Micatrone MG-4000-R2 Hoja de especificaciones

MG-4000-R2

Mi-262gb / 2017-04-03

USE

MG-4000-R2 is designed to measure the O2-con-

tent in flue gases from oil burners, gas burners

and biomass-fired boilers. MG-4000-R2 can, to-

gether with a controller, optimize the air/fuel ratio.

The result is the highest possible firing efficiency

can be obtained and sustained over time indepen-

dent of changes in the fuel and combustion air.

The probe (MG-4000-R2/S) is installed in the flue

gas duct directly after the boiler. The tip of the pro-

be is easy to adjust so that it is positioned in the

centre of the flue gas zone. No special gas is re-

quired for calibration, this is done directly in the

surrounding air. Installation and use are as easy

as using a standard temperature sensor.

The O2-transmitter consists of two parts: the probe

and the central unit. The probe houses a sensor of

zirconium dioxide (ZrO2), heating element, signal

amplifier and generator for the ion pump. The cen-

tral unit houses the electronics for measuring the

sensor signal, analogue outputs, relay contacts for

the alarm outputs, control panel and the power

supply. All functions in the central unit are mana-

ged and monitored by a microprocessor.

Current measurement values, error indications

and set parameters are all presented on the inte-

grated display.

8 LEDs provide a quick indication of the operating

status.

Oxygen (O2) transmitter with monitoring

catrone®

Operating and Installation manual

Version 1.3x

PGM ESC

O -transmitter

2MG-4000-R2

Measuring

Relay 1

Relay 2

High O -content

Low O -content

Out of range

Calibration

Error

AB MICATRONE

O2-cont 3.1 %

TABLE OF CONTENTS

USE........................1

MEASUREMENTPRINCIPLE..........3

Relationship between O2-content in dry and

wetfluegases ................4

Fuel-Oil...................4

Fuel-Biomass...............4

INSTALLATION..................4

Centralunit..................4

Probe.....................5

Galvanicisolation..............5

Wiring....................5

NOTE!....................5

OXYGENE SENSOR CROSS SENSITIVITY . . 6

CombustibleGases..............6

HeavyMetals.................6

Halogen and Sulphur Compounds ......6

Reducing Atmospheres ............6

Others.....................6

ELECTRICALCONNECTION..........7

Description ..................7

Signals to the probe .............7

Ground currents ................7

Connection diagram for Central unit and

Probe.....................8

Translation chart MG-4000 // MG-4000-R2. . 9

FUNCTIONS ..................10

Measurementvalues.............10

O2-content.................10

Nernst ...................10

Current&Voltage .............10

Temperature................10

Output signals ................10

Relays....................10

Communication ...............11

INITIALIZEOPERATION............11

PROGRAMMING................12

LCDdisplay.................12

Keypad....................12

Startmenu..................12

Theindicationofparameters ........12

Programmingaparameter..........12

Programmemenu.............12

Parameterselection............12

Programmingavalue ...........13

Cancelling programming mode ......13

Thefunctionmenu..............13

Defaultsettings ...............14

Communication...............14

Defaultsettings ...............14

Factory...................14

INDICATIONS..................15

Displays...................15

LEDs.....................15

Measuring.................15

Out of range ................15

Calibration.................15

Relay1...................15

Relay2...................15

High O2-content ..............15

Low O2-content...............15

Error....................15

Measurementvalues.............15

Status ....................15

PROBECALIBRATION.............16

Limitsforcalibration............17

MAINTENANCE.................17

Fuses.....................17

TROUBLESHOOTING.............18

Notextdisplayed..............18

The Out of range LED is lit.........18

TheHighO

2-contentLEDislit.......18

The Low O2-contentLEDislit.......18

MG-4000-R2 shows incorrect O2-content . 18

MG-4000-R2 cannot be calibrated.....18

Ground currents ..............18

Glitches...................18

Errorindications..............18

TECHNICAL DATA ...............19

Central unit MG-4000-R2 ..........19

Measuring probe MG-4000-R2/S ......19

LISTOFPARAMETERS ............20

This instruction applies for MG-4000-R2 software

version 1.2x

MEASUREMENT PRINCIPLE

At higher temperatures (>500 °C) stabilised zirco-

nium dioxide (ZrO2) is a solid electrolyte for oxy-

gen. This can be used in two ways:

1. To transport oxygen through a ZrO2-disc (ion

pump) according to Faraday’s first law.

