manual aquatrace iv - dks-engineering.de · electrolysis of water, which is adsorbed by phosphorus...

1 GmbH Radeberger Str. 21; 01900 Großröhrsdorf

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E-Mail: [email protected]; www.dks-engineering.de

Manual

AQUATRACE®- IV The advancement of the successful measuring equipment for

analysis of moisture traces in gases

0 - 2000 Vppm H2O

mailto:[email protected]


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Content

1.INTRODUCTION ........................................................................................................................ 3

2. THE STANDARD DEVICE STRUCTURE OF THE MEASURING INSTRUMENTS .............................. 3

3. MEASURING PRINCIPLE ........................................................................................................ 4

4. MEASUREMENT SETUP ........................................................................................................ 4

5. PRECONDITIONS FOR TROUBLE-FREE OPERATION OF THE MEASURING .............................. 6

6. EXPLANATION OF THE MENU STRUCTURE AND CARRY OUT THE MEASUREMENT .................. 7

7. SPECIAL FUNCTIONS .............................................................................................................. 19

7.1 VIRTUAL NETWORK COMPUTING ........................................................................................ 19

7.2. ULTRA VNC ON A WINDOWS PC ......................................................................................... 21

7.3 CUSTOMIZED ADJUSTMENT OF THE CHARACTERISTIC ........................................................ 22

8. PIN ASSIGNMENT PER CHANNEL ........................................................................................... 25

8.1 MEASURING CELL - DEVICE .................................................................................................. 25

8.2 ANALOG OUTPUT SCALABLE, 4 – 20 MA .............................................................................. 26

8.3 ALERT RELAY OUTPUT 1 + 2 ................................................................................................ 26

8.4 ALERT RELAY OUTPUT 3 + 4 ................................................................................................. 26

9. STATUS OUTPUT (ONCE PER DEVICE) .................................................................................... 27

10. FAQ ..................................................................................................................................... 28

10.1 WHAT IS THE RESPONSE TIME OF THE SENSOR AT A MOISTURE EVENT? .......................... 28

10.2 HOW DOES THE SENSOR AT A DECREASING HUMIDITY? ................................................... 28

10.3 WHAT DO THE ERROR MESSAGES MEAN ON THE DISPLAY? .............................................. 28

11. DESCRIPTION OF OPERATING ELEMENTS ............................................................................ 29



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1.Introduction

The instruments of the type AQUATRACE® IV are an advance on the successful series of moisture trace measuring instruments that work on a basis of P2O5-sensors and are used for the determination of moisture in all gases (except NH3) in the ppm range.

The measuring system consists of a separately installed measuring cell (for example from PVDF for aggressive gases), that can be integrated in a gas handling system, and an electronic evaluation unit.

The measuring instruments are available as o portable lab unit o portable lab unit with battery o industry unit 19” Rack or o wall mounted model

2. The standard device structure of the measuring instruments

The device can process up to 4 independent channels

The display is designed as a touch screen and does not use prone operating elements

The large graphics display with a resolution of 800 x 480 pixels shows the time-dependent course of the measured values for one or all integrated channels. can be set to Vppm or Dp°C for the device selectively

The running-in process after recoating is shown with logarithmic scaling. After falling below the upper measuring value scaled for the channel, the display automatically switches to the linear scale.

Advanced menu navigation by fading in of practical notes, especially regarding the sensor coating.

The display can be set to Vppm or Dp°C for the device selectively. The conversion is done automatically using the Magnus formula.

The user language can be selected from 9 languages.

Production according to ISO 9000

Certification according to current NAMUR – recommendation, status signals for every channel are supplied as potential free relays for:

o Failure o Limit exceeded o maintenance requirements o Device in maintenance

An automatable Sensor Check enables the self-monitoring of the device

All changes and settings are saved on several levels (user, engineer, administrator) with password protection

The analog output can be scaled freely 4 – 20 mA (for each channel)

The device records all measurements and changes to the device per channel in background on. It features a USB interface through which all data can be read as a logbook

.



