TELEDYNE ANALYTICAL INSTRUMENTS Oxygen Transmitter Model 9060Z Technical Manual
Model 9060Z Manual TABLE OF CONTENTS TABLE OF CONTENTS........................................................................................................... 1 1. IMPORTANT NOTICES...................................................................................................... 7 2. INTRODUCTION .............................................................................................................. 8 2.1 9060Z TRANSMITTER.........................................................................
Model 9060Z Manual 5.3 KEYPAD........................................................................................................................ 28 5.3.1 Keypad in RUN mode .......................................................................................... 29 5.3.2 Keypad in SETUP / COMMISSIONING / CALIBRATION modes............................... 29 6. SETUP MODE................................................................................................................. 31 6.
Model 9060Z Manual 8.1 FUNCTION SUMMARY TABLE ...................................................................................... 42 8.2 CALIBRATION MODE FUNCTIONS ................................................................................ 43 8.2.1 Reference Voltages ............................................................................................. 43 8.2.2 Output Channel 1 and 2 Calibration .................................................................... 43 8.2.
Model 9060Z Manual Copyright TELEDYNE ANALYTICAL INSTRUMENTS — 2012 This manual describes the transmitter firmware version 1.24, September 2012 Neither the whole nor any part of the information contained in, or the product described in, this manual may be adapted or reproduced in any material form except with the prior written approval of Teledyne Analytical Instruments. The product described in this manual and products for use with it are subject to continuous developments and improvement.
Model 9060Z Manual Important Notice Regarding 9060 Probe Option ‐ FIL‐3 WARNING: The only identifiable standard for flame arresters for general use is British Standard BS EN 12874:2001. British Standard BS EN 12874:2001 refers to an operating environment up to 150 Degrees Centigrade. The FIL‐3 device optionally fitted to 9060 Heated Zirconia Probes (the “Probes" or "Probe") operate in an environment considerably greater than 150 Degrees Centigrade.
Model 9060Z Manual 1. IMPORTANT NOTICES This manual is intended as a supplement to the 9060Z Operators Manual. It is intended to be used by technical personal that are qualified to install, commission, service and calibrate electronic industrial control equipment. Please read the safety information below before connecting power to the transmitter. CAUTION 1 The probe heater is supplied with mains voltage. This supply has electrical shock danger to maintenance personnel.
Model 9060Z Manual Please note that if this equipment is not installed and used in the manner described in this manual then the safety protection provided by the equipment may be impaired. 2. INTRODUCTION 2.1 9060Z TRANSMITTER The Teledyne Analytical Instruments 9060Z oxygen transmitter is designed to measure the oxygen gas concentration in combustion applications such as power stations and industrial boilers.
Model 9060Z Manual Teledyne Analytical Instruments series 9060H oxygen probes and sensors employ state‐of‐the‐art zirconia sensors and advanced materials, which provide the following benefits: Improved control due to fast response time to typically less than four seconds Cost‐efficient design provides improved reliability Longer‐life probes with greater resistance to corrosion from sulfur and zinc contaminants in flue gas Low cost allows maintenance by replacement Reduced probe breakage due to gre
Model 9060Z Manual Caution, risk of danger. See additional information in the manual. 3.1 HARDWARE SPECIFICATIONS 3.1.1 TRANSMITTER SPECIFICATIONS Number of oxygen probes: Oxygen range: Oxygen accuracy: 2 maximum 0‐1% to 0‐100% ±1% of actual measured oxygen value with a repeatability of ±0.
Model 9060Z Manual Probe insertion length (from process end of mounting thread to probe sensing tip. 3.1.3 SERIES 9060H PROBES SPECIFICATIONS MODEL Application Temperature Range Length Process Connection Electrical Connection Cable Heater Thermocouple Response Time Head Temperature Reference Gas Ref Air Connection Filter Calibration Check Gas Connection Weight 9060H 9060UL/UH Combustion flue Combustion flue gases gases below above 700°C (1290°F) with 900°C (1650°F) no contaminants. Refer to note 1 eg.
