DT450G Dust Monitor
Contents
1. Power Wiring eps AC power supply Figure 3 2 Wiring diagram of the DT450G to a power supply 3 3 3 Piping and Wiring 3 3 Connection of Wires for the Output Signals 3 4 This section discusses the wiring necessary to transmit analog output signals and alarm contact signals to each device Wire the analog output and alarm contact signals of the DT450G using a single cable Use a cable with an outside diameter of 5 to 10 mm comprising three shielded twisted pair wires with the nominal cross section of the conductor being not more than 0 5 mm If only the analog output signal is used and it is unlikely to be affected by noise as the signal is wired at a location distant from the power line it is not always necessary to use twisted pair wires Insert the cable through the cable connection fitted with a Pg11 cable gland into the internal assembly of the DT450G Connect the core wires of the analog output signal to the mA positive side and mA negative side terminals Also connect the core wires of the alarm contact signal to the c of RL1 or RL2 and nc terminals for an open contact upon alarm output or to the c and no terminals for a closed contact upon alarm output Ground the shielded wires of the cable on the receiver side AN CAUTION The out2. 500 V Contact output signal high low alarm Contact capacity 5A 240 V AC or 24 V DC Setting range 1 to 99 1 step of measurement span Contact type NO closed when alarm contact is activated or NC 2 outputs Note Relay is energized when alarm contact is activated Damping time constant 10 to 300 seconds 10 second step Relay output time constant 10 to 180 seconds 10 second step Ambient conditions Temperature 20 to 45 C Humidity 95 RH or less non condensing Vibration 5 m s 0 5G or less Construction Converter Integrated with detector protection rating IP 64 Sensor probe Direct insertion 1 2 IM 11K01C01 01E IM 11K01C01 01E 1 Overview Materials Sensor probe Stains steel 31685 Insulation of sensor PEEK Case Aluminum Finish Polyester resin coated Colors Case Silver gray Munsell 3 2PB 7 4 1 2 Cover Mint green Munsell 5 6PG 3 3 2 9 Power supply Rating 100 to 120 VAC 200 to 240 VAC Operating voltage range 90 to 132 VAC 180 to 264 VAC Power consumption 8 VA Wiring connection 2 ports DIN with PG11 cable gland applicable to cable with 5 to 10 mm OD for power wiring DIN with PG11 cable gland applicable to cable with 5 to 10 mm OD for output wiring Note Use one cable for analog output and contact signals Air purge Connection Re 1 4 Air source Clean dry air equivalent to instrument air at process pressure 50 kPa Air consumption ap
3. 1 Overview IM 11K01C01 01E 2 Installation 2 Installation The DT450G is designed for indoor installation or installation in an outdoor location free from splashes of rainwater and direct sunlight This chapter explains how to install the DT450G in the following order of topics Selection of installation location Machining of inlet for sensor probe Installation of DT450G 2 1 Selection of Installation Location The DT450G is designed for mounting on a duct with a width of 650 to 4000 mm when the standard probe length is 460 mm or other alternative locations Install the DT450G in a location where optimal measurement can be carried out and inspection and mainte nance is easy When selecting an installation location make sure it also satisfies the measuring and ambient environmental conditions described in Section 1 2 In addition the installation location must meet the following requirements Availability of Typical Dust Concentration The most suitable location along a duct is where there is no flowmeter or valve that may disturb the gas flow and where the duct is straight and the length is adequate in compari son with the inside width of the duct Ideally the straight portion should be no less than eight times the length of the width Locate the probe inlet in a position 3 8 the length of the straight portion from the downstream edge and 5 8 the length from the upstream edge Note Insert the sensor probe into th
4. 2005 Yokogawa Electric Corporation CMPL 11K01C01 01E Subject to change without notice 2nd Edition Feb 2012 YG Yokogawa Electric Corporation Revision Record Manual Title DT450G Dust Monitor Manual Number IM 11K01C01 01E Edition Date Remark s Ist Sep 2005 Newly published 2nd Apr 2007 p 2 2 Deleted some descriptions in No Noise Effects p 2 4 Section 2 2 Machining of Probe Inlet Deleted some descriptions in When Mounting to Socket p 3 3 Section 3 2 Connecting the Wires for the Power Supply Deleted some descriptions p 3 4 Section 3 3 Connection of Wires for the Output Signals Deleted Note p 3 5 Section 3 4 Grounding the Duct Deleted Figure 3 4 and some descriptions pp 4 4 and 4 5 Setting Time Constants Automatic Range Setup and Manual Setting of the Measuring Range Fully revised 3rd Jul 2009 p 1 2 Section 1 2 Specifications Added item of DT450G 5 p 1 4 Section 1 3 1 Dust Monitor table Added suffix code for Analog output in 5 p 3 4 Section 3 3 Conection of Wires for the Output Signals Figure 3 3 Added item DT450G 5 in ED 4 3 Section 4 2 4 Setting of Parameters Added item of DT450G 5 4 4 Section 4 2 4 Setting of Parameters Added table 4 3 4 6 Section 4 2 4 Setting of Parameters Added item 3 4th Apr 2012 1 2 Section 1 2 Specification Seiup level Deleted of the description 5 e 9 1 4 Section 1 3 1 Dust Moni
5. 3 2 3 2 Connecting the Wires for the Power Supply oooonccnocnnccnconoccnonnnanconanancnncinnonno 3 3 3 3 Connection of Wires for the Output Signals nene eee emana ana enae 3 4 3 4 Grounding the Duet a uses sinn 3 5 4 Oper alone E d Capa acte ees ead ee Miel 4 1 Components and Their Functions 2 0 00 eee nenea enma nana nana en en 4 1 4 2 Preparation for Operation AAA es ages Ca ea its ouale 4 2 4 2 1 Inspection of the State of Installation oe eee en enma eee 4 2 4 2 2 gt Supply OF Purge Alfa essen 4 2 4 2 3 Supply Of Power 2 22 0 0er tape i apa 0 a atena ca apt 4 2 4 24 Setting of Parameters oonccnconconnnonnocnncnonorncnrncon noo nono nro Eo nr recen con no ananas 4 3 4 3 Steady state Operation 2 4 42 iad a conse aa mbar 4 6 4 3 1 Examining the Operating Condition ooooncnnnconnnoncnoncnncnnnonnconncnncnnncononnnon 4 6 4 3 2 SNUtdOWI see ie casei se oct denota is pd 4 6 A RR 4 6 5 Inspection and Maintenance cscccsssccssssccssssssssscssssscssssccsssscsssccssescsssssssssssssssessees D L 5 1 Periodic AAA ca oi aaa iba aa aa posta aaa ana 5 2 5 1 1 Cleaning the Sensor Probe uurersesnessnesnnennesnnennennennnnenennnonsnennn nn 5 2 5 1 2 Correcting Resetting the Measurement Range 5 2 5 2 Replacing E a E e ec 5 2 5 2 1 Replacing the O ringS mean ne nn nene nenea eee ana eee 5 2 5 2 2 Replacing the Sensor Probe uusursnesneesnesnnesnesnnennennnennennennnnnnn