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3. Measuring principle The principle of the detection of the moisture content of gases is based on the electrolysis of water, which is adsorbed by phosphorus pentoxide. In the AQUATRACE the sensor coated with H3PO4 is surrounded by a precisely defined gas volume. The cell parameters and the flow velocity are coordinated in such a way that the acid always absorbs a constant portion of the gas moisture and this fraction is electrolyzed in the same time unit. The result of this is the setting of a dynamic equilibrium in which the flowing current is

4. Measurement setup The measurement cells consist of the sensor in the form of a cylindrical target, alternatively from - ZrO2 with an interdigital structure of Pt-Layersor or - Glass with bifilar wounded Pt electrodes,

and the sensor housing, which is available in stainless steel ( V4A ) or in PVDF



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This allows all the requirements are met regard to the corrosion resistance.

The sensors are coated with an about 40% H3PO4 (half concentrated acid). The cleaning and recoating of the sensor is described in the operating menu in the device. This step is particularly important because the proper functioning of the P2O5 sensor is highly dependent on its care. The handling of the sensor requires some practice: - It is basically to make sure that no moisture enters the cell (sensor housing) during the cleaning and the re-coating of the sensor. After thorough cleaning of the sensor under running water this must be dried thoroughly with a lint free cloth (paper) - To coat the sensor sure the sensor tip always must be kept down. Only 1 - 2 drops of electrolyte should be distributed on the "active" sensor surface (slight rotation, possibly spread with a brush). - To prevent a "splash" of electrolyte in the sensor housing, should be subside the strong formation of bubbles on the sensor first, before you put him in the chamber. - Please note! Moisture remains on the housing surface are very slowly degraded by the flowing dry gas, resulting in over a longer period to falsified (increased) measurements.

Operation of the measuring cell is basically to ensure a constant gas flow. The flow rate has influence on the response time after change of humidity but also on the absolute value, because a corresponding calibration curve is tightly defined in the evaluation electronics. Measuring cells are available in 20 NL/h or 100 NL/h for flow rates. The unit automatically recognizes which of the two cells is connected. The cells are designed for a pressure up to 10 bar for safety reasons, the sealing is carried out vertically over a Viton O-ring. Normally, the measurement is done under low input pressure (20-100 mbar). Higher pressures are to reduce with a pressure regulator or throttle valve.

A reliable measuring result requires the acquisition and the constancy of the flow. All components used in front of the measuring cell should have a leak rate of better than 10-4 mbar l / s. Behind the cell the measured gas must flow without pressure, which must be installed an exhaust pipe of at least 1 meter length. Shorter tube length can easily be the back diffusion of moisture from the environment. The pipe lines for the measurement should always be made in stainless steel. PTFE pipes must be used for particularly aggressive gases such as chlorine. Other plastic materials may cause diffusion of moisture into the gas



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5. Preconditions for trouble-free operation of the measuring

Basically, it is sure that the gas supply channels to the cell are as short as possible. Keep in mind that the water molecules are always inclined to attach themselves to the "inner surfaces". The effect is greater in appearance, the bigger these surfaces are, i.e. the greater the roughness of the pipe wall and the moisture content of the gas is higher.

That represents a feature of the behavior of water molecules and not a property of the measuring system.

Put enough time for the "free rinse of the measuring device" after initial start-up and openings E.g. after servicing.

The measuring cable between cell and analyzer is standard 2.0 m long. However, distances of up to 150 m between the point of measurement and the evaluation unit are possible. Please contact us for the dimensioning of the cable to.

For measurements in explosive gases, an intrinsically safe version of the measuring arrangement is required. Please contact us due to the necessary specific device design!

Before measuring is to rinse thoroughly and check the entire system for leaks. Depending on the cleanliness of the parts and the length of the gas supply pipe, this process can take several hours to complete, since the shares of moisture adsorbed on the "inner surfaces" must be dismantled.

This preparatory phase is finished when the value displayed on the device no longer changes within about 30 minutes.



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6. Explanation of the menu structure and carry out the measurement

After the system start-up is finished, the system configuration reports. In the system configuration the desired language can be selected. All operating elements are shown in the chosen language.

Menu item CONFIGURATION • display in Vppm or Dp °C • language selection • user management • channel administration (not existent, invisible, sensor type….) • data export (value range, channel...) • date, time • „Stamp“ (e.g.: measuring point name; gas name...) • name of channels • alarm/ limit setting • setting of automatic sensor test (per channel) • scaling of analog output (per channel)



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Menu item INFORMATION :

• type of device • serial number • date of delivery • software version • firmware version • date of last data output

According to company structure many users with different access authorization can be put on under the menu point 'User‘.

