Input using the left-hand side of the touchscreen. If any concentration is outside its alarm limits, the ALARM screen will normally show either HIGH or LOW for that gas. Concentration limits are set using the menu system (for more information refer to the heading Changing system settings). For more information about alarms, refer to the heading Displaying ALARM information. Any warnings or general alarm messages are shown in the auxiliary information area of the display. The four buttons in the screen footer can be used to access other system functions. In the Home screen, these buttons are labelled: OPERATOR, which gives access to the various security levels built into the system MENU, which gives access to the menus that control system settings. HOME, which causes the display to revert back to the Home screen from whichever screen is displayed at the time (this will of course be inoperative when the Home screen is displayed). BACK, which takes the operator back one screen at a time. Some Procal analysers are fitted with dual sensitivity ranges. This is to allow for situations where a process gas concentration is normally at a relatively low level but has occasional excursions of up to ten times the normal value. During these excursions, gas concentration still needs to be measured. With a single range analyser, the accuracy of all readings is a proportion of the full scale sensitivity. As the full scale sensitivity would need to accommodate the larger values, this may not give sufficient accuracy on the lower level readings that are present for most of the time. On a dual sensitivity range, two channels with different full scale sensitivities are processed and the results are presented to the user as a single reading. At concentrations below the full scale sensitivity of the lower range the low range channel readings are shown, and the accuracy of these readings is related to the lower full scale sensitivity. At higher concentrations the high range channel information is displayed and the accuracy is now related to the high range fullscale sensitivity. During routine operation various sub-menus will need to be accessed. Access to and use of these sub-menus is described below. page 4-4 KITTIWAKE PROCAL LTD issue 1

37 4 Operation Software operation Normally you will see the Home screen on the LCD of the AU (Figure 4-1). The following section describes the various Sub-menus that are available and their use. Touching the MENU key on the footer of the Home screen will give the following display: Figure 4-4 The additional directional keys in the left-hand side of the footer allow the user to select different AUs/Inputs without reverting to the Home screen whilst the additional information on the right-hand side shows which AU/Input is being accessed and its current status. Setup Key Pressing the SETUP key will give the following screen for each AU connected: issue 1 KITTIWAKE PROCAL LTD page 4-5

38 ACU Mk5 Operating Manual Figure 4-5 This screen is used for setting up initial system parameters and would normally be restricted to Supervisor access. (see Figure 4-5). If an I/O module is connected to the input instead of an AU, a different menu to the one shown above will be presented (See Figure 4-36 later in this section). It is assumed that input 6 will always be an I/O Module. System Menu Key Pressing the SYSTEM MENU key will allow various part of the system to be configured. The sub-menu derived contains the following configurable areas: SYSTEM GENERAL, which allows a title to be assigned to the System. Touching the Full Name box will display a keypad for data input. Once the screen is changed the SAVE key will be available to store the new data. If the user makes a change and tries to exit without saving, a prompt will appear highlighting the SAVE and CANCEL buttons. MODBUS SLAVE, which allows the user to set up the following functions by touching the relevant box: Enabled - Yes or No, toggled. Port Type - Serial RTU or Serial ASCI, choice from a sub-menu. Address - Free entry via keypad. Baud Rate - Choice from a sub-menu. Data Bits - 7 or 8, choice from a sub-menu. Stop Bits - 1 or 2, choice from a sub-menu. Parity - Odd or Even, choice from a sub-menu. CONFIG ALARMS, which allows the user to set up the System Alarms and has a sub-menu as follows: Alarm Type Field is pre-defined. System General or System Reading can be toggled by the Prev and Next keys. page 4-6 KITTIWAKE PROCAL LTD issue 1

39 4 Operation Name - Free entry via keypad. The Prev and Next keys will toggle between System Fault and System Reading Error, each of which can be renamed. Trigger Value - True or False, toggled by touching the box. Enabled - Yes or No, toggled by touching the box. Alarm Level - Can be toggled between Fault and Reading using the Prev and Next keys. UTILITIES, which allows the user to setup the System Utilities and has a submenu as follows: Set System Date - Data entry from a further sub-menu. Set System Time - Data entry from a further sub-menu. Update Config Database From USB - A further sub-menu prompts to insert a USB drive(see Figure 4-6) and provides an Update key. Figure 4-6 Dump Database To USB - A further sub-menu prompts to insert a USB drive(see Figure 4-6) and provides keys to export the Configuration or Log Databases. Dump Error Log To USB - A further sub-menu prompts to insert a USB drive(see Figure 4-6) and provides a key to export the Error Log Database. Dump Auto Verification Logs To USB - A further sub-menu prompts to insert a USB drive(see Figure 4-6) and provides a key to Export All Records. issue 1 KITTIWAKE PROCAL LTD page 4-7

40 ACU Mk5 Operating Manual Instrument General Key Pressing the INSTRUMENT GENERAL key will allow each AU/Input connected to the system to be configured. The sub-menu derived contains the following configurable areas (see Figure 4-7): Figure 4-7 This screen is used for setting up general parameters for each AU/Input and would normally be restricted to Supervisor access. Each of the 6 available AUs/Inputs can be selected from this screen using the Prev and Next keys. Once a change has been made the Save and Cancel keys become available. Full Name Insert chosen input name. Free entry via keypad accessed by touching the box. The default is an instrument number derived from the system configuration. Serial No - Insert AU Serial Number. Free entry via keypad accessed by touching the box you cannot use the same number for two instruments. Enabled Toggle Yes or No by touching the box.. This allows you to have an instrument and its channels to the hierarchy but block communication with that instrument. Smoothing Level Defines what percentage of the previous reading that is averaged with the new reading. The analyser updates readings every 1 to 2 seconds. As there are random variations in individual readings due to thermal noise and optical effects, the displayed values are averaged to give a more realistic value. This average is set as a percentage of the previous running value, and is normally set to 95%. Setting to a lower figure will provide less averaging, show more short-term fluctuation and will, electronically, respond to changes more quickly. Setting the percentage higher will cause the data to vary more slowly and show less short-term variation. The range of values available is 0 to 99.9%. Free entry is via a keypad accessed by touching the box. page 4-8 KITTIWAKE PROCAL LTD issue 1