6. changed on any change of specification construction and parts when the change does not affect the functions or performance of the product e If the product is used in a manner not specified in this manual the safety of this product may be impaired 2 Safety and Modification Precautions Follow the safety precautions in this manual when using the product to ensure protec tion and safety of personnel product and system containing the product IM 11K01C01 01E 3 The following safety symbols are used on the product as well as in this manual A DANGER This symbol indicates that the operator must follow the instructions laid out in this manual in order to avoid the risk of personnel injury electric shock or fatalities The manual describes what special care the operator must exercise to avoid such risks A WARNING This symbol indicates that the operator must refer to the instructions in this manual in order to prevent the instrument hardware or software from being damaged or a system failure from occurring A CAUTION This symbol draws attention to information essential for understanding the operation and functions A Tip This symbol gives information that complements the present topic N SEE ALSO This symbol identifies a source to which to refer amp Protective Conductor Terminal al Function Earth Terminal Do not use this terminal as the protective conductor terminal v Alternating current e Spe
7. the following State of Failure The output signal overshoots toward the 20mA side Table 6 1 Causes of Failure and Corrective Actions Air purge is not effective Condensation occurs at the probe inlet Corrective Action Check that the gap at the purge air exit is as specified If the exit is contaminated with dust increase the purge pressure remove the dust on the exit Take appropriate heat insulation measures The output signal gives abnormal readings The output signal does not stabilize The purge air exit is contaminated with dust The sensor probe is in a state of insulation failure because of inappropriate purge air e g contains moisture The gas under measurement has entered the purge air piping causing an insulation failure in the sensor probe The flow velocity of the gas under measurement is not constant The humidity of the gas under measurement changes Clean the exit see subsection 5 1 1 Use normal dry purge air Set the pressure relatively higher and continue air purge for a while If contaminants still remain in the piping contact Yokogawa Electric for assistance Change the measurement point to a position in the straight portion of the duct where the flow of gas is regular If the change occurs constantly check if measuring the gas is practicable at all The output signal becomes disturbed momentarily The wiri
8. 579 Unit mm 173 Max 20 67 Teflon coated Power Cable Inlet Option TC Output Signal Cable Inlet Rc1 4 A 5 to 10 65 to 610 Air Purge Piping Connection Welding euch 30 Welding socket type eps Duct wall Weld all around the socket be careful not to deform the socket Socket 38 2 cutout N Locate the cutout for tubing at the bottom Max 15 a Max 19 gt A A Section air purge tubing gt Welding Socket accessory of Stainless Steel JIS SUS316L Equiv Welding of Socket Welding Socket EPS Dimensions of DT450G Dust Monitor Flange Mounted Model O Flange Mounted Model Unit mm 93 579 172 30 460 Ss Insertion Length 265 Wa 250 2 o iz m x g S D amp Y o Max 20 30 67 Teflon coated Option TC Power Cable inlet __Ret 4_ E Output Signal Cable Inlet 5 to 10 Air Purge Piping Connection Sh 5 to 10 JIS 5K 65 FF Example Flange Dimensions Unit mm Class D c g h t JIS 5K 65 FF 155 130 4 15 14 JIS 10K 80 FF 185 150 8 19 18 NA JIS 10K 100 FF 210 175 8 19 18 ANSI Class 150 2 1 2 RF 177 8 139 7 4 19 1 22 4 JPI Class 150 2 1 2 RF 178 139 7 4 19 22 5 D Flange type eps yo g h JIS 10K 80 FF Example Dimensions of DT450G Dust Monitor Welding Socket Mounted Model IM 11K01C01 01E 1 5 1 6
9. 6 IM 11K01C01 01E 3 Piping and Wiring 3 Piping and Wiring IM 11K01C01 01E Before operating the DT450G the pipe for air purge and wires for output signals must be connected This chapter explains how to connect the pipe and wires to DT450G in the following order of topics Connecting the pipe for air purge Connecting the wires for the power supply Connecting the wires for the output signals Grounding of a duct or other alternative facilities where the DT450G is mounted 3 1 3 Piping and Wiring 3 1 Connecting the Pipe for Air Purge As a rule the insulated part of the sensor probe should be air purged before the DT450G 1s put into use Air purge is mandatory if any of the following cases apply The concentration of dust in a gas is extremely high and the resistance of the insu lated part of the sensor probe is likely to decrease due to dust accumulation The gas temperature at the probe inlet is likely to drop resulting in condensation Note that clean air such as air specified for instruments must be used for air purge If air is not available use gas such as nitrogen instead Note For reasons of the measurement principle any dust accumulating on the insulated part of the sensor probe can cause malfunction The purpose of air purge is to prevent such dust accumulation Care must be taken since an air purge with air containing moisture or oil mist causes the same phenomenon as dust accumulation
10. Air purge is normally carried out by continuously supplying air to the DT450G with a pressure of approximately 50 kPa higher than that of the gas being measured If the effect of air purge is inadequate due to the presence of moisture in the gas being measured the DT450G may require air purge at a higher pressure For air purge use an air source with a sufficiently large capacity The normal rate of air consumption is approx 50 Nl min under the pressure of 50kPa When connecting the pipe to the DT450G for air purge note the following The DT450G may be removed during inspection or maintenance When connecting the pipe to the DT450G use a one touch connector and or a pipe made of flexible material to ensure easy maintenance Install a stop valve or pressure reducing valve in a position as close as possible to the DT450G Connect a pipe with an inside diameter of 6 to 8 mm to the DT450G Note that the pipe connection of the DT450G is Rc1 4 threaded Note The rate of air consumption is approximate 50 Ni min In some cases the pressure of air supply may need to set higher than the specified HE u A Pressure of gas under measurement Piping material plus approximately 50 kPa with 6 to 8 mm inside diameter Air source Stop valve Pressure a control valve Sp Figure 3 1 Method of Piping for Air Purge If air purge need not be carried out attach a blind plug to the pipe