4 Operation levels: 0. - free (access without PIN code) 1. Operation staff-PIN – authorized for channel switching; sensor test; coating sensor 2. Engineer-PIN – authorized for changing device configuration; read out data resp. device status 3. Service - protected interface – change Soft-/ Firmware; error diagnosis



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For every available channel the intended parameters can be defined or select. The recorded measurement data can be selected and red out by "export logfile" on an USB stick. All measuring data are saved in .csv format for each day.

Main design of the menu with headline for function buttons



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The arrangement of the channel display can be changed user defined

By touching a channel field, it appears in the foreground.

The time axis can be zoomed by touching.



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Display of a “run-in” process with logarithmic scaling. As long as the adjustable limit value is exceeded, the display blinks in red

Regular curve linearity after a fall below the limit value. Limit value: 55,0 ppm e.g.



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If the visible curve value in the left picture edge has reached the scaled maximum value, the scaling switches to linear scaling again

For checking the measuring cell, a sensor test is carried out. By touching, the required sensor/measuring point can be selected.



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For the sensor test the PIN (engineer or operator level, if this is set) is required. (look at menu point „USER“)

Select „Enter“ for the Test-Menu. Start the test (yes), or leave the menu (no).



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When the test has been started, it runs automatically and the chronological sequence can be monitored. In the meantime, the output will be switched to „maintenance“ and the measuring value to „sample and hold“.

The test result will be displayed and – as shown here – set to the measuring mode with „OK“.



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When the test has been negative, the relay “maintenance” will be switched on. It can be decided whether to switch to the coating mode (yes) or to continue to measure (no). In this case, the service symbol remains active

If confirmed with "yes", the operator receives an indication of possible hazards. At the same time, the voltage at the sensor is switched off, the analogue output switches to "sample and hold", the display shows the last measured value (here 10,3 ppm) and the "Maintenance" relay is activated. The sensor will be cleaned and the success will be tested with “ok”.



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If the cleaning procedure was not successful, meaning the electrical zero has not been reached, the procedure has to be repeated.

After a positive cleaning result (< 0,1 ppm) the coating process can be carried out. With „ok“ the voltage is switched back on and the sensor will be coated with phosphoric acid.



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NOTE: Insert the sensor into the housing only bubbling subsided. With the "ok" confirmation, the display shows the entry curve in logarithmic representation. The relay "Maintenance" is deactivated only after the value has fallen below the limit and releases the analog output ("sample and hold" is switched off).

If maintenance work must be carried out on the measuring system, you can select the channel for which maintenance is to be carried out via the main menu "maintenance sensor". (See NAMUR recommendations; Function "key switch") The following screen appears with the selection option.



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If maintenance has been confirmed with "yes" for the selected channel, the symbol on the display for this channel appears for the duration of the maintenance.

After the work has been completed, the maintenance mode can be deactivated via the "Wait sensor" button



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7. Special functions All devices except the battery-powered have a digital Ethernet interface with Modbus TCP protocol. In the AQUATRACE IV, the following functions are possible via this interface - Modbus TCP (direct, current data transfer of PLS) - Remote control of an AQUATRACE IV device via VNC - FTP (File Transfer) This is the prerequisite for Virtual Network Computing (VNC) to communicate from a local computer with the AQUATRACE IV as far away as you would be in front of it. VNC implements the Remote Framebuffer Protocol and is therefore, unlike other remote maintenance software, platform-independent. 7.1 Virtual Network Computing Using the digital interface with Modbus TCP protocol. For this purpose, the IP address of the Aquatrace®-IV must be adapted to the conditions at the site of operation. When the system has finished loading, please press "change configuration".



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Next, please navigate to "digital output". Under "IP address" the address can now be changed according to your wishes. To complete the configuration, press "close configuration". Software is restarted and the IP address is accepted. Then a VNC connection to Aqua Trace IV is possible.



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7.2. Ultra VNC on a Windows PC The UltraVNC software is available on the included USB stick.

This version is portable and doesn’t need to be installed.

Please start the UltraVNCViewerPortable application on your PC.

In the window “VNC Server”, please enter the IP address from the Aquatrace IV, which was assigned as described above.

Other settings needn’t be changed.