41 4 Operation Limit Readings To Min Scale - Toggle Yes or No by touching the box. Use Yes is you don t want the readings to go below the minimum scale value. Display Position Defines the position of the channel within it s type group. I.e DCChan1, DCChan2 and DCChan3 would have display positions 1, 2 and 3 respectively. Free entry via keypad accessed by touching the box. Once the data for the first AU/Input has been entered, move on to the next one using the Prev and Next keys and configure that and so on until all AUs/Inputs have been configured. Once a change has been made the screen cannot be exited without using the Save or Cancel keys. Procal 2000 Specific Key Pressing the Procal Specific key will allow each AU connected to the system to be configured. The sub-menu derived contains the following configurable areas (see Figure 4-8): Figure 4-8 This screen is used for setting up specific parameters for each AU connected to the system and would normally be restricted to Procal or Supervisor access. Each of the 6 available AUs/Inputs can be selected from this screen using the Prev and Next keys. Once a change has been made the Save and Cancel keys become available. Hardware Version - A further sub-menu allows the version to be set as appropriate. Source Intensity - Free entry via keypad accessed by touching the box. Note. This option is set at Procal for the type of Source fitted. Phasing - Free entry via keypad accessed by touching the box. Note. This option is used to set the points on the detector waveform at which measurements are taken. It is set during calibration, and should not be changed. issue 1 KITTIWAKE PROCAL LTD page 4-9

42 ACU Mk5 Operating Manual XSens Maths Version - A further sub-menu allows selection of the version as appropriate for compatibility with legacy instrument calibrations or the current version. Procal to set only Drives 1 thro 4 - A further sub-menu allows selection of the following functions: None, Cal Gas 1, Cal Gas 2, Cal Gas 3, Educator, Special Purge and Analyser Heater. Function selections, via the sub-menu keypad accessed by touching the relevant box, will change depending which functions have already been chosen for the other drives. Each function can only be assigned to one drive. Instrument Communications Key Pressing the Instrument Communications key will allow comms settings for each AU/Input to the system to be configured. The sub-menu derived contains the following configurable areas (see Figure 4-9): Figure 4-9 This screen is used for setting up the communications for each AU/Input connected to the system and would normally be restricted to Supervisor access. Each of the 6 available AUs/Inputs can be selected from this screen using the Prev and Next keys. Once a change has been made the Save and Cancel keys become available. Com Port - A further sub-menu provides a keypad for free entry of the required port number through which the connection is made to this instrument. Modbus Address - Com Port - A further sub-menu provides a keypad for free entry of address of the instrument on the Modbus communication link. Compensations Menu Key Pressing the Compensations Menu key will allow compensations to be set for page 4-10 KITTIWAKE PROCAL LTD issue 1

43 4 Operation each AU/Input to the system to be configured. The sub-menu derived contains the following configurable areas (see Figure 4-10). As before, each AU connected can be accessed for setting using the Prev and Next keys and a different sub-menu is presented where an input other than an AU is connected to the system: Figure 4-10 ANALYSER TEMPERATURE COMPENSATION allows temperature compensation to be assigned to each AU connected to the system. Touching the boxes will display further sub-menu for either built-in selections or free data entry. (Figure 4-11). As before, once a screen is changed the SAVE key will be available to store the new data. If the user makes a change and tries to exit without saving, a prompt will appear highlighting the SAVE and CANCEL buttons. Each relevent input is selected using the Prev and Next keys. Figure 4-11 issue 1 KITTIWAKE PROCAL LTD page 4-11

44 ACU Mk5 Operating Manual Analyser Temp Chan Provides a further sub-menu which prompts selection of the particular instrument and component used for this compensation. The list contains all the channels defined for the selected compensation instrument. Note that the sub-menu screen will have different options depending which selections have been made previously. Analyser Temp Ref Provides a free entry keypad to set the reference temperature for the compensation. The default value is 25. SAMPLE TEMPERATURE COMPENSATION, Similar to the Analyser Temperature Compensation set-up but for the sample. Controls are as before (see figure 4-12). Figure 4-12 Sample Temp Chan Provides a further sub-menu which prompts selection of the particular instrument and component for the compensation required. Note that once again, the sub-menu screen will have different options depending which selections have been made previously and that temperature compensation can be taken from another instrument in the system if required. Sample Temp Ref Provides a free entry keypad to set the reference temperature. The default temperature is 25. WATER COMPENSATION, again similar to the Analyser Temperature Compensation set-up but for the water temperature. Controls are as before but with only one configurable box (see figure 4-13). page 4-12 KITTIWAKE PROCAL LTD issue 1