11. User s EXA DT Manual DT450G Dust Monitor IM 11K01C01 01E vigilantplant YOKOGAWA 4 IM 11K01C01 01E Yokogawa Electric Corporation 4th Edition Introduction The DT450G Dust Monitor is a process instrument designed to detect solid particles in gas and integrates a control unit and a sensor probe into a compact enclosure The DT450G can be used in a wide variety of applications including continuous monitoring of the dust content of the exhaust gas This manual describes the procedures for installing operating inspecting and maintain ing the DT450G Dust Monitor Before using the instruments thoroughly read the manual to ensure optimum performance This manual consists of six chapters For your reference the following table shows the outlines of each chapter and indicates which chapters should be read for installation operation or maintenance work Table of Contents Chapter Outline Relates to Installation Operation Maintenance 1 Overview Standard specifications Model and Suffix O A O codes or part number and dimensions 2 Installation Installation procedures etc A 3 Piping Wiring Piping and wiring procedures A 4 Operation Operation and display in detail A 5 Inspection Maintenance Inspection items and replacement procedures O 6 Troubleshooting Failures possible causes and remedies A CMPL User replaceable parts list A O CMPL Customer Maintenance Pa
12. ber by 10 s Decrease number by 10s Decrease number by 10s 10s 10s Percent level of full range 10 to 50 Increase number by 10 Decrease number by 10 20 Not available Fine adjustment for measuring range Pin code o o oj 10 7 1 to 100 Increase number Not available Decrease number Set measuring range 1 0 0t05 Increase number Decrease number Save parameters SP 1 0 10 in 2 digits sp in 3 digits IM 11K01C01 01E Save all Save all T0402 eps 4 3 4 4 4 Operation Do not set parameters except 0 for the leftmost digit 8 9 and 10 Setting Alarm Contacts Press the leftmost A key until the leftmost digit shows 1 or 2 Set the alarm contact of relay 1 or 2 in percent of the output full scale value Each press of the middle B or the rightmost C key only increases the number which will roll back to 1 after it reaches 99 The percentage is displayed by the two rightmost display digits Trimming Analog Output Signals 4 mA and 20 mA Press the leftmost A key until the leftmost digit shows 3 or 4 Increase or decrease the output current The display shows the nominal mA value with its two rightmost digits Connect a calibrated mA meter to the analog output terminal to check the actual current value Allow 30 minutes warm up time before trimming the mA ou
13. ce 5 Inspection and Maintenance LA WARNING If the DT450G is installed in the downstream of an electrostatic dust collector there is a danger of serious injury or death from electric shock due to high potential static electricity Carry out maintenance without disconnecting the grounding line that was connected when the DT450G was installed If the DT450G is not yet grounded with a grounding line ground it before you start maintenance This chapter explains inspection and maintenance carried out to repair or replace worn out or deteriorated parts and thereby maintain the DT450G in its optimal operating condition A CAUTION When inspecting and maintaining the DT450G remove it from where it is installed Be careful not to inflict severe impact to the monitor during inspection and mainte nance otherwise it may be damaged IM 11K01C01 01E 5 1 5 1 5 1 1 5 1 2 5 2 5 2 1 5 2 2 5 2 Periodic Maintenance If the sensor probe is contaminated with a large amount of dust or significantly worn out by dust the output signal level for the same dust concentration may differ from the level when the DT450G was initially put into operation To be able to revert to the initial output signal level the sensor probe must be cleaned or the measurement range must be reset Do not disassemble such components as the printed circuit board from the internal unit of the DT450G otherwise the DT450G may fail to operate correc
14. cial descriptions in this manual This manual indicates operation keys displays and drawings on the product as follows n Displays on the panel Ex message display BASE Ex data display 102 IM 11K01C01 01E ii NOTICE e Specification check When the instrument arrives carefully unpack and check that the instrument has not been damaged during transportation Please make sure that the product received meet the purchase order specifications and all the accessories are present Specifications can be checked by the model codes indicated on the nameplate For details of the model codes refer to Chapter 1 Overview e Details on operation parameters The DT450G is preset with defaults prior factory shipment Before measurement verify that these factory default settings meet the operating conditions and if neces sary reconfigure parameters For checking the parameter settings refer to Chapter 4 It is recommended that the reconfigured parameter settings be recorded IM 11K01C01 01E After Sales Warranty O Do not modify the product O During the warranty period for repair under warranty carry or send the product to the local sales representative or service office Yokogawa will replace or repair any damaged parts and return the product to you O Before returning a product for repair under warranty provide us with the model name and serial number and a description of the problem Any diagra
15. connection 3 2 IM 11K01C01 01E 3 Piping and Wiring 3 2 Connecting the Wires for the Power Supply IM 11K01C01 01E AN CAUTION The DT450G has no power switch For reasons of safety during inspection and maintenance install a double pole switch in the power line A CAUTION Since the DT450G may be removed for inspection or maintenance allow each cable to have a sufficient margin of length Connect a power supply that conforms to the voltage and frequency in the specifications of the DT450G For wiring use a three core cable of a 5 to 10 mm outside diameter with the nominal cross section of the conductor being at least 1 5 mm Ground one core appropriately Lead the cable from the power supply through the DT450G s cable connection fitted with a Pgl1 cable gland into the DT450G s inner assembly Then connect the cable to the AC1 terminal non grounded side and AC2 terminal grounded side Terminate the end of the grounding wire with an M5 crimp terminal and then connect it to the ground terminal inside the enclosure The ground resistance should be 100 Q or less JIS Class D grounding Note The DT450G main unit and the duct on which the monitor is mounted are in electrical continuity Should the measured value be adversely affected by the method of two point grounding at the duct see Section 3 4 and the terminal remove either of the two grounding lines Power Connector