2. To measure the ratio of partial pressure from

oxygen on each side of a ZrO2-disc according

to Nernst’s equation.

Most modern oxygen meters available on the mar-

ket use one of the aforementioned principles. To

avoid disadvantages such as relatively large pro-

bes, linearization of measurement signals, refe-

rence air, etc. both principles can be combined

into a dynamic oxygen sensor.

The sensor consists of two identical ZrO2-discs

with platinum electrodes and a platinum ring which

creates a small chamber between the discs. One

disc is used as a reversible ion pump according to

Faraday. The other disc generates a measurement

voltage proportional to the ratio of the oxygen par-

tial pressure in the chamber (P2) and surroundings

(P1)accordingtoNernst.

When measuring, the reversible ion pump will al-

ternately pressurise and evacuate the chamber.

Reversing takes place at two preset voltage levels

V1and V2on the Nernst voltage VN.

The time of a pump cycle (tp) becomes directly

proportional to the surrounding partial pressure

from the oxygen (P1). An increase in the surroun-

ding oxygen content increases the partial pressure

(P1) and tp increases. With a decreasing oxygen

content tp falls. At 0 % O2tp is approximately 0.5

seconds and in fresh air (20.7 % O2) tp is approxi-

mately 7 seconds.

The sensor is enclosed by a heating element to

maintain the temperature of the ZrO2-discs at 700

°C. This makes the sensor insensitive to changes

in the flue gas temperature and the flow rate.

qBased on this principle the sensor is very small

and with that the probe can be made small.

qNo reference air is required and the Nernst

voltage does not need to be linearized.

Figure 1

Principle construction for a dynamic O2-sensor.

Platinum-

electrodes

Platinum-

electrodes

Platinum-

ring

ZrO2-

disc

Ion pump

ZrO2-

disc

Voltage

VNacc. to

Nernst

Figure 2

Measuring signal from the O2-sensor.

Figure 3

Cross-section view of the sensor element.

Sensor of

ZrO2

Heating-

element

Relationship between O2-content in

dry and wet flue gases

MG-4000-R2, which has its probe mounted in the

flue gas duct, measure the O2-content in wet flue

gases. Portable O2-measurement instruments ex-

tract a gas sample from the duct and measure the

content in dry gases.

Fuel - Oil

Following approximate relation between wet and

dry flue gas is valid when excess air does not ex-

ceed 50%.

O2-content (wet gas) = 0.9 x O2-content (dry gas)

Fuel - Bio mass

See graph to the right

Note! If the measuring probe is exposed for redu-

ced atmospherers, e.g. high content of CO (car-

bon oxide), the life-span of the probe is reduced.

Therefore, it is of great importance the the O2-

control is operating properly.

INSTALLATION

Central unit

MG-4000-R2 should be located fully visible and

easily accessible. It is important to remember the

ambient temperature, max. 45 °C when positioning

the unit. The case is fitted with hinges on the

left-hand side of the cover for easy opening. Make

sure the cover can be opened fully.

Outside dimensions:

H x W x D = 360 x 300 x 140 mm.

Hole pattern for wall mounting:

When choosing the position for installation, re-

member the following:

1. The central unit must not be subjected to an

ambient temperature higher than 45 °C. Prefe-

rably the ambient temperature should be

below 30 °C.

2. The signal cable between the probe and the

central unit must be a shielded 10 conductor

cable e.g. FKAR-G 10 x 0.5 mm2. The area of

each conductor should be at least 0.5 mm2.

The correct cable, which is a prerequisite for

reliable operations, is enclosed. The cable shi-

eld must only be connected in the central unit.