45 4 Operation Figure 4-13 Water Chan Provides a further sub-menu which prompts selection of the channel of the component used for the compensation. The list contains all the appropriate channels defined for the selected compensation instrument. Note. Comments on selection as above PRESSURE COMPENSATION, again similar to the Analyser Temperature Compensation set-up but for the sample pressure. Two configurable boxes are available (see figure 4-14).. Figure 4-14 Pressure Chan Provides a further sub-menu which prompts selection of the particular pressure correction channel of the component you wish to apply to readings from this instrument. The list contains all the instruments and components defined for the selected normalisation instrument. Note. Comments on selection as above issue 1 KITTIWAKE PROCAL LTD page 4-13

46 ACU Mk5 Operating Manual Pressure Ref Provides a free entry keypad to set the pressure that will be used as a reference for the compensation. The default value is NORMALISATION, again similar to the Analyser Temperature Compensation set-up but for the normalisation. Five configurable boxes are available (see figure 4-15) Figure 4-14 Normalisation Chan Provides a further sub-menu which prompts selection of the particular normalisation (diluent correction) channel you wish to apply to readings from this instrument. The list contains all the instruments and components defined for the selected normalisation instrument. Note. Comments on selection as above Normalisation Level Provides a free entry keypad to set the level of the normalisation component at which the process is expected to run. Normalisation Type Provides a further sub-menu which prompts selection from all the applicable components for the selected instrument. Low Calc Limit Provides a free entry keypad to set the Low Level value suitable for the application. Note that if Normalisation Factor falls outside of the limit, no normalisation will take place High Calc Limit Provides a free entry keypad to set the High Level value suitable for the application. Note that if Normalisation Factor falls outside of the limit, no normalisation will take place Analyser Temperature Control Key Pressing the Analyser Temperature Control key will allow settings to be made for each AU to be configured. The sub-menu derived contains the following page 4-14 KITTIWAKE PROCAL LTD issue 1

47 4 Operation configurable areas (see Figure 4-15). As before, each AU connected can be accessed for setting using the Prev and Next keys. Figure 4-15 Control Type provides a further sub-menu which prompts selection of the type of HEAD temperature control relevent to the instrument indicated in the header and footer. (choose from None, Fan cooler, Vortex cooler, Heater or any combination). Temperature Setpoint provides a free entry keypad to set the temperature to be maintained in the electronics area of the AU by the cooling and/or heating system. Cooler Proportional Term - provides a free entry keypad to set cooling proportional term, a gain setting dependant on the thermal system parameters. This should not be changed. Cooler Integral Term provides a free entry keypad to set a value for removal of long term error. This should not be changed. Cooler Derivative Term provides a free entry keypad to set a value for a differential term for the cooler to provide faster response. This should not be changed. Adaptive Setpoint, Toggle Yes or No to allow modification of the head temperature Setpoint to reflect the mean head temperature measured over the previous 24 hours. Heater Proportional Term - provides a free entry keypad to set heating proportional term, a gain setting dependant on the thermal system parameters. This should not be changed. Heater Integral Term provides a free entry keypad to set a value for removal of long term error. This should not be changed. Heater Derivative Term provides a free entry keypad to set a value for a differential term for the heater to provide faster response. This should not be changed. issue 1 KITTIWAKE PROCAL LTD page 4-15

48 ACU Mk5 Operating Manual Sample Temperature Control Key Pressing the Sample Temperature Control key will allow settings to be made for each AU to be configured. The sub-menu derived contains the following configurable areas (see Figure 4-16). As before, each AU connected can be accessed for setting using the Prev and Next keys. Figure 4-16 Sample Temp Control Type provides a further sub-menu which prompts selection of the type of SAMPLE temperature control relevent to the instrument indicated in the header and footer. (choose from None, Cooler or Heater). Sample Temp Setpoint provides a free entry keypad to set the temperature to be maintained in the sample cell of the AU by the cooling or heating system. Sample Temp Proportional Term - provides a free entry keypad to set the proportional term, a gain setting dependant on the thermal system parameters. This should not be changed. Sample Temp Integral Term provides a free entry keypad to set a value for removal of long term error. This should not be changed. Sample Temp Derivative Term provides a free entry keypad to set a value for a differential term for the heater/cooler to provide faster response. This should not be changed. page 4-16 KITTIWAKE PROCAL LTD issue 1

49 4 Operation Auto Verification Menu Key To satisfy the environmental regulations in the USA and some other countries, it is necessary both to check and to demonstrate that the analyser is within its quoted calibration accuracy. This requires that the Autozero facility should be augmented by an automatic check of the span calibration of the analyser. Once a day the analyser zero and span accuracy must be checked and recorded. This record is maintained on a rolling seven day basis, and the record for the previous seven days must be available for viewing and printing at any time on demand. This section describes the settings to be made for the automatic calibration of the Procal 2000, which is designed to meet the requirements of US EPA 40 CFR Part 75. It must be read in conjunction with the Procal 2000 Operating Manual. For Autocalibration to work, a Procal Autoverification Unit must be fitted adjacent to the Analyser to which it will provide gas. Pressing the Auto Verification Menu key will allow settings to be made for each AU to be configured. The sub-menu derived contains the following keys (see Figure 4-17). As before, each AU connected can be accessed for setting using the Prev and Next keys. Figure 4-17 AUTO ZERO allows auto zero settings to be made for each each AU connected to the system. Touching the boxes will display further sub-menu for either built-in selections or free data entry. (Figure 4-18). issue 1 KITTIWAKE PROCAL LTD page 4-17