16. de input signal obtained at the detector block is transferred to the converter block where the signal is converted to a 4 20 mA DC analog output signal The converter block outputs an alarm contact signal at a desired level in addition to the analog output signal 1 1 1 Overview 1 2 Specifications Measurement objects Solid particles in gas Particle size 0 3 um or greater Measurement range 0 1 mg m to 1 kg m Measurement principle Triboelectric detection Process conditions Temperature 250 C or less Pressure 200 kPa or less Gas flow rate 4 m s or greater approx 30 m s max Humidity 40 RH or less Input surge voltage 100 V or less Gf 500 V or greater converter may be damaged Note When installing downstream of ESP see Item 2 1 Measurement range Range setup One touch automatic setup or manual setup Measurement range does not directly represent dust concentration To know the absolute value of dust concentration the relationship between the output signal and the dust concentration should be obtained by laboratory analysis or relevant way Note With one touch automatic setup function measurement range is set so that the dust concentra tion of the process corresponds to a setpoint of setting level In manual setup the measurement range is set by gain x1 x10 x100 x1000 x10000 Setup range level Variable 10 to 50 10 step Analog output signal 4 20 mA DC insulated load resistance
17. e When installing downstream of ESP see Item 2 1 Measurement range Range setup One touch automatic setup or manual setup Measurement range does not directly represent dust concentration To know the absolute value of dust concentration the relationship between the output signal and the dust concentration should be obtained by laboratory analysis or relevant way Note With one touch automatic setup function measurement range is set so that the dust concentra tion of the process corresponds to a setpoint of setting level In manual setup the measurement range is set by gain x1 x10 x100 x1000 x10000 Setup range level Variable 10 to 50 10 step Drift Zero drift 2 month Span drift 2 month Analog output signal 4 20 mA DC insulated load resistance 500 V Contact output signal high low alarm Contact capacity 5A 240 V AC or 24 V DC Setting range 1 to 99 1 step of measurement span Contact type NO closed when alarm contact is activated or NC 2 outputs Note Relay is energized when alarm contact is activated Damping time constant 10 to 300 seconds 10 second step Relay output time constant 10 to 180 seconds 10 second step Ambient conditions Temperature 20 to 45 C Humidity 95 RH or less non condensing Vibration 5 m s 0 5G or less Construction Converter Integrated with detector protection rating IP 64 Sensor probe Direct insertion 1 2 IM 11K01C01 01E
18. e inlet so that it is perpendicular to the stream of gas The DT450G can be positioned in such a manner that its sensor probe is level or facing downward at an angle up to 90 4 Downstream Me Upstream Dust monitor Install at the center of the duct and perpendicular to the gas flow F0201 EPS Figure 2 1 Installation of Dust Monitor on Straight Part of Duct IM 11K01C01 01E 2 1 2 Installation No Noise Effects Make sure the output signal will not be affected by noise arising from plant equipment or other structures In an electrostatic dust collector is used locate the DT450G at least 20 m away from the dust collector When monitoring such dust collectors as a bug filter locate the DT450G in the upstream of the blower Minimal Vibration For reasons of sensor structure avoid installing the DT450G in a location exposed to mechanical vibration at a level greater than 5 m s Note It is virtually impossible for vibration to affect the measured value No Splashes of Rainwater Direct Sunlight or Abnormal Temperature Rises due to Heat Radiation from Equipment The DT450G may be installed outdoors However avoid installing the monitor in a location exposed to direct sunlight or heat radiated from equipment in order to prevent the temperature of the main unit s casing from rising above 45 C Note The DT450G can be operated within an ambient temperature range of 20 C to 45 C If the part of the duct assigned for t
19. en 5 2 6 Troubleshooting u a Customer Maintenance Parts List ooooooo CMPL 11K01C01 01E Revision Record i cico iei iioca c t ocscsdesscescibied socvensceacacaccse cdecscescioasasececascescisccadbccsassescdoasceeceeascesee I IM 11K01C01 01E vii viii IM 11K01C01 01E 1 Overview 1 Overview 1 1 Product Measuring Principle IM 11K01C01 01E This chapter discusses the following topics Product overview Specifications Model and suffix code Dimensions Overview Powder is used in many industries including ceramics cement chemicals pharmaceuti cal and food In their processes powder is collected in order to reduce the loss incurred in the process Dust emissions from industrial plants are limited by the air pollution control law local regulations or other guidelines Each industrial facility is required to be maintained so that its dust emissions do not exceed the allowable level Air pollution control systems such as bag filters and electrostatic precipitators are used to separate particulate or dust from the gas stream before it is exhausted into the atmosphere To maintain the dust concentration of the emission gas below the specified level through effective operation of the control system it is essential to continuously monitor the dust concentration of the exhaust gas Based on installation and application experiences with the existing DT400G model the microprocessor based DT450G Dust Monito
20. f a large amount of dust on the sensor probe of the DT450G may adversely affect its normal operation If the measured value is found to be abnormal remove the DT450G and examine the state of dust contamination of the sensor probe If the cause of the abnormal measured value is dust accumulation clean the sensor probe periodically If you are using the DT450G in a high temperature or moist gas atmo sphere also examine the effectiveness of air purge If the amount of dust accumulating on the outlet of purge air is found to be gradually increasing increase the supply pressure of purge air If condensation is observed around the probe inlet it is advisable that heat insulation measures be taken To shut down the DT450G turn off the power switch installed in the power line If the DT450G will not be used for a prolonged period only turn off the power switch without turning off the air purge line The air purge line need not be left turned on if there is no flow of gas to be measured provided that the ambient humidity is not too high There is nothing in particular that needs to be done before restarting the DT450G If the DT450G has not been in use for a prolonged period however make sure there are no abnormalities with the sensor probe before you restart the DT450G When there are no abnormalities with the DT450G it will come into steady state operation in approxi mately 30 minutes after power on IM 11K01C01 01E 5 Inspection and Maintenan