3. The length of the signal cable between the

probe and the central unit should be as short

as is practically possible, maximum 10 m.

4. The signal cable between the probe and the

central unit must not be routed together with

cables used for low or high voltages.

The minimum permitted distance to low

andhighvoltagecablesis30cm. Cables

must cross at right angles.

5. Avoid placement where the central unit is sub-

jected to vibration.

6. The central unit should be positioned so that

the control panel is approximately at eye level.

O -content flue gases

10 20 30 40 50 60

% Excess air

Dry flue gas

Wet flue ga

Water content

in fuel (%)

Figure 4

Relationship between O2-content

in dry and wet flue gases.

250 mm

335 mm

Diameter 10 mm

Probe

When installing the probe it is important to select cor-

rect placement. It should be easy to remove the pro-

be from the flue gas duct and easy to connect the

signal cable between the probe and the central unit.

1. Fit a 3/4" union on the flue duct after the boiler.

Make sure the union extends outside of the in-

sulation to facilitate installation of the probe. It

should be installed at a 15° angle to the hori-

zontal plane, so that the tip of the probe points

slightly downward (see figure 5), alt. top moun-

ted (see figure 6). This is to protect the probe

from condensation water.

2. Always install the supplied radiation protection

(see figure 7) on the probe’s insertion tube to

prevent the sensor’s electronics from overhea-

ting. Sole use of the radiation protection is not

recommended, the flue gas duct should also

be insulated.

3. The probe should be inserted so far that at le-

ast 10 cm of the tube hangs free inside the

duct. This is so the tip of the probe is not coo-

led via the union.

4. The supplied warning sign concerning precau-

tions that should be taken when the boiler is

swept must be set up where it is fully visible.

Galvanic isolation

The O2-probe should always be mounted using

the attached compression fitting which is fitted with

a isolation socket made of PTFE (TEFLON â)to

seperate the probe galvanically from protective

earth (ground) in the boiler/flue-gas duct which

could interfere with the measuring. Check that no

electrical connection is between the probe and

boiler/duct by measuring the resistance between

them both.

Wiring

The cable between the probe and the central unit

must NOT be extended. Leave an "eye" on the

cable by the probe so that the probe can be easily

removed from the flue gas duct for calibration and

duct sweeping.

The cable between the probe and the central unit

and cables to analogue output signals and data

communications must be shielded for the best me-

asurement result. The shield must only be connec-

ted to the ground rail in the central unit.

NOTE!

The probe must be operational (voltage fed) and

always maintain the operating temperature if it is

installed in the flue gas duct, irrespective of whet-

her the boiler is operational or not. When the pro-

be is not in use it should be kept in the surroun-

ding air. Wipe the probe dry if it is moist before in-

sertion.

NOTE! The measuring probe connection box should not be exposed to tempertures above 60 °C and must therefore be protec-

ted against the radiation heat caused by the flue gas duct or the boiler. Good insulation of the flue gas duct and enough space

between the insulation and the probes connection box is important. Always use the attached radiation protection shield.

max 20 m/s

max 400°C

~ 15°

min10cm

max 60°C

Union 3/4" inner thread

Max 260°C

Radiation shield

Probe pipe

INSULATION

Figur 5

Side mounting of the probe

Warning against dry-firing!

When "dry-firing" a biomass-fired boiler, the probe must not

be placed in the flue gas duct.

~ 15°

max 20 m/s

max 400°C

min10cm

Figure 6

Top mounting of the probe

Figure 7

Radiation shield for connection box

OXYGENE SENSOR CROSS SENSITIVITY

Cross sensitivity with other gases:

The oxygen sensor measures partial oxygen pressure. Gases or chemicals that will have an influence on

the life of the sensor or on the measuring results are:

Combustible Gases

Small amounts of combustible gases will be bur-

ned at the hot Pt-electrode surfaces or Al2O3filters

of the sensor.