Model 9060Z Manual 3.1.4 OXYGEN PROBE MODEL SELECTION GUIDE Heated probes‐temperature range 0‐900°C (1650°F). *Note: (1) The Inconel option has all inconel wetted parts except for the ceramic sensor and viton ‘o’ rings.
Model 9060Z Manual Unheated probes for clean gases‐temperature range 700‐1400°C (1290‐2550°F). *Note: (2) A standard oxygen probe for carburising furnaces, has a 253 MA sheath.
Model 9060Z Manual 3.2 OPERATIONAL SPECIFICATIONS Range of outputs: Function Linear oxygen #1 Very low oxygen #1 Linear oxygen #2 Very low oxygen #2 Average oxygen Logarithmic oxygen Reducing oxygen Oxygen deficiency Aux temperature Combustibles Carbon dioxide Probe #1 sensor EMF Probe #2 sensor EMF Burner efficiency No output ** (Adjustable zero) Range of local indication: Minimum 0 to 1% 0 to 0.001% 0 to 1% 0 to 0.001% 0 to 1% 0.1 to 20% 0 to 1x10‐30% ‐10 to 0% 0 to 100°C 0 to 0.
Model 9060Z Manual The oxygen deficiency output can be used in the same way as a combustibles analyzer to signal the extent of reducing conditions of combustion processes. 4. INSTALLATION AND COMMISSIONING 4.1 MOUNTING THE TRANSMITTER Surface mount the transmitter case on to a flat surface or bracket, using the four mounting brackets provided. The transmitter should never be mounted so that it is directly expose to the sun or rain. Always leave at least 10cm of clearance around the four sides of the case.
Model 9060Z Manual Probes can be mounted at any angle. However, if the probe is to be mounted on a vertical duct wall, it is better to angle the probe (approx. 15°) down to avoid process condensation inside the cold end of the probe. If there are any particulates in the flue gas, a filter can be omitted by pointing the probe vertically downwards. Otherwise the transmitter can be configured to automatically purge the filters, or they can be replaced periodically.
Model 9060Z Manual 4.3 INSTALLING THE AUXILIARY THERMOCOUPLE Weld a 1/2 inch BSP mounting socket to the flue within about 300 mm (12”), and upstream of the oxygen probe. The thermocouple should be of similar length to the oxygen probe to prevent flue temperature distribution errors. The thermocouple should be connected to terminals 7 & 8. These terminals will not be available for an auxiliary thermocouple if a second probe has been installed. 4.
Model 9060Z Manual Connection Diagram for 9060Z Transmitter and one or two 9060H Heated Sensors 18
Model 9060Z Manual Connection Diagram for 9060Z Transmitter and one or two 9060UL/UH Unheated Probes 19
Model 9060Z Manual • • The mains power must be either 100/110VAC or 220/240VAC with a mains frequency of 50 or 60Hz The supply circuit must be fused to at least 10Amps and have a dual pole isolation switch within easy access of the oxygen transmitter. The isolation switch must be marked as the isolation switch for this equipment. It is recommended that a separate isolation switch be used for each transmitter so that a transmitter can be serviced individually.
Model 9060Z Manual Connection of Probe Cable for Unheated Probes Models 9060UL/UH. Connection of Probe Cable for Heated Probes Model 9060H .
Model 9060Z Manual 4.8 CONNECTING THE AUXILIARY THERMOCOUPLE (OPTIONAL) For 9060H heated probes, the auxiliary thermocouple must be a separate TC with the junction isolated from earth, mounted near to and upstream of the oxygen probe. It can be either a K, J, R or S type thermocouple. It is optional. If the auxiliary temperature or combustion efficiency is not to be displayed or transmitted, then an auxiliary thermocouple is not necessary. The thermocouple should be connected to terminals 7 & 8.
Model 9060Z Manual The on‐line auto purge and calibration check system is optional. For details on its operation see chapters 4.24, 4.25 and chapter 11. To automatically sense a blocked probe filter, a flow switch should be installed in the ‘purge’ line to the probe ‘CAL’ port. It should be adjusted so that it energizes just below the purge flow with new or clean filters installed. The flow switch contacts should be connected to terminals 16 & 17 (FLOW SW).