50 ACU Mk5 Operating Manual Figure 4-18 Scheduled AutoZero. Toggle Yes or No to select whether Autozero is to run automatically at set time intervals. Interval - provides a free entry keypad to set the time (in hours) at which the Autozero cycle will be repeated automatically. The default is 12 hours. Offset From Midnight (Hours) provides a free entry keypad to set the time delay (hours) from midnight after which the first Autozero will be started. The default is 0. Offset From Midnight (Mins) provides a free entry keypad to set the time delay (minutes) from midnight after which the first Autozero will be started. The default is 0. Zero Purge Period (Mins) provides a free entry keypad to set the time allowed (in minutes) for the zero gas to expel the sample gas from the sample cell. The procedure to set the zero gas flow rate is described in the Operating Manual for the particular Analyser Unit. Measure Period Mins provides a free entry keypad to set a value for the AutoZero measurement period. This is normally factory set at 2 minutes and should not be changed without prior consultation with Procal. Process Purge Period (Mins) provides a free entry keypad to set a value for the time to be allowed after the autozero cycle when the purge air or calibration gas is switched off, for the process to purge the sample cell and the AU readings to become unfrozen and live again. The default value is 2 minutes. Special Purge On Toggle Yes or No to select a special purge Gas input during Auto Zero cycle instead of Air. Special Purge Name provides a free entry keypad to enter a name to appear on Status messages when in use AUTO CALIBRATION allows auto calibration settings to be made for each each AU connected to the system. Touching the boxes will display further sub-menu for either built-in selections or free data entry. (Figure 4-19). page 4-18 KITTIWAKE PROCAL LTD issue 1

51 4 Operation Figure 4-19 Auto Calibration Limit provides a sub-menu to set autocalibration to Off if not required or to select a limit band from: 2.5% to 5%, 5% to 10% or 2% to 5%. This selection determines the action to be taken if an instrument is found to be out of calibration. If you select 2% to 5% then an error in the range 0 to 2% results in no action, errors of 2% to 5% will be corrected and errors over 5% will give an out of range error. If you select 2.5% to 5% then an error in the range 0 to 2.5% results in no action, errors of 2.5% to 5% will be corrected and errors over 5% will give an out of range error. If you select 5% to 10%, then an error in the range 0 to 5% results in no action, errors of 5% to 10% will be corrected and errors over 10% will give an out of range error. Adjust Calibration. Toggle Yes or No to select if Autocalibration is to adjust the calibration automatically if any detected deviations are within the selected Autocal limit set as above Schedule Type provides a sub-menu to select from: Linear, Weekly, 2 Weekly, Monthly, 2 Monthly or Quarterly from drop down menu. Interval Days provides a sub-menu to select 0 to 99 days inclusive. Interval Hours provides a sub-menu to select 0 to 23 hours. Offset From Midnight provides a sub-menu to select 0 to 23 hours. Note: The selected Auto Calibration schedule must correspond to the Auto Zero schedule as a calibration can not take place without an Auto Zero. issue 1 KITTIWAKE PROCAL LTD page 4-19

52 ACU Mk5 Operating Manual Cal Gas 1 Purge Period (Mins) provides provides a free entry keypad to enter the number of minutes required to purge the cal gas through the system before a reading is taken. Cal Gas 2 Purge Period (Mins) as above for Cal gas 2. Cal Gas 3 Purge Period (Mins) as above for Cal gas 3. BLOW BACK allows blow back settings to be made for each each AU connected to the system. Touching the boxes will display further sub-menu for either built-in selections or free data entry. (Figure 4-20). The blow back feature helps clear the sample cell of debris. High pressure air is repeatedly blasted into the sample cell for the Purge Period. The air on/off times are configured by the Pulse On and Pulse Off periods. Gas measurments are not resumed until the Purge Period and Hold Period have expired. Figure 4-20 Scheduled Blow Back. Toggle Yes or No to select whether blow back is to run automatically at set time intervals. Interval (Hours) - provides a free entry keypad to set the time (in hours) at which the Autozero cycle will be repeated automatically. Offset From Midnight (Hours) provides a free entry keypad to set the time delay (hours) from midnight after which the first blow back will be started. The default is 0. Purge Period (Secs) provides a free entry keypad to set the duration of the blow back operation. Pulse On Period (Secs) provides a free entry keypad to set the duration of the pulse on period of the blow back operation. Pulse Off Period (Secs) provides a free entry keypad to set the duration of the pulse off period of the blow back operation. page 4-20 KITTIWAKE PROCAL LTD issue 1

53 4 Operation Hold Period (Mins) provides a free entry keypad to set the duration of the hold period of the blow back operation. Air Purge On During Blow Back. Toggles Yes or No to select whether the air purge is to be active during the blow back operation. ALARM TRIGGERS allows the user to set alarm initiation functions which will trigger system alarms for each each AU connected to the system. Touching the boxes will display further sub-menu for built-in selections. (Figure 4-20). A fault condition on one particular AU can be used to trigger the alarm of a different AU if required. Figure 4-21 Air Purge Trigger Provides a further sub-menu which prompts selection of the fault condition to be used to trigger the Air Purge.The list contains all the available functions for this setting. These being as follows for each AU where applicable: None System Fault Reading Error Specific AU Fault Instrument Reading Error Instrument Disconnected AutoZero In Progress Calibration In Progress Wheel Fault Blowback In Progress And for for each measured component, Measurement Channel, DC Channel, Derived Channel and some Instrument functions: Calculation Error Calibration Error Low Signal Suppressed (Freezes channel reading when alarm is active). issue 1 KITTIWAKE PROCAL LTD page 4-21