In general combustion will be stoichiometric as

long as enough oxygen is available, the sensor will

measure the residual oxygen pressure. Investiga-

ted were:

qH2(Hydrogen) up to 2%; stoichiometric

combustion

qCO (Carbon Monoxide) up to 2%; stoichio-

metric combustion

qCH4(Methane) up to 2.5%; stoichiometric

combustion

qNH3(Ammonia) up to 1500 ppm; stoichio-

metric combustion

Heavy Metals

Vapours of metals like Zn (Zinc), Cd (Cadmium),

Pb (Lead), Bi (Bismuth) will have an effect on the

catalytic properties of the Pt– electrodes. Exposu-

res to these metal vapours has to be avoided.

Halogen and Sulphur Compounds

Small amounts (< 100ppm) of Halogens and/or

Sulphur compounds have no effect on the perfor-

mance of the oxygen sensor. Higher amounts of

these gases will in time cause readout problems

or, especially in condensing environments, corro-

sion of sensor parts. Investigated gases are:

qHalogens, F2(Flourine), Cl2(Chlorine)

qHCL (Hydrogen Chloride), HF (Hydrogen

Fluoride)

qSO2(Sulphur Dioxide)

qH2S (Hydrogen Sulphide)

qFreons

qCS2(Carbon Disulfide)

Reducing Atmospheres

Long time exposure to reducing atmospheres may

in time impair the catalytic effect of the Pt-electro-

des and has to be avoided.

Others

qVapours (organic silicone compounds) of

RTV (Room Temperature Vulcanised) rub-

bers are well known pollutants of zirconia

based oxygen sensors. The organic part of

the compound will be burned at hot sensor

parts, leaving behind a very fine divided

SiO2(Silicone Dioxide/Silica). This SiO2

completely blocks the pores and active

parts of the electrodes. If RTV rubbers are

used we advise to use high quality, well

cured.

qDust. Fine dust (Carbon parts/soot) might

cause clogging of the porous stainless ste-

el filter and might have an effect on the re-

sponse speed of the sensor.

qHeavy Shocks or Vibrations might alter

sensor properties.

qWater vapour. Condensing water vapour

might cause clogging of filters or internal

corrosion of sensor parts. We advise to

keep the sensor at operating temperature

or standby temperature when exposed to

exhaust gases. Direct exposure to water

droplets has to be avoided.

ELECTRICAL CONNECTION

Description

Voltage supply

MG-4000-R2 is fed with 230 VAC, 50 Hz on termi-

nals 1 (neutral) and 3 (phase). The supply should

incorporate a circuit-breaker to facilitate servicing.

Alarm function

On terminals 5-7 and 8-10, are two potential free

switching relay contacts. The relay contact func-

tion can be programmed on MG-4000-R2, e.g.

alarm with low O2-content and probe error. The re-

lay contacts are low voltage, 230 VAC.

Probe

Terminals 11-19 are connected to the probe’s ter-

minals 1-9.

Output signals

MG-4000-R2 has two analogue output signals for

the current O2-content, a mA-signal (0/4..20 mA)

on terminals 21 (+) and 22 (-) and a Volt-signal

(0/2...10 V) on terminals 23 (+) and 24 (-).

NOTE! Common neutral (-). The output signals

are not galvanically isolated from each other.

Communication

MG-4000-R2 has 2 interfaces, RS-232 and

RS-485. Only one interface at a time can be used.

RS-232 is connected to a modular jack (RJ45) and

is designed for Micatrone’s Programming adapter,

part no. 60-0972-2.

RS-485 is connected to terminals 25 (A) and 26

(B) and requires MG-4000-R2 to be equipped with

Micatrone’s Communication module, part no.

60-0973.

If both RS-232 and RS-485 are connected simulta-

neously RS-232 is given priority for communica-

tions. Also see the operating description for com-

munications on page 11.

Signals to the probe

Term Description Signal

11 Positive supply to the

probe’s electronics.

+7 Volt DC, 2.5 mA.

12 Feedback signal from

heating element in

probe.

± 50 mVolt, square

wave 1 kHz at 700 °C.