Model 9060Z Manual network line from the transmitters is taken from the middle of the transmitter network string, a terminating resistor should be enabled with LK3 at each end of the network line. The MODBUS™ protocol of the network is – Baud Rate Parity Stop Bits RS485 Mode 19,200 Even 1 2‐wire (half duplex) RTU (binary mode) For more details see Appendix 5. 4.14 ONNECTING POWER Before commissioning the probe, sensor or transmitter, read the CAUTION paragraphs at the front of this manual.
Model 9060Z Manual high impedance alarm, ‘Probe 1 (2) High Impedance’, is not active. The actual impedance can be displayed on the lower line. It should be less than 9 KΩ at 720°C (1320°F). Once it has been established that the impedance is normal, the offset may be set using the millivolt value marked on the oxygen probe. See chapter 6.3.1, Probe Offset. The probe offset can be tested on site. A small flow of air must be admitted to both the ‘REF’ and ‘CAL’ ports when testing the probe offset.
Model 9060Z Manual downwards with the filter removed. Probes can also be mounted horizontally with no filter with some dusts. An occasional automatic back purge is helpful in this case. Normally heated probes are supplied with filters for applications with particulates in the flue gas. The probe response time should be tested when the probe is first installed, and then regularly until it remains constant for a significant period. Filter purging should be set up on the time periods determined by these tests.
Model 9060Z Manual 5. DISPLAY AND KEYPAD Operator interaction with the oxygen transmitter is done through a graphical display and 8 keys on the front of the case. The five LED indicators are used to show the status of the transmitter and to alert the operator of any errors.
Model 9060Z Manual 5.2 OXYGEN DISPLAY UNITS The measured oxygen content displayed on the top line of the transmitter for probe 1 and on the lower line for probe 2 can be shown in either % or parts per million (ppm). See chapter 6.3.3 Oxygen Display Units for how to change the oxygen display. The format of the oxygen display changes to maintain the best resolution for the measurement. If ‘Oxygen %’ is selected the transmitter will display oxygen in the following format: Range 30.0 to 100.0% 1.00 to 29.99% 0.
Model 9060Z Manual SETUP / RUN key Pressing this key will put the transmitter into one of the menu‐driven SETUP, COMMISSIONING or CALIBRATION modes (see chapters 6, 7 and 8 for details). The function of all the keys will then change to the functions that they have in the SETUP mode. DISPLAY UP / DOWN keys The display keys are used to scroll the lower line up and down through the variety of measurements that are available on the lower line. For a complete list of options see chapter 6.3.2, Lower Line Items.
Model 9060Z Manual FUNCTION up and FUNCTION down keys These two keys allow for the selection of the setup function. A function summary table is found at the start of the relevant SETUP, COMMISSIONING or CALIBRATION mode chapter. OPTION up and OPTION down keys These two keys allow for changing the option for the selected function. A list/range of options for each function is found in the function summary table at the start of the relevant SETUP, COMMISSIONING or CALIBRATION mode chapter.
Model 9060Z Manual 6. SETUP MODE The SETUP mode is mode is accessed by pressing the SETUP key momentarily so the words ‘Setup Mode’ appear at the bottom of the display. The transmitter will return to the RUN mode when the SETUP key is pressed again or 60 seconds after the last key press. 6.1 FUNCTION SUMMARY TABLE When the transmitter is in the SETUP mode the SETUP light will be on and the words “Setup Menu” will be shown at the bottom of the display.
Model 9060Z Manual 6.3 SETUP MODE FUNCTIONS 6.3.1 Probe 1 Offset Each Teledyne Analytical Instruments probe has an offset calibration value printed on a tag that is attached to the probe when it is dispatched. To achieve accurate measurement the offset value must be entered with the same polarity as it is printed on this label. The offset value should be within ±1.0mV NOTE: An offset of 1.0mV will change the oxygen reading by approximately 1% oxygen when the probe is in ambient air.