54 ACU Mk5 Operating Manual Safety Purge High Range Auto Zero Trigger Provides a further sub-menu which prompts selection of the fault condition to be used to trigger an Auto Zero. Selections as detailed above Auto Cal Trigger As above but to trigger an Auto Calibration. Selections as detailed above. Channel Menu Key Pressing the Channel Menu key will allow settings to be made for each AU to be configured. The sub-menu derived contains the following keys (see Figure 4-22). As before, each AU connected can be accessed for setting using the Prev and Next keys however in this instance, the required AU needs to be selected at the higher menu level (see Figure 4-6). Once the AU is selected and the Channel Menu key pushed, the Prev and Next keys allow the setting of the available measurement channels for that particular AU. The sub-menus displayed will differ from that shown in Figure 4-22 for each channel, depending on the type of channel and the settings available. The screen illustrated in Figure 4-22 is specifically for measurement channels. See later in this section (Figure 4-32 on) for other screens. Figure 4-22 GENERAL. This key is applicable to all channels and hence will appear in all the sub-menus. The sub-menu generated by using this key is shown in Figure Full Name provides a free-entry keypad to name the component or other measurement assigned to the particular channel. (ie. Water Vapour, Carbon Dioxide, Head Temperature etc). Short Name provides a free-entry keypad to give the measurement assigned to the particular channel, a short name. (ie. H2O, CO2, T Head etc). Units provides a sub-menu for the selection of the units concerned. page 4-22 KITTIWAKE PROCAL LTD issue 1

55 4 Operation Figure 4-23 Display Format provides a sub-menu for the selection of the required number of decimal places to which the measurements are displayed. This should not be adjusted to display a resolution significantly greater than the accuracy of the analyser. Typically 1 decimal point will be used for full scale sensitivities of and 2 decimal points for full scale sensitivities of less than 10. Otherwise, no decimal points are included. Min Scale provides a free-entry keypad to set the lower calibration limit. Max Scale provides a free-entry keypad to set the upper calibration limit. Suppression Alarm provides a sub-menu for the selection of an alarm which if active will suppress (freeze) the reading on the particular channel concerned. The suppression of a reading on one AU could be set to come from another AU if desired. All choices are available from this menu. Display Position provides a free-entry keypad to set the list position of the channel measurement on the Home and Test Screens. MEASUREMENT CHANNEL SPECIFIC. This key refers to measurement channels only channels and hence will not appear in all the sub-menus. The submenu generated by using this key is shown in Figure WARNING: The ACU is supplied pre-configured in accordance with the calibration of each AU. System settings should only be changed for good operational reasons. Experimenting with system settings may disturb the proper functioning of the system. issue 1 KITTIWAKE PROCAL LTD page 4-23

56 ACU Mk5 Operating Manual Figure 4-24 Measurement Filter Position provides a free-entry keypad to set the measurement filter number. For each component on the Procal 2000, two signals are recorded; the upper reading is from a measure filter and the lower reading is from a reference filter. This setting defines the measure filter number.the number of the filter used; for example, 1 indicates the first of up to eight filters on the filter wheel. Filters 0 and 9 are fixed references. Reference Filter Position provides a free-entry keypad to set the reference filter number. Use Gas Correlation. Use this button to toggle Yes or No according to whether or not correlation is required. For some gases on the Procal 2000 it is possible to significantly reduce the effect of interfering components by the use of a gas cell as well as matched filters. The use of this technique is described in the Operating Manuals for each Procal Analyser Unit. CALIBRATION COEFFICIENTS. This key refers to measurement channels only and hence will not appear in all the sub-menus. The sub-menu generated by using this key is shown in Figure Each type of channel has its own combination of calibration coefficients. The calibration coefficients for each Analyser can be viewed. Access to change most of the calibration coefficients is restricted to service engineers only. Dry Basis Use this button to toggle Yes or No according to the requirement for a wet or dry measurement basis. Not applicable to a Water measurement screen. Pressure Compensation Use this button to toggle Yes or No according to the requirement for a pressure compensated measurement. Normalisation Use this button to toggle Yes or No according to the requirement for normalisation correction to be applied to the measurement. page 4-24 KITTIWAKE PROCAL LTD issue 1

57 4 Operation Figure 4-25 WARNING: Other Settings and Coefficients on this page for which a freeentry keypad is provided, should not be altered unless instructed to do so by a Service Engineer or after consultation with Procal. As the user cycles through the various channels for any particular AU, variations of the above screen will appear. DC Channels, for example, will have only the Dry Basis, Pressure Compensation and Normalisation keys while the Derived Channels will also have additional Coefficient keys. AUTO VERIFICATION. (See also comments on Auto Verification earlier in this section). Again, this key refers to measurement channels only and hence will not appear in all the sub-menus. The sub-menu generated by using this key is shown in Figure Each type of channel has its own combination of settings and keys may differ between channels. The settings for each Analyser can be viewed. Access to change most of the settings is restricted to service engineers only. Figure 4-26 issue 1 KITTIWAKE PROCAL LTD page 4-25