13 Control signal to the ion

pump for evacuation.

+6 / -4 Volt, square

wave 1 kHz.

14 Supply to the heating

element.

1.7 A, approx. 4.2 Volt

DC on probe.

15 Measurement zero from the electronics.

16 Neutral wire to the heating element.

17 Control signal to the ion

pump for pressurising.

+6 / -4 Volt, square

wave 1 kHz.

18 Measurement signal

from the zirconium

dioxide sensor.

Periodic signal

0...4 Volt DC.

19 Negative supply to the

probe’s electronic.

-5 Volt DC, 2.5 mA.

Ground currents

The probe has low voltage signals, 50 mV. Any

ground currents may influence the measurement

and it's important that the probe is galvanically iso-

lated from ground. This can easy be checked by

measuring the resistance between terminal 15 and

the ground rail in the central unit.

The result of the measuring should be a resistance

over 1 MW(Megaohm), break is prefered.

If the resistance is under 1 MW, the installation of

the probe need to be checked. Also check that the

output signal don't shorting between terminal 15

and ground. You might need a transmitter with gal-

vanic separation to the output signal.

Connection diagram for Central unit and Probe

AB MICATRONE

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O:\Produkter\MG-4000-R2\CDR\

MG-4000-R2 Inkoppling.cdr

S-3767

Connection diagram for

MG-4000-R2 Ver 1.10

Page 1 (2)

PAD 1

SNAP1 SNAP2

SNAP5 SNAP6 SNAP7 SNAP8

SNAP4

SNAP3

E17

AC6

R55

C41

R26

AC24

R77

C43

IC1

LED1

C12

C27

C10

C16

C15

C17

C20

C28

D10

C63

R16

R67

D11

E18

E11

E3 E4

E15 E16

E10 E6

C13

IC3

IC8

IC24

IC25

KD1

C11

R76

R78

C53 D12

R70

C26

TR1

TR2

FH3

FH2

FH1

PL1

400 mAT

5x20 mm

(3x)

IC2

IC4

KD2 K2

TD2 TD1 IC9

C29

IC11

C30

IC12

FH4

2AT

5x20 mm

C18

D4 C19

C23 D5

FM1

FM2 FM3

TD3

PL2

PL3

E12 E13

E14

IC17

R75

C54

R51

R42

C55

R46

R44

IC6

IC7

AC7

R8 R9 R10 R11 R12

IC13

R61

AC21

AC22

R30

R31

C56

C59

C44

C52

R54

C35

D13

R20

C64

C65

R73

R28

D14

C48

R27

R50

AC17

R45

R69

R74

R17

R29

AC25

C50 R57

R52

R43

R71

R68

AC8

C51

R49

R48

R47

C60

C61

AC20

R62

R63

R64

IC20

R60

R66

C62

R65

C31

C57

AC27

R40

R72

C34

R32

C47

C49

C58

P3 P4

IC21

IC22

AC29 AC28

R58

R56

AC26

R25

R59

R53

IC27

IC29

IC28

IC26

IC15

IC16

C42

AC15

AC16

IC10

R23

R21

C36

C37

R18

D7 D8

R38

R41

R39

R37

AC19

IC19

C32

R15

C33

R13

R33

AC14

IC14

C38

R24

C39

C40

R19

C22

C46

R36

IC18

AC18

RL1 RL2

AC23

R35

C45

R34

IC5

C25

R14

C14

AC13

R22

C24

C21

IC23

P-3728 V2.00

2007-02

Top Silk

714 21

22 24 25 26

10 16

BRS-485

Current loop

Output signal 1

Output signal 2

19 20 23

NC Relay 2, 230 VAC

Signal voltage

Fuse FH4 for heating

element in sensor 2 AT

5x20 mm

Fuses for the electronics

3 pcs. 400 mAT 5x20 mm

Location for RS-485

Communication.

plug-in module

10 11 26

0/4...20 mA RL max 500 ohm

-5 Volt

Low voltage

230 VAC

+7 Volt

132 4

Neutral

Line

230 VAC

MG-4000-R2

NC Relay 1, 230 VAC

0/2...10 Volt Ri min 50 kohm

+++

132 4

Probe

MG-4000-R2/S

NOTE!!! The shield of the signal

cable may NOT be connected to

the O -probe. The shield must

only be connected to the ground

rail in the central unit.