21. he probe inlet is covered with insulating material that is likely to contribute to a temperature rise in the casing remove the insulating material around the probe inlet in an area approximately 20 cm wide across the inlet Insulating material DT450G Insulating material Probe inlet Example of unacceptable mounting The DT450G is affected by heat radiation from the insulating material 400 mm DT450G Area of insulating material to be removed Example of acceptable mounting F0202 eps The temperature rise is minimal because of air ventilation Figure 2 2 Measures to Take When the Temperature of the DT450G s Casing Is Likely to Rise due to Insulating Material 2 2 IM 11K01C01 01E 2 Installation Ease of Inspection and Maintenance The DT450G dust monitor must be detached for cleaning the sensor probe For safe operation of these maintenance works a sufficient maintenance space as shown below is required See Figure 2 3 Duct Maintenance space F0203 EPS Figure 2 3 Maintenace Space at Installation Location of DT450G Dust Monitor IM 11K01C01 01E 2 3 2 Installation 2 2 Machining of Probe Inlet The DT450G is designed for mounting on a socket or flange attached to an inlet on a duct or other alternative facility Equip the inlet with a socket or flange that complies with the specifications of the DT450G At this point make
22. ms or data explaining the problem would also be appreciated O If we replace the product with a new one we won t provide you with a repair report O Yokogawa warrants the product for the period stated in the pre purchase quotation Yokogawa shall conduct defined warranty service based on its standard When the customer site is located outside of the service area a fee for dispatching the mainte nance engineer will be charged to the customer In the following cases customer will be charged repair fee regardless of warranty period e Failure of components which are out of scope of warranty stated in instruction manual e Failure caused by usage of software hardware or auxiliary equipment which Yokogawa Electric did not supply e Failure due to improper or insufficient maintenance by user e Failure due to modification misuse or outside of specifications operation which Yokogawa does not authorize e Failure due to power supply voltage frequency being outside specifications or abnormal e Failure caused by any usage out of scope of recommended usage e Any damage from fire earthquake storms and floods lightning disturbances riots warfare radiation and other natural changes O Yokogawa does not warrant conformance with the specific application at the user site Yokogawa will not bear direct indirect responsibility for damage due to a specific application O Yokogawa Electric will not bear responsibility when the u
23. n the process where the dust concentration is a certain level and stable during normal operation range setting by Auto Setup button is also available Before the Auto Setup the setting level should be confirmed The dust monitor has an Automatic Setup function You can change the default percent of full range 20 in steps of 10 from 10 to 50 Press the leftmost A key until the leftmost digit shows 7 and increase or decrease the value using the middle B or the rightmost C key IM 11K01C01 01E IM 11K01C01 01E 4 Operation The setpoint of 20 means that the 4 20 mA output at the typical dust concentration will be 4 mA 20 mA 4 mA X20 which makes 7 2 mA If the dust concentration is five times the typical value or higher the output will be 20 mA and if the dust concentration is zero the output will be 4 mA Next the measuring range should be set Press the leftmost A key until the leftmost digit shows 1 0 Press the middle B key or the rightmost C key to increase or decrease the value until the rightmost digit shows 0 see Table4 1 Last press the leftmost A key until the display shows SP Press the middle B or the rightmost C key to save the setting For Automatic Setup make sure that the process is running with a normal dust concen tration Then open the cover of the dust monitor After move the parameters setting mode initiate Automatic Setup by pressing the small key button
24. near the indicator lamp on the lower printed circuit board see Figure 4 1 Note The indicator lamp should be green before you press the key Note Initiate Automatic Setup in parameters setting mode Collecting data of the dust concentration will take an hour or less The three digit display counts down towards zero and the indicator lamp is red as long as the data are being collected To avoid interference from the background electrical noise you should close the cover of the enclosure right after having initiated the Automatic Setup After an hour the setup is ready and the dust monitor is in normal operation The indicator turns back to green when setup is ready Note The setting level is valid only when the automatic range setup parameter 0 is used 3 Fine adjustment for measuring range Fine adjustment adjusts measuring range from 1 100 Press the leftmost A key until the leftmost digit shows 0 set the value from 1 100 In case of setting 10 the maximum range is 2 times higher than current range In case of setting 50 the maximum range is 0 4 times higher than current range In case of setting 100 the maximum range is 0 2 times higher than current range The following is relationship between the setting value and multiplication for measuring range 20 Multiplicationnnn for measuring range Setting value e Relay connection and parameter setting mode 1 When both relays connected t
25. ng is inappropriate and therefore picks up noise There is equipment nearby serving as a source of noise Check the states of grounding and wiring and correct a problem if there is any Take measures for protecting the DT450G from the source of noise IM 11K01C01 01E There is no output signal The fuse is blown or there is something wrong with the wiring connections There is something wrong with the electric circuit components Turn off the power switch temporarily if the green indicator lamp is unlit Then examine the wiring connections and check if the fuse has blown Consult Yokogawa if the fuse has blown Request repair to be carried out by Yokogawa Table6 1 eps Table 6 2 Corrective Action against Errors at Automatic Setup Display Input signal is too low Description Corrective action Try Automatic Setup again Manully set measurement range to Range 5 Input signal is too High Try Automatic Setup again Manully set measurement range to Range 1 Table6 2 eps 6 1 6 2 IM 11K01C01 01E Customer Model DT450 il Maintenance Dust Monitor Parts List Part Number Description B1026ER O ring Flange assembly K9479DA JIS 5K 65 FF K9479DB JIS 10K 80 FF K9479DC JIS 10K 100 FF K9479DE JPI Class 150 2 1 2 RF K9479DD ANSI Class 150 2 1 2 RF K9479CA Socket L9800TC Bolt DT450G for CMPL eps YOKOGAWA All Rights Reserved Copyright
26. o NO Relay 1 contact Open Relay 2 contact Close 2 When relay 1 connected to NO and relay 2 connected to NC Relay 1 contact Open Relay 2 contact Open 3 When relay 1 connected to NC and relay 2 connected to NO Relay 1 contact Close Relay 2 contact Close 4 When both relays connected to NC Relay 1 contact Close Relay 2 contact Open 4 5 4 Operation 4 3 Steady state Operation 4 3 1 4 3 2 4 3 3 4 6 Proceed to steady state operation after making sure there is no problem with the DT450G during start up Before going into steady state operation make sure the cover is securely attached to the DT450G main unit Moisture or corrosive gas entering into the DT450G may result in malfunction This section discusses the following topics concerning the handling of the DT450G during steady state operation Examination of operating condition carried out only at the beginning of operation Shutdown Restart Examining the Operating Condition At the beginning of operation examine the following points to ensure that the DT450G continues to operate in its optimum condition O Effects of External Noise Etc If the DT450G is being affected by noise to such a degree that normal operation becomes problematic first make sure the DT450G is installed and wired correctly as instructed by this manual Then take appropriate noise countermeasures O State of Dust Accumulation Shutdown Restart Accumulation o