To establish the connection, you will be prompted for a password. The password consists of only numbers and is the device number from Aquatrace IV (see entry) Now the image of the device display appears on your PC.



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7.3 Customized adjustment of the characteristic As charged options the following options are available:

• Programming of a separate - customized - characteristic, or • Moving the characteristic stored in the device (zero point correction) or • Adjustment of Sensitivity (slope)

The adjustment of the sensor characteristics may be carried out only by specially trained and authorized staff. The same applies to the adjustment of a desired "max. value".

With the following pictures, this possibility should be illustrated:



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8. Pin assignment per channel View from solder side of the plug or top view to the socket.

8.1 Measuring cell - device

Type of socket on the device Binder Serie 680, 5 pins (Connector for the cable: 09 0317 00 05)

1 Measuring voltage output

2 Measuring voltage input

3 100 Nl sensor identification

4 GND


Connection of the measuring cell via cable Miniature coupling plug angled,, Binder Serie 712, 5 pins Type: 99 0413 70 05

1 Measuring voltage output

2 Measuring voltage input


4 GND


23

1

4

5

2

31

4 5



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8.2 Analog output scalable, 4 – 20 mA Type of socket on the device Binder Serie 680, 4 pins (Connector for the cable: 09 0309 00 04)

1 + Output mA ( + )

2 - Output mA ( - )

3 open

4 open

8.3 Alert relay output 1 + 2 Type Socket on the device Binder Serie 680, 6 pins (Connector for the cable: 09 0321 00 06) Relais 1 für „F“ ( Failure; „fale save“)

Relais 2 für „S“ ( out of spezification )

1 Relais CH 1 potentialfree -COM

2 Relais CH 1 Connector -NO

3 Relais CH 1 Opener - NC




8.4 Alert relay output 3 + 4 Type of socket on the device Binder Serie 680, 6 pins

(Connector for the cable: 09 0321 00 06) Relais 3 für „C“ ( Check )

Relais 4 für „M“ (Maintenance/ Wartungsbedarf )







2 3

1 4

23

1

4

56

23

1

4

56



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9. Status output (once per device) Type of socket on the device Binder Serie 680, 5 pins (Connector for the cable: 09 0313 00 05)


2 Relais CH5 Connector -NO

3 Relais CH5 Opener - NC

4 Open

5 Open

Relay 5 is controlled as a "fail save".

A Watchdog timer monitors the functioning of the equipment and switches off the relay in case of failure.

23

1

4

5



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10. FAQ 10.1 What is the response time of the sensor at a moisture event?

The response time from "dry" to "moist" depends mailly on the particular moisture level. For example, at a moisture increase of less than 1 ppm to about 10 ppm only leads to approx. 1 min. delayed rise of reading, what indicates surface effects on the inner surfaces of the measuring system (adsorption of the “first" water molecules). If it comes to a "moisture event" with a significant entry of water molecules (over 100 ppm), the sensor response immediately (<1 sec.). In this case the visualization of the measured values as a curve on our touchscreen is also very helpful.

10.2 How does the sensor at a decreasing humidity?

In the case of decrease of the gas humidity, the sensor behaves similarly. Where the electrolytic moisture degradation generally much slower than at a moisture increase in the measured gas (T90 about 15- 20 min. under condition that the whole measuring system was dried!)

10.3 What do the error messages mean on the display?

- „communication error“ Connection device hardware with PC board is disturbed; will be resolved timed automatically for short-term disruption

- „Destination drive is not available“ Data should be outsourced on a USB stick, but no stick is connected

- „no sensor“ no signal input at the measuring channel = no measuring cell connected; measuring cable or sensor is faulty



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Start-Stop switch; To start, press at least 3s - green ring lights - ok

Key switch - for power disconnection

Status output, see pt. 9.0 Ethernet socket

Measuring cell, see pt. 8.1 analog output, see 8.2 Relays outputs, see 8.3 Relays outputs, see 8.3

USB – slot - Updates or - copy of logged data



Key switch - for power disconnection

Status output, see pt. 9.0

Ethernet socket


Mains connection

11. Description of operating elements Type R - 19 Rack

Type W – Wall mounted



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Ethernet socket

Power switch and mains connection


Type T – Portable device


manual aquatrace iv - dks-engineering.de · electrolysis of water, which is adsorbed by phosphorus...

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