Translation chart MG-4000 // MG-4000-R2

AB MICATRONE

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Datum Sökväg

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I:\MG-4000-R2\CDR\

MG-4000-R2 Inkoppling.cdr

S-3767

Inkoppling av MG-4000-R2

Ver 1.00

Sidan 2 (2)

714 21

22 24 25 26

10 16 19 20 23

132 4

714

10 16 19 20

132 4

MG-4000-R2

MG-4000

FUNCTIONS

Measurement values

O2-content

MG-4000-R2 measures the O2-content in flue gas

using a zirconium dioxide sensor. The measure-

ment range of the output signal can be selected

between 0...5%, 0...10%, 0...20% or 0...100% O2.

If the measured O2-content is outside of the selec-

ted measurement range an orange LED is lit on

the control panel.

MG-4000-R2 has visual alarms (red LEDs on the

control panel) for specific high and low O2-content.

The limits are stated in % O2-content.

Theprobemustfirstbecalibratedtoprovideaccu-

rate measurements. Calibration is performed in

fresh air, see page 16. The current barometric

pressure can be programmed during calibration on

MG-4000-R2 to give the best possible accuracy.

The value is stated in mBar.

Nernst

Indicates the measurement signal from the probe.

Nernst will vary between 0 and 4 Volts during nor-

mal measurements.

Current & Voltage

Indicates the present current and voltage to the

probe’s heating element.

Temperature

Indicates the present temperature of the probe’s

zirconium dioxide sensor.

Output signals

MG-4000-R2 produces two output signals (one for mA

and one for Volt). The output signals state the current

O2-content for the selected measurement range.

Output signal 1 can be selected between 0...20

mA or 4...20 mA and output signal 2 can be selec-

ted between 0...10 Volt or 2...10 Volt.

Relays

MG-4000-R2 has two potential free switching con-

tactsthatcanbeusedtomonitortheO

2-content or

the function of the probe.

The function is activated in parameter 14/21 by se-

lecting whether the high or low signal is to be mo-

nitored. Select a source (input signal) in parameter

15/22. If error indication is chosen the function

(parameter 14/21) needs to be programmed to

HIGH.

When monitoring the O2-content a level is pro-

grammed (parameter 16/23) and a hysteresis (pa-

rameter 17/24). The level and the hysteresis are

stated in % O2-content. These two parameters are

not used when monitoring error indication.

Switching on and off can be delayed by the cho-

sen number of seconds in parameters 18/25 and

19/26. In parameter 20/27 the position of the swit-

ching contact is selected when the monitoring sta-

te is in normal mode. A yellow LED on the control

panel comes on when the relay contact is active.

Par.no: Description Range Value

O2-measurement

1Range 0..5%

0..10%

0..20%

0..100%

2High O2 0,0...99,9

3Low O2 0,0...99,9

4Barometer 800...1200

Par.no: Description Range Value

Outputs

28 Source 1 O2-cont

29 Signal 1 0..20mA

4..20mA

30 Source 2 O2-cont

31 Signal 2 0..10V

2..10V

Par.no: Description Range Value

Relay 1

14 Function OFF

HIGH

LOW

15 Source O2-cont

ERROR

16 Level 0,0...99,9

17 Hysteresis 0,1...99,9

18 Delay on [s] 0...999

19 Dly fall [s] 0...999

20 Norm.pos. FALLEN

ACTIVE

Relay 2

21 Funktion OFF

HIGH

LOW

22 Source O2-cont

ERROR

23 Level 0,0...99,9

24 Hysteresis 0,1...99,9

25 Delay on [s] 0...999

26 Dly fall [s] 0...999

27 Norm.pos. FALLEN

ACTIVE

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