27. prox 50 Nl min Mounting Socket dedicated or flange Weight Approx 2 3 kg excluding flange Dimensions 172W x 173H x 672D mm 1 3 1 Overview 1 3 Model and Suffix Codes 1 3 1 Dust Monitor Model Suffix Code Option Code Description DT450G Dust monitor heat resistant up to 250 C 4 20 mA DC analog output fine adjustment for measuring range Sensor material 316SS Air purge With air purge Instruction Manual Japanese English Mounting Socket mounting welding socket Flange mounting ANSI Class 150 2 1 2 RF Flange mounting JIS 5K 65 FF Flange mounting JIS 10K 80 FF Flange mounting JIS 10K 100 FF Flange mounting JPI Class 150 2 1 2 RF Always A Probe Teflon coated MS code eps Note Teflon coated probe option code TC is recommended to prevent the insufficient insulation by dust and moisture deposited on sensor probe ensure better insulation of sensor probe Teflon coated probe is designed to operate at a temperature not exceeding approximately 150 C 1 3 2 Spare Parts Part Number O ring B1026ER Flange assembly JIS 5K 65 FF K9479DA JIS 10K 80 FF K9479DB JIS 10K 100 FF K9479DC JPI Class 150 2 1 2 RF K9479DE ANSI Class 150 2 1 2 RF K9479DD Socket K9479CA Bolt L9800TC SpareParts eps Note The sensor assembly can be replaced only at the manufacturer s shop 1 4 IM 11K01C01 01E 1 Overview 1 4 Dimensions O Welding Socket Mounted Model 93
28. put signal may be mixed with electric noise if the cable swings If the cable is likely to be affected by wind fin the cable DT450G id Not used SHIELD Not used Junction Box Power Switch AC power supply DT450G Wiring eps Grounding 1 The nomonal cross sevtion of each conductor should be 1 5 mm The nomonal cross sevtion of each conductor should be not more than 0 5 mm 3 This terminal is used for the grouding on the receiver side The above wiring diagram shows the one when using no contacts Connect wires to terminals nc and c when using nc contacts Figure 3 3 Wiring Diagram IM 11K01C01 01E 3 Piping and Wiring 3 4 Grounding the Duct AN CAUTION When such equipment as an electrostatic dust collector is used be sure to ground both the duct and the DT450G Otherwise there may be a danger of electrical shock due to high potential static electricity If a duct or other alternative facility where the DT450G is mounted is charged with electricity the electricity will serve as noise possibly affecting the signal under mea surement Ground
29. r features improved operationality and reliability Features include one touch automatic range setup in response to process conditions and automatic drift compensation Also the DT450G can measure at a process temperature of up to 250 C allowing it to cover a wide range of applications When two solid particles come into contact with each other charge transfer takes place between them This charge transfer is known as the principle of triboelectrification or contact electrification and the DT450G utilizes this principle More specifically charge transfer occurs when particles in a gas stream collide with or pass nearby the sensor probe producing an electric current The DT450G amplifies this current to convert it into its output current The electric current produced by frictional electricity is subject to the effects of the following factors Amount of the particles electrostatic charge and a change in the polarity Particle size Velocity of particles Components of particles The behaviors of these factors vary widely depending on the object of measurement and their effects are in no way uniform In the case of fixed position measurement in a particular plant however measurement conditions such as the components of particles are almost constant and therefore the effects are usually marginal Dust concentration is also constant in the case of gases emitted from a bag filter cyclone or electrostatic dust collector A current mo
30. ris List Intro eps Carefully read and fully understand before work O Read through before work and whenever necessary A Recommended to read 4th Edition Apr 2012 YK All Rights Reserved Copyright 2005 Yokogawa Electric Corporation IM 11K01C01 01E For the safe use of this equipment A DANGER Connect the power supply cord only after confirming that the supply voltage matches the rating of this equipment In addition confirm that the power is switched off when connecting power supply Some process gas is dangerous to people When removing this equipment from the process line for maintenance or other reasons protect yourself from potential poison ing by using a protective mask or ventilating the area well 1 About This Manual e This manual should be passed on to the end user e The contents of this manual are subject to change without prior notice e The contents of this manual shall not be reproduced or copied in part or in whole without permission e This manual explains the functions contained in this product but does not warrant that those will suit the particular purpose of the user e Every effort has been made to ensure accuracy in the preparation of this manual However should any errors or omissions come to the attention of the user please contact the nearest Yokogawa Electric representative or sales office e This manual does not cover the special specifications This manual may not be
31. s selected and simutaneously press and hold down B and C key for one second Parameter setting mode Press the leftmost A key of the three keys below the display until the leftmost digit indicates the number of the parameter you wish to change refer to Table 4 1 The two other display digits now show the parameter value Pressing the middle B key and rightmost C key you may now change the parameter value See instructions below for each individual parameter When you have set all the parameters press the leftmost A key again until the display shows SP Press one of the other keys B or C to save all the parameters NOTE All parameters must be as you wish to have them when you save them If you want to make more changes or decide not to save the parameter you have changed press the left most A key again Table 4 1 Parameter Change Table Parameter Display Factory Default Left Number Alarm contact relay 1 1 Alarm contact relay 2 Range Key Effect Key B Increase number by 10 Increase number by 10 Key Effect Key C Increase number by 1 Increase number by 1 5 60 1 to 99 1 to 99 4 mA trim Increase number Decrease number Set to 4 mA 20 mA trim Increase number Decrease number Set to 20 mA Alarm contact time constant Analog output signal time constant ol Aa P o 10to 180s 10 to 300s Increase number by 10 s Increase num