Model 9060Z Manual NOTE: An asterisk (*) on the end of the line identifies the item is enabled by default after a COLD‐START. 6.3.3 Oxygen Display Units The top line of the display that shows the oxygen measurement can be displayed in either % or ppm (see chapter 5.2 Oxygen Display Units) 6.3.4 Damping Factor The oxygen measurement can be damped by averaging successive readings from the probe.
Model 9060Z Manual 7. COMMISSIONING MODE This chapter describes the functions available when the COMMISSIONING mode is entered on the transmitter. The COMMISSIONING mode is accessed by pressing and holding the SETUP key for approximately 2 seconds until the words “Commissioning Menu” appears at the bottom of the display. The transmitter will return to the RUN mode when the SETUP key is pressed again or 60 seconds after the last key press.
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Model 9060Z Manual 7.2 COMMISSIONING MODE FUNCTIONS 7.2.1 Internal Date / Time The date and time are used in the transmitter to run time based operations such as impedance readings and gas calibration checks. The correct date and time should be entered by pressing and holding the OPTION UP & DOWN keys. The date and time will change faster the longer the OPTION key is held. 7.2.2 Service Date The service date can be used to keep a record of when a probe was changed.
Model 9060Z Manual The zero and span of the selected output are set in the following two menus (functions 11&12 and 14&15). NOTE: Regarding channel output configuration; both 4‐20mA channels are separately isolated and output variables and scaling are individually configured for each channel.
Model 9060Z Manual 7.2.8 Flue Pressure Units and Value The 9060Z transmitter is capable of fixed or variable input pressure compensation in the calculation of oxygen from ‐1 Atm to +3 Atm. If the probe is running in a pressurized environment this value should be set to allow for accurate oxygen measurement. If the flue pressure is constant select 'Fixed" in this function and set the pressure units and value in the proceeding menus.
Model 9060Z Manual 7.2.16 Solenoid 1 & 2 Post Freeze Duration of time the transmitter waits before resuming live readings following a gas calibration or purge event. (See also chapter 7.2.10) 7.2.17 Oxygen Content Calibration Gas 1 & 2 When configured as a gas calibration check solenoid this value specifies the oxygen content of the calibration gas. 7.2.18 Maximum Calibration Gas 1 & 2 Positive / Negative Error Specifies the maximum positive & negative error levels used during the gas calibration check.
Model 9060Z Manual All of the items in this list are selected as the default setting. Any of these items can be disabled from the common alarm by pressing the ENTER key, and they will then appear on the list in the other alarm relays. 7.2.22 Operation of the Alarm Relays when an Alarm is Accepted An option is available to in the commissioning menu to change the operation of the alarm relay when an alarm has been accepted.
Model 9060Z Manual 7.2.25 Communications Port Options The 9060Z transmitter has a serial communications port available at terminals 18 to 22. The default protocol is for RS‐232 running at 19,200 baud rate with 8 bits, Even parity and 1 stop bit. Function 60 Serial Interface 61 Serial Baud Rate 62 Serial Parity MODBUS 63 Address Options RS‐232 or RS‐485 (Use RS‐485 for MODBUS) 9600, 19200, 38400, 57600 (RS‐232 up to 19200 only) Even, Odd or No Parity Set the MODBUS address for this device between 1 and 246.
Model 9060Z Manual 8. CALIBRATION MODE This chapter describes the functions available when the CALIBRATION mode is selected on the transmitter. For specific information about calibrating the transmitter see chapter 10, Instrument Calibration. The CALIBRATION mode is accessed by pressing and holding the SETUP key for approximately 4 seconds until the words “Calibration Menu” appears at the bottom of the display.
Model 9060Z Manual 8.2 CALIBRATION MODE FUNCTIONS 8.2.1 REFERENCE VOLTAGES The calibration of the analogue inputs is based on the voltage of a temperature compensated voltage reference integrated circuit. There are 4 voltages generated from the standard reference voltage. They will vary by about 1% from one transmitter to another but can be trimmed by setting the actual voltages into CALIBRATION menu functions #1 to 4.