58 ACU Mk5 Operating Manual Air Offset. In some cases there can be a significant amount of one of the measured components in the zero gas supply, for example carbon dioxide. You can enter this level here on the free entry keypad so that the Autozero process can allow for this residual level. Zero Offset. Each infra red channel measurement has an offset value that is adjusted to give a zero reading in the absence of any measured component. This is adjusted automatically during Autozero, but you can enter a value here via the free entry keypad, to give a positive offset during analyser testing in order to assess stability as required. Cal Gas Drive provides a sub-menu to select which of 3 possible calibration gas cylinders is to be used or none. Cal Gas Concentration provides a free-entry keypad to set the concentration of the calibration gas being used for that particular measurement. CROSS SENSITIVITY. This key refers to measurement channels only and hence will not appear in all the sub-menus. The sub-menu generated by using this key is shown in Figure Each measurement channel has its own combination of cross sensitivity settings. The settings for each component/au can be viewed. Access to change most of these settings will be restricted to service engineers only. WARNING: The cross-sensitivity parameters are set during the initial system calibration and must not be changed. Any amendments made after calibration may severely affect the performance of the instrument and your whole system. Figure 4-27 Since the keys shown above are all Factory/Engineer set or user set under direct instructions from Procal, no further instructions for change are provided in this manual. page 4-26 KITTIWAKE PROCAL LTD issue 1

59 4 Operation CROSS PRODUCTS. Again, this key refers to measurement channels only and hence will not appear in all the sub-menus. The sub-menu generated by using this key is shown in Figure Each type of channel has its own combination of settings and keys may differ between channels. The settings on one key may affect the availability of another key for example, the keys on the left of the screen will be inactive if the keys on the right are set at None. They will only activate once a selection is made in either or both of the right-hand keys The settings for each Component/Analyser can be viewed. Access to change most of the settings is restricted to service engineers only. Figure 4-28 Since the keys shown above are all Factory/Engineer set or user set under direct instructions from Procal, no further instructions for change are provided in this manual. The warning given above also applies to this screen. CONFIG ALARMS. Again, this key refers to all channels however the sub-menus will vary depending on the type of channel. The sub-menu generated by using this key to set a typical measurement alarm is shown in Figure Each type of channel has its own combination of settings and keys may differ between channels. The settings on one key may affect the availability of another key. The settings for each Component/Analyser can be viewed. Access to change these settings may be restricted to Supervisor level only. Alarm Type. Pre-defined and no changeable. Typical alarm types that are available on a channel basis (depending on the type of channel) are: Channel Out Of Cal Channel Low Signal Channel Suppressed Channel Calculation Channel Low Low Channel Dual High Range issue 1 KITTIWAKE PROCAL LTD page 4-27

60 ACU Mk5 Operating Manual Figure 4-29 Name provides a free entry keypad to enter the alarm name. Trigger Value toggles True or False depending on requirements. Select whether the Value is the normal (True) condition or will cause the alarm to be triggered. Enabled toggles Yes or No to enable or disable the alarm. Alarm Level preset for the type of alarm being configured. Box will show one of the following: Fault. (Triggering of the alarm indicates a fault has been detected). Warning. (Triggering of the alarm indicates that a warning has been generated). Reading. (Triggering of the alarm indicates a reading has been taken). Info. (Triggering of the alarm indicates that there is information for the user). As mentioned at the beginning of the Channel Menu Key section, some specific settings will be necessary on DC and Derived Channels which do not apply to measurement channels. These are illustrated in Figures 4-32 thro 4-36 below. page 4-28 KITTIWAKE PROCAL LTD issue 1

61 4 Operation Figure 4-30 DC CHANNEL SPECIFIC is the only key on this screen which has not been covered above. Touching the key will give the display shown in Figure Reading Address provides a free entry keypad to enter the Modbus address that ACU will read to retrieve data for this channel. Note: All other keys on the screen in Figure 4-30 have been dealt with previously. Additional keys may appear depending on the DC Channel function. See Figure Figure 4-31 An alternative screen display for a DC Channel is shown in Figure 4-32 below. Keys operate as before. issue 1 KITTIWAKE PROCAL LTD page 4-29

62 ACU Mk5 Operating Manual Figure 4-32 The equivalent screen display for a Derived Channel can be seen in Figure 4-33 below. Derived channels are channels that show information derived from two other channels. There are a number of algorithms that can be used to derive the channel values from the source information. Figure 4-33 DERIVED CHANNEL SPECIFIC is the only key on this screen which has not been covered above. Touching the key will give the display shown in Figure page 4-30 KITTIWAKE PROCAL LTD issue 1

63 4 Operation Figure 4-34 Derived Type provides a selection list of the types of Derived Channel that are available. Typically: Dual Plus Minus Times Divide Cool Heat Nox Plus Digital Rolling Average Compensated Percent In Limit Source Channel 1 provides a selection list to choose the channel that will be used to supply the first set of values in the algorithm for the method used to derive the channel information. Source Channel 2 provides a selection list to choose the channel that will be used to supply the second set of values in the algorithm for the method used to derive the channel information. Alarm Config Key Pressing the Alarm Config key will allow instrument alarm settings to be made for each AU to be configured. (Component measurement alarms have been covered in a previous section). As before, each AU connected can be accessed for setting using the Prev and Next keys however in this instance, the required AU needs to be selected at the higher menu level (see Figure 4-6). Once the AU is selected and the Alarm Config key pushed, the Prev and Next keys allow the setting of the available alarms for that particular AU. A typical setting screen is shown in Figure issue 1 KITTIWAKE PROCAL LTD page 4-31

64 ACU Mk5 Operating Manual Figure 4-35 Alarm Type defines the alarm to which the current screen refers and is preset within the software. For any particular AU the available alarms are: Inst General Inst Reading Inst Disconnected Inst Auto Zero Inst Autocal Inst Wheel Inst Blowback Name provides a free entry keypad to enter an alarm name. Trigger Value toggle True or False to select whether the trigger value is the normal (True) condition or will cause the alarm to be triggered. Enable toggle Yes or No to select whether the alarm is the normally enabled or not. Alarm Level preset to one of the options shown below: Fault. (Triggering of the alarm indicates a fault has been detected). Reading. (Triggering of the alarm indicates a reading has been taken). Info. (Triggering of the alarm indicates that there is information for the user). The ACU controls both Procal 2000 instruments and I/O modules. The main menu for an I/O Module will be presented as shown in Figure page 4-32 KITTIWAKE PROCAL LTD issue 1