32. ser configures the product into systems or resells the product O Maintenance service and supplying repair parts will be covered for five years after the production ends For repair for this product please contact the nearest sales office described in this instruction manual IM 11K01C01 01E V vi IM 11K01C01 01E Contents Introduction cesta daia ee doaatalscado dadea coaada sa ad i daaoaaadelscadodidaa cada oris secese os sacco keso oo aa oi oa edade I For the safe use of this equipment nene en nene nenea nana nana 11 NOTICE ee sd iv After Sales Warranty eee aan ana ana enan aan a nn v Vs Overview onsin nenne nee a Al 1 1 Producti OVervidW a a en 1 1 12 A cs bead la baste bca aaa dada a a 1 2 1 3 Model and Suffix Codes cecene eee eee ee nea e ee 1 4 1 31 Dust Monitor raza aaa isn 1 4 1 3 2 Spare Parts sa sei east a oa a 282 eigenen 1 4 14 DIMENSIONS are rennen S iei or ta de it aa eta du d 1 5 2 Installation cs iccecsdecasencicceldsissasseciccocessconcsnscdgcessesceicosecdccecscscsadsesceacesbeccsdessecaccecesscessoassecee 2 2 1 Selection of Installation Location ooocnnnncnnonccinnonononnncononnaconnnnononnncononacnnnanonos 2 1 2 2 Machining of Probe Inlet ceea ema neee nenea ana eee ana eee 2 4 2 3 Installing the DT A50G i iii it ns i 2 6 3 Piping and WII o OO L 3 1 Connecting the Pipe for Air Purge uruesnnssnesnnennesnesnnesnennnennnnnnensennnenn
33. sure the DT450G s casing and the duct are in electrical continuity When Mounting to Socket Use the socket that comes with the DT450G for installation Weld this socket paying attention to the following precautions e The standard insertion length of the sensor probe is 460 mm e For welding the socket cut out a 38 0 mm diameter hole on the duct or pipe The socket s outer diameter is 37 7 mm e Weld all around the socket stainless steel JIS SUS316L Make sure there are no spots not welded Be careful not to deform the socket while welding Be careful about the orientation of the socket When installing the dust monitor on a vertical plane place the cutout for air tubing at the bottom Unit mm Duct wall socket welding plane Weld all around Be careful not to deform the socket Socket accessory 38 0 0 1 hole Duct Cutout for Socket Place the cutout for air purge tubing at the bottom F0204 EPS Figure 2 4 Connection Port for Socket Mounting Model 2 4 IM 11K01C01 01E 2 Installation O When Mounting to Flange IM 11K01C01 01E Prepare the DT450G with a flange that meets the specified standard Prepare the tie in flange at the connection port of the duct or pipe Note that the standard sensor probe insertion length is 460mm on the flange specification Flange Duct Inner dia 38 mm F0205 EPS Figure 2 5 Connection Port for Flange Mounted Model A drop of water on the insulated par
34. t of the sensor probe will prevent correct measure ment If the process gas is cooled down around the sensor connection port when measuring high temperature and high humidity gas be sure to purge the air in order to prevent condensation at the neck of the sensor connection flange If there is a possibil ity of the ambient temperature decreasing to 0 C or less provide thermal insulation at the neck of the connection flange Mounting N screw DT450G Note The DT450G body can be detached by removing the mounting screw Cable Provide thermal insulation here Duct Tubing for air purge F0206 EPS Figure 2 6 Thermal Installation for Preventing Condensation 2 5 2 Installation 2 3 Installing the DT450G Securely fix the DT450G onto a socket or flange on the probe inlet When fixing the DT450G onto a socket use the supplied two M8 size bolts When fixing the DT450G onto a flange use bolts having a size that conforms to the flange specifications Be careful not to damage the O ring when mounting the DT450G onto a socket A CAUTION If the gas to be measured is flowing constantly through a duct where the DT450G is mounted air purge the monitor as instructed in subsection 4 2 2 If you leave the monitor exposed to the gas for a prolonged period without air purging the monitor the resistance of the insulated part of the sensor probe will decrease This may result in a failure of the monitor to start smoothly 2
35. the O rings The O ring that needs replacement is the one that prevents leakage of the gas under measurement from the probe inlet If the O ring is found to be damaged in any way such as scratches or cracks or permanent deformity due to deterioration replace it Note O rings are also used in the DT450G main unit and on the contact surfaces of the sensor probe though they are not visible from outside Ask Yokogawa Electric Corporation for replacement of these O rings Replacing the Sensor Probe Even if the sensor probe becomes worn it does not fall into a state of being totally unable to take measurements If wear of the sensor probe is extreme however replace the whole sensor assembly Determine the time of replacement on a case by case basis by judging from what degree of correction has been made to the measurement range set when the DT450G was first put into use whether the sensor probe is still adequately rigid and so on Yokogawa Electric should be asked to carry out any replacement of the sensor assembly IM 11K01C01 01E 6 Troubleshooting 6 Troubleshooting This chapter explains measures that should be taken when the output signal gives abnormal readings Note that not all anomalies are due to failure disorder or malfunc tion in the DT450G Some of them may be due to a change in the physical properties types of components the flow velocity etc of the gas being measured If such a change is likely first check for
36. the duct where the DT450G is mounted as well as other nearby structures in order to prevent the duct from being charged with electricity IM 11K01C01 01E 3 5 3 6 3 Piping and Wiring IM 11K01C01 01E 4 Operation 4 Operation The ranges and other parameters of the DT450G must be configured before you start Operation This chapter explains how to operate the DT450G including preparations in the following order of topics Components and their functions Preparation for operation Regular operation 4 1 Components and Their Functions IM 11K01C01 01E e 27 Ma 4 I i A Li Y SHIELD 7 Not used mA a mA i no Ebo Je 4 1 A nc 4 y no y c nc x lt eg Auto Setup Button y Not used LI 1 1 1 Output UN A Key Parameter Setting Button Relay contact Li BlKey CIKey Display lamp Green Operation Red Autotuning LED Display Power Supply Connector d y ACI A2 0 LO Name amp Func eps Figure 4 1 Components of the DT450G and Their Functions 4 1 4 Operation 4 2 Preparation for Operation Before you start operating the DT450G carry out the follo