Model 9060Z Manual 8.2.8 HEATER SSR FAULT CORRECTION In the event of one of the heater solid state relays (SSR) failing in single probe mode, the heater drive output can be swapped to the HEATER 2 output. Select “Heater 1<‐> Heater 2”. If you are running in dual probe mode but not using the calibration gas or purge solenoid outputs the solenoid outputs can be swapped to the 2 heater outputs. Select “Heaters <‐> CalPurge”. The default setting is “Normal”. 8.2.
Model 9060Z Manual 9. ALARMS The 9060Z has 4 alarm relays and a built in alarm annunciator. If an alarm occurs, the ALARM light will flash. To find out what the alarm is, press the ALARM up key. When the ALARM up key has been pressed, the transmitter goes into the alarm display mode. In this mode some of the keys take on a special function.
Model 9060Z Manual 4. ‘Probe 2 High Impedance’ Oxygen probe or electrode failure. The sensor has a high impedance measurement. Replace the probe. This alarm is inhibited when the probes are less than 650°C (1200°F). 5. ‘Probe 1 TC Open Circuit’ 6. ‘Probe 2 TC Open Circuit’ Probe thermocouple is open circuit. The heater in heated probes will switch off. 7. ‘Aux TC Open Circuit’ The AUX thermocouple is open circuit.
Model 9060Z Manual 19. ‘Gas 1 Calibration Error’ 20. ‘Gas 2 Calibration Error’ At the end of an automatic gas calibration check cycle the oxygen reading was outside the values set in the COMMISSIONING menu #26 to 28 (#35 to 37). This alarm will not reset until the next calibration check cycle. The cycle can be initiated manually or automatically. 21. ‘BBRAM Fail’ All of the setup options are held in the battery backed memory (BBRAM).
Model 9060Z Manual level. With heated probes this relay will be de‐energised while the probe is heating up from ambient, making the contacts open circuit. 30. ‘Cal 1 in Progress’ 31. ‘Cal 2 in Progress’ A calibration check is occurring, either manual or automatic mode. 32. ‘Purge 1 in Progress’ 33. ‘Purge 2 in Progress’ A probe purge is occurring, either manual or automatic mode. 9.3 ALARM RELAY OPTIONS The three process alarm relays (relays 1 to 3) are user defined.
Model 9060Z Manual 10. INSTRUMENT CALIBRATION 10.1 CALIBRATION SUMMARY The 9060Z oxygen transmitter has a self calibration and diagnostic system built into the hardware and software. Once the reference voltages have been set into memory the self calibration system maintains the calibration of the transmitter. An automatic update of the zero and span is done every minute. The 4‐20mA outputs can be automatically calibrated with the press of the AUTO CAL key or manually fine tuned.
Model 9060Z Manual 11. The output should go 20.00mA. The value in function #7 (10) can be fine tuned if necessary. 12. Go back to function #5 (8) and select ‘Calibrate 4mA’ again and check that the output is still set to 4.00mA. If it is not exactly 4.00mA the value in function #6 (9) can be trimmed again. 13. Go back to function #5 (8) and select ‘Manually Calibrated’. 10.1.3 PROBE CALIBRATION There is only one calibration factor for the calibration of the oxygen probe.
Model 9060Z Manual 11. GAS CALIBRATION CHECK AND PURGE The oxygen sensor that is used in the Teledyne Analytical Instruments oxygen probe is extremely predictable, stable and reliable. For this reason, the calibration of a Teledyne Analytical Instruments oxygen system does not require the use of calibration gases. However, all Teledyne Analytical Instruments oxygen probes have a built in gas connection that does allow the accuracy of the probe to be checked in‐situ.
Model 9060Z Manual 12. SOFTWARE UPGRADES The software for the 9060Z series transmitters is contained in memory inside the microprocessor integrated circuit (IC). The transmitter therefore does not require an external memory IC for the software. Provision has been made to enable the software to be upgraded in the field without the use of a computer. If an upgrade is to be made to the software it will be supplied in a 32 pin EEROM IC type 29F010B. To do the upgrade, use the following steps: 1.