65 4 Operation Figure 4-36 System Menu Key The sub-menu provided by using this key for an IOM is the same as has already been covered earlier in this section. See Page 4-6. Instrument General Key The sub-menu provided by using this key for an IOM is the same as has already been covered earlier in this section. See Page 4-8 Instrument Communications Key The sub-menu provided by using this key for an IOM is the same as has already been covered earlier in this section. See Page 4-10 Compensations Menu Key The reduced sub-menu provided by using this key for an IOM is the same as has already been covered earlier in this section buy with no specific AU settings. See Page 4-13 Channel Menu Key Using the Channel Menu key with the IOM input selected rather than an AU at the higher level will provide a sub-menu similar to that already shown in Figure The keys in this sub-menu however, permit additional/different settings to be made and these are covered below. GENERAL. This key is applicable to all channels and hence will appear in all the sub-menus. The sub-menu generated by using this key is shown in Figure With an IOM selected, settings can be made for all DC Channel, Relay and Transmitter connections to the IOM. See also Page issue 1 KITTIWAKE PROCAL LTD page 4-33

66 ACU Mk5 Operating Manual DC CHANNEL SPECIFIC. Up to this point we have dealt with DC Channels associated with AUs (See Page 4-30). When configuring Relays or Transmitters, different screens with different parameters become available. Figure 4-37 illustrates such a screen for Relay settings whilst Figure 4-38 shows the same screen for Transmitters. Figure 4-37 Address provides a free entry keypad to enter the Modbus address that ACU will read to retrieve data for this channel. Inverted toggle Yes or No. Choose yes if you want the relay to be normally close, then open on triggering. Source Alarm provides a keypad to select the source of the signal which will operate the relay. Delay provides a free entry keypad to enter a delay (in seconds) that will elapse after the alarm condition before the relay is triggered. Figure 4-38 page 4-34 KITTIWAKE PROCAL LTD issue 1

67 4 Operation Address provides a free entry keypad to enter the Modbus address that ACU will read to retrieve data for this channel. Source Channel provides a keypad to select the source of the signal which will operate the relay. 4ma Count provides a free entry keypad to enter the Zero Value bit count. 20ma Count provides a free entry keypad to enter the Full Scale value bit count. Frozen During Calibration toggle Yes or No to freeze output during Auto Zero/Auto Calibration. CALIBRATION COEFFICIENTS. This key applies to the IOM DC Channels in the same way as for the DC channels on the AU. See Page Not relevant to Relays or Transmitters. COMPENSATIONS. This key applies to the IOM DC Channels only in the same way as for the DC channels on the AU. See Page The Sample Temperature Compensation key is not relevant here and is replaced by the STP Compensation key which generates the screen shown in Figure Not relevant to Relays or Transmitters. Figure 4-39 STP Temperature Channel provides a sub-menu for the selection of the temperature correction signal. STP Pressure Channel provides a sub-menu for the selection of the pressure correction signal. CALIBRATE. This key applies to the IOM DC Channels in the same way as for the DC channels on the AU. See Page issue 1 KITTIWAKE PROCAL LTD page 4-35

68 ACU Mk5 Operating Manual CONFIG ALARMS. This key applies to the IOM DC Channels in the same way as for the DC channels on the AU. See Page Config Alarms Key Using the Config Alarms key with the IOM input selected rather than an AU at the higher level will provide a sub-menu similar to that already shown in Figure The keys and settings in this sub-menu are similar to those already covered on Page 4-33 with choice of settings limited only by relevance. page 4-36 KITTIWAKE PROCAL LTD issue 1

69 4 Operation Test Screen Key Pressing the TEST SCREEN key in the main menu will give the following test information screen (Figure 4-40) for each AU connected. No user changes are available within the Test Screens: Figure 4-40 The following screen (Figure 4-41) is displayed for each IOM connected: Figure 4-41 Using the Prev and Next keys, the Operator can page between AUs and IOMs. The current device selected is displayed in both the header and footer of issue 1 KITTIWAKE PROCAL LTD page 4-37

70 ACU Mk5 Operating Manual each screen. Inst Status Key Using the Inst Status key selected provides addition information as to the health of the AU. The screen presented is shown in Figure 4-42 with typical parameters displayed being: Sample Temp Power Analyser Heater Power Analyser Cooler Power Wheel Speed Figure 4-42 Measured Key Using the Measured key will revert the screen back to the component measurement information from any other screen. DC/Derived Key Using the DC/Derived key provides information regarding the DC and Derived Channels for the AU selected. See Figure These are typically: AU electronics compartment temperature (T Head) Sample Temperature (T Sample) Sample Pressure (P Sample) DC Channels (DCChanx) Derived Channels (DerChanx) page 4-38 KITTIWAKE PROCAL LTD issue 1

71 4 Operation Figure 4-43 The Inst Status, Measured and DC/Derived keys are not relevant to the IOM test screen(s) and instead are replaced with keys labelled 4 and 20 for Transmitter outputs (See Figure 4-41) and Test for Relay outputs (See Figure 4-44). Figure Key Using the 4 key will over-ride the live value and force the reading to the 4ma calibration reading (typically 0%) for 30 seconds after which the live reading will be restored. 20 Key Using the 20 key will over-ride the live value and force the reading to the 20ma calibration reading (full scale) for 30 seconds after which the live reading will be issue 1 KITTIWAKE PROCAL LTD page 4-39