37. tly Cleaning the Sensor Probe If the sensor probe tends to gather a significant amount of dust it is advisable that the probe be cleaned periodically If dust accumulation is not very serious its effect on the output signal is in most cases negligible therefore 1t is not necessary to clean the sensor probe frequently Remove dust on the sensor probe with a dry cloth For correct and normal measure ment keep the insulation resistance of the purge air outlet at a high level To ensure this completely remove contaminants from the outlet When cleaning the sensor probe also remove dust that has accumulated on the probe inlet Correcting Resetting the Measurement Range The sensor probe may be worn out by dust contained in the gas under measurement Although wear in the sensor probe may not directly lead to the inability to measure the level of current arising from frictional electricity may change affecting the output signal If you need to know precise dust concentration correct or reset the measure ment range according to your degree of necessity Correct reset the measurement range according to the procedure of measurement range setting discussed in subsection 4 2 4 If the wear on the sensor probe is extreme it must be replaced Replacing Parts In order to keep the DT450G serviceable over a prolonged period you must replace parts that are worn out or have deteriorated as a result of the gas under measurement Replacing
38. tor Table Deleted of the suffix code 1 3 Section 1 3 2 Spaer parts Deleted of the parts number p 3 4 Section 3 3 Connection of Wires for the Output Signals Figure 3 3 Change of the description with mark p 4 3 Section 4 2 4 Setting of parameters Deleted of the description and the table 4 1 and 4 2 p 4 5 Section 4 2 4 Setting of parameters 2 Auto Setup Deleted of the description CMPL CMPL 11K01C01 01E Revision to 2nd edition TT AA pad DT450G Supplement Dust Monitor Thank you for selecting our DT450G Dust Monitor In User s Manual IM 11K01C01 01E 4th Edition supplied with the product some corrections additions have been made Please replace the corresponding pages in your copy with the attached revised pages Revisions e p 1 2 Section 1 2 Specifications Measurement principle Change of the description All Rights Reserved Copyright 2005 1st Edition Oct 2013 YK nd IM 11 K01 C01 01 E Subject to change without notice 4th Edition 1 Overview 1 2 Specifications Measurement objects Solid particles in gas Particle size 0 3 um or greater Measurement range 0 1 mg m to 1 kg m Measurement principle Inductive Electrification Process conditions Temperature 250 C or less Pressure 200 kPa or less Gas flow rate 4 m s or greater approx 30 m s max Humidity 40 RH or less Input surge voltage 100 V or less Gf 500 V or greater converter may be damaged Not
39. tput Setting Time Constants Press the leftmost A key until the leftmost digit shows 5 or 6 Change the time constant of the alarm contact or the analog output signal in increments of 10 seconds The alarm contact time constant will change back to 0 s from 180 s the analog output signal time constant from 300 s The two leftmost digits of the value are displayed by the two rightmost display digits Setting of the Measuring Range The measuring range can be set manually or by Auto Setup button 1 Manual Setting In manual setting the measuring range is set by amplifying the signal detected by the sensor in 5 stages Press the leftmost A key until the leftmost digit shows 1 0 and press the middle B or the rightmost C key until the rightmost digit shows the number of the desired parameter Table 4 2 shows that the rightmost digit number and its parameter Table 4 2 Measuring Range Setting Display Parameter Description Right Number 0 Automatic range setup 1 Maximum range For high concentration of dust 2 Gain x 10 3 Gain x 100 4 Gain x 1000 5 Gain x 10000 For low concentration of dust T0403 eps When parameter 1 is selected the measuring range is maximized If the dust concentra tion is high select this parameter The output sensitivity becomes higher as the param eter number increases from 1 to 5 Chose the most appropriate parameter for your process 2 Auto Setup I
40. urn on the power switch installed in the power line to feed power to the DT450G When the power is turned on the green LED indicator lamp on the monitor comes on It takes approximately 30 minutes for the DT450G to reach steady state operation 4 2 IM 11K01C01 01E 4 Operation 4 2 4 Setting of Parameters The dust monitor has a 4 20 mA output and two relay contact alarm outputs The effect of sudden change of measured value can be removed by setting a user configurable time constant The output current of the 4 20 mA signal can be trimmed The relay output s change their state when the measured dust concentration exceeds a user selected alarm trigger level The relay output s are also protected against the effect of sudden change of input signal with a user configurable time constant common for both relays All the user selectable parameters have factory default values which in many cases will suffice If your application requires changing parameters proceed as follows How to Change Parameters Open the cover of the dust monitor You see a front panel a display unit and three parameter buttons A B and C It is needed to enter PIN code before setting parameters 1 Press A key and select first PIN code digit O to 9 2 Press B key and select second PIN code digit O to 9 3 Press C key and select third PIN code digit O to 9 Factory default for PIN code is 1 1 1 Parameters can be changed after the right PIN code i
41. wing tasks Inspection of the state of installation Supply of purge air Supply of power Parameter Setting of measurement range Setting of alarm points Setting of damping action 4 2 1 Inspection of the State of Installation Check that all the specifications are completely satisfied with the installation of the DT450G Also check that the DT450G wiring and piping have been correctly con nected Especially make sure the following are true The DT450G is securely mounted onto the probe inlet and is free from effects of strong mechanical vibration In addition the short tubing of the probe inlet is adequately heat insulated and the main unit s casing is not exposed to direct sunlight that causes an abnormal temperature rise or subject to heat radiated from other equipment The duct or other alternative facilities where the DT450G is mounted is reliably grounded Wires are correctly connected to the terminals of the DT450G In addition the cables are securely fixed by cable glands so as to prevent any corrosive gas or moisture from entering the monitor The air purge piping and each cable connected to the DT450G have a sufficient margin of length necessary for maintenance 4 2 2 Supply of Purge Air Using the pressure control valve adjust the supply pressure of purge air as noted below Then fully open the stop valve Supply pressure Pressure of gas under measurement approximately 50 kPa 4 2 3 Supply of Power T
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