Model 9060Z Manual 13. TROUBLESHOOTING The Teledyne Analytical Instruments oxygen transmitter has proved an extremely reliable instrument. The trouble shooting guide here is based on an analysis of the potential problem that may occur after many years of operation in the field. A current list of problems and solutions can be found on the Teledyne Analytical Instruments web site at www.teledyne‐ai.com when any are identified. 13.1 FIRST APPROACH The probe will not heat up.
Model 9060Z Manual 14. MAINTENANCE 14.1 TRANSMITTER MAINTENANCE The 9060Z transmitter has several hardware checking systems that confirm the correct operation of the transmitter and raise an alarm if there is a fault detected. Because of this system, the transmitter only requires periodic maintenance. Teledyne Analytical Instruments recommends an annual check of the transmitter. The annual check should include the following items – 1.
Model 9060Z Manual 15. INDEX 9060H Oxygen Probes ....................................................................................................................... 9 Alarm connections .......................................................................................................................... 23 Alarm log clearing ........................................................................................................................... 43 Alarm relay options ...............................
Model 9060Z Manual Probe offset entry ............................................................................................................................ 34 Purge ................................................................................................................................................ 53 Purge and calibration connections ................................................................................................... 24 Reference air connection...............................
Model 9060Z Manual APPENDIX 1, CONSTITUENT VALUES FOR VARIOUS FUELS If the transmitter is set up to have readout or output of combustibles, oxygen deficiency, maximum carbon dioxide or combustion efficiency, then the fuel constituents must be entered. Any or all of the variables can be modified and entered in COMMISSIONING menu functions #50 to 56. (See chapter 7.2.23). Your fuel supplier or chemist should be able to give you all these values.
Model 9060Z Manual APPENDIX 2, PROBE EMF TABLES ZIRCONIA OXYGEN SENSOR OUTPUT (mV) PROBE TYPE 9060H, SENSOR OXYGEN % Probe EMF @ 720°C (1320°F) OXYGEN % 20.95 0 20.5 0.517 20 1.046 19.5 1.589 19 2.147 18.5 2.719 18 3.306 17.5 3.911 17 4.533 16.5 5.173 16 5.834 15.5 6.515 15 7.219 14.5 7.947 14 8.7 13.5 9.481 13 10.292 12.5 11.134 12 12.011 11.5 12.925 11 13.881 10.5 14.881 'K' Type TC 29.965 mV @ 720°C (1320°F) These tables are based on the Nernst equation: O2 ₂ EMF = 58 . .
Model 9060Z Manual ZIRCONIA OXYGEN PROBE OUTPUT (mV) PROBE TYPE 9060UL/UH These tables are based on the Nernst equation: 59
Model 9060Z Manual ₂ EMF = . . Where T is temperature° K Thermocouple information from NIST ITS‐90 data tables APPENDIX 3, % OXYGEN SCALE TO LOGARITHMIC 60 OXYGEN % FULL SCALE % 0.1 0.15 0.2 0.3 0.4 0.6 0.8 1 1.5 2 3 4 6 8 10 12 14 16 18 20 0 7.65 13.1 20.7 26.2 33.8 39.2 43.5 51.1 56.5 64.2 69.6 77.3 82.7 86.9 90.4 93.3 95.
Model 9060Z Manual APPENDIX 4, MODBUS™ The Teledyne Analytical Instruments 9060Z transmitter has the ability to work as a Modbus slave node on serial RS‐232 or 3‐wire RS‐485 via RTU mode transmissions. By accessing information stored in the input and holding registers it is possible to access runtime variables, alarm conditions and modify the device configuration. The implementation of the Modbus protocol is limited to the specific command set relevant to reading and writing register variables.
Model 9060Z Manual Alarm status is stored as an integer value: 0 clear 1 self cleared 2 3 active acknowledged 9060Z Transmitter Modbus Input Register Table for firmware v1.
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Model 9060Z Manual 9060Z Transmitter Modbus Holding Register Table for firmware v1.
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Model 9060Z Manual 0x41 Special Instruction Function This command allows you to interact with the transmitter allowing access to functionality that would otherwise only be accessible via the keypad. The request length will vary from one command to the next depending on what arguments are required.