72 ACU Mk5 Operating Manual restored. More Key Using the More key will page to the next set of readings. A total of 20 channels are available. Test Key Using the Test key allows the Relay channels to be toggled on or off for test purposes. After 10 seconds the relay will revert to its live state. page 4-40 KITTIWAKE PROCAL LTD issue 1

73 4 Operation Active Alarms Key Pressing the ACTIVE ALARM key in the main menu will give a list of all the active alarms in the system. See Figure Figure 4-45 Where there is more than one screen displaying active alarms, the More key becomes active to move to the next screen. No user settings are applicable to this screen. issue 1 KITTIWAKE PROCAL LTD page 4-41

74 ACU Mk5 Operating Manual Actions Key Pressing the ACTIONS key in the main menu will give a sub-menu containing keys to enable manual operation of various system functions. See Figure Figure 4-46 START MANUAL XX. These keys allows the user to toggle the particular function inscribed on the key to the On or Off position. Once activated, the inscription on the key will change accordingly. START AUTO ZERO SEQUENCE. This key initiates an immediate auto zero sequence. The auto zero timings can be configured in the auto verification settings pages. START AUTO CALIBRATION SEQUENCE. This key initiates an immediate auto calibration sequence. The auto calibration timings can be configured in the auto verification settings pages. START BLOW BACK SEQUENCE. This key initiates an immediate blow back sequence. The blow back timings can be configured in the auto verification settings pages. MANUAL ALARMS. This key allows the user to access a second screen to manually activate any alarms that are configured for the system. page 4-42 KITTIWAKE PROCAL LTD issue 1

75 4 Operation CALIBRATE. This key refers to all channels however the sub-menus will vary depending on the type of channel. The typical sub-menu generated for a measurement channel by using this key to set a calibration value is shown in Figure Each type of channel has its own combination of settings and keys may differ between channels. The settings on one key may affect the availability of another key. The settings for each Component/Analyser can be viewed. Access to change these settings may be restricted to Engineer or Supervisor levels only. Measured Value provides a live measurement reading of the calibration sample being analysed. Where to two readings differ, the software will apply a correction factor to the measurement reading. Figure 4-47 Expected Value provides a free entry keypad to enter the concentration of the component in the calibration sample. The Channel to calibrate key displays a list of channels for the particular AU on which calibration is possible. All component measurements and derived measurements will appear as shown in Figure 4-47 however the AU Sensors and other configured DC channels with have a different screen as shown in Figure Note that during normal operation of the System there should be no reason to change any settings. Changes would only be necessary if a replacement sensor was fitted to the AU concerned or DC Channels were being reconfigured. issue 1 KITTIWAKE PROCAL LTD page 4-43

76 ACU Mk5 Operating Manual Figure 4-48 Count at -10 Deg C provides a live measurement reading of the digital value from the sensor or output. The example reading shown in Figure 4-48 relates to the AU electronics compartment temperature sensor at the specified temperature. Min Calibration Value provides a free entry keypad to enter the value at which the AU is being checked at the low end of the range. Min Calibration Count provides a live measurement reading of the counts being produced by the sensor at the calibration temperature. Pressing the Get Live key will give an up-to-date reading in the box. Pressing the Save key will then update the reading in the top field and complete the low end calibration. In certain circumstances, it may be necessary to manually enter a count value in this box for which a free entry keypad is accessed by using this key. Count at 60 Deg C as above but for a different (high) calibration point. Max Calibration Value as above but for a different (high) calibration point. Max Calibration Count as above but for a different (high) calibration point. Info Key Pressing the INFO key provides details of the Version of software that is being used on the ACU. Always quote the software version when discussing the system with Procal. See Figure page 4-44 KITTIWAKE PROCAL LTD issue 1

77 4 Operation Figure 4-49 issue 1 KITTIWAKE PROCAL LTD page 4-45

78 ACU Mk5 Operating Manual Alarm Log Key Pressing the Alarm Log key displays a log of the alarm actions which have occurred since the unit was first powered up. At the end of each month, the data from that month is saved and the data from the previous month deleted. The log will then continue to log the alarms for the current month. There is no limit to the number of pages available, each successive screen being accessed by the direction keys (<< < > >>). See Figure 4-50 Figure 4-50 Note: There are no reporting or printing functions available on the ACUMK5 as it is envisaged that the unit would be used as an interface between the AUs and IOMs and a DCS system which would provide all these functions. If independent Trending, Logging, Printing etc is required the the user should consider installing an ACWn unit which contains all these functions. page 4-46 KITTIWAKE PROCAL LTD issue 1

79 4 Operation Autocal Log Key Pressing the Autocal Log key displays a log of the alarm actions which have occurred since the unit was first powered up. At the end of each month, the data from that month is saved and the data from the previous month deleted. The log will then continue to log the alarms for the current month. There is no limit to the number of pages available, each successive screen being accessed by the direction keys (<< < > >>). See Figure 4-51 Figure 4-51 Shutdown Key Pressing the Shutdown key displays a window asking you to confirm the shutdown operation (Figure 4-52). Normal running can be resumed be selecting No. If Yes is selected, all instrument and Modbus slave communications are stopped and the system is put in a state ready for safe power off (Figure 4-53). Figure 4-52 issue 1 KITTIWAKE PROCAL LTD page 4-47