Technical Data

CarboSen ST

For the detection of oxidisable CO/H2 gas constituents in gases,

the optimisation and monitoring of combustion processes

Sensors and Systems for Combustion Engineering

The advantages:

High resolution Rapid response behaviour Mechanically robust, resistant to chemicals and high temperatures

Compact, electronic evaluation unit in sensor head

Wide range of application Low-maintenance

CarboSen ST

Brief outline The CarboSen is a miniaturised sensor system for the detection of flammable gases such as CO, H2 or CxHy, for example. In this Manual, these gases are also referred to as CO equivalent (COe). The system consists of the sensor unit, sensor housing and sensor electronics in the head. The sensor electronics enable temperature compensation during operation, flexible control of the sensor and the acquisition of all sensor signals. The CarboSen1000 is a high-resolution measuring system for the detection of small concentrations of COe in the range of 0 - 3000 ppm (ideally up to 1000 ppm). In the ST version, the electronics are integrated in the head of the sensor (Figure 1).

Figure 1: CarboSen1.000ST (part number 658R0010) This design can be used at temperatures up to 450°C. The Ø 8mm dip pipe can be produced in customised lengths of up to 1 m. Connection to the process is achieved e.g. by means of a straight male coupling. With integrated electronics, the sensor system is also suitable for other industrial processes, even for on-site monitoring of the boiler wall atmosphere in power stations. Basic method of functioning The CarboSen functions on the principle of solid-state electrolysis. The technology used for this method is well known and widely used in the form of the lambda sensor. However, unlike the lambda sensor, which measures oxygen on the basis of the Nernst principle, the CarboSen functions according to the Non-Nernst principle. By varying the geometry, material and electrical circuitry, sensors working according to the Non-Nernst principle can also detect other gases such as COe, for example.

CO2(g)

CO(ad)CO2(ad)CO2(ad)O2(ad)

Anode Cathode

CO(ad)O2(ad)O2(ad)O2(ad)

O2-

Electrolyte

CO(g)CO2(g) O2(g)

Figure 2: Principle of the Non-Nernst sensor The result of the material pairing that we have selected is that the Pt reference and working electrodes have different adsorption characteristics. This enables the detection of the products of incomplete combustion according to

Us = R Tsn F ln CCOe(ad,K)

CCOe(ad,A) whereby the universal gas constant is R, the sensor temperature TS, the valence number of the oxygen ions involved in ion transport n = 2, and the Faraday constants F. The concentrations cCOe(ad,A) and cCOe(ad,K) represent the COe adsorbed on the anode or cathode. To operate the sensor, it first has to be heated to the operating temperature of 630°C. This is achieved by means of a heating structure, which is affixed to the back of the sensor element. The electronics adjust the sensor temperature automatically and maintain it at a constant level during operation. The sensor temperature can be varied for special applications. If the operating temperature changes, so does the sensor characteristic. Increasing the temperature of the sensor results in reduced sensitivity, i.e. the sensor becomes less sensitive to COe and the curve is flatter. The sensor dynamics get faster, i.e. the response and decay times are accelerated.

Heater-spiral

Contacts

Substrate

Reference-electrode

Functional

View offront

View ofback

ceramic

1

US Uh

Working-elecrode

Working-elecrode 2

Figure 3: The CarboSen COe sensor

CarboSen ST

Components Electronics XC164: The microprocessor-controlled sensor electronics perform the following functions in the system:

Heating the sensor and regulating the sensor temperature so that it remains constant

Acquisition of the sensor voltages in mV Conversion of measured sensor voltages and

output via the analogue output (0/4-20mA) Monitoring of both sensor voltages Checking the analogue outputs Output of measured values via CAN bus

The XC164 electronics are available in a single and a double-channel version. In the single-channel version, all the above functions are assumed by a circuit board. Here, both sensor signals are averaged for the output at the analogue output. Internally, both sensor signals are compared and checked on the basis of the following failure criteria:

Difference greater than 10mV, or Difference greater than 10% of the current

measured value. If the higher of the two criteria is exceeded, the electronics indicate an error (red LED flashes, analogue output = 0mA). In the two-channel version, a second circuit board is integrated in the electronics. This has the task of recording, evaluating and outputting the second sensor signal separately via the second analogue output. In this case, the sensor is only heated via the first circuit board. The circuit boards communicate via the internal CAN bus.

The latter enables the exchange of measured sensor voltages and error signals. Both circuit boards compare the sensor voltages they have measured themselves with the sensor voltage measured by the other board on the basis of the above-mentioned criteria, and output an error signal if necessary. The XC164 sensor electronics can be parameterised via USB CAN bus using PC software.

Figure 4: Electronics XC164 Sensor In CarboSen, as in other probes, zirconium dioxide doped with yttrium is used as ceramic electrolyte. This ceramic is characterised by its high oxygen conductivity at temperatures above 400°C, and by its high chemical stability. Worth special mention is the generation of a directly measurable sensor signal voltage USen with a logarithmic characteristic. The origin is at 0mV, free from drift and in a physically defined manner. With response times of less than 1s and high resolution in the lower range, flammable gases can be reliably detected from concentrations as low as 1ppm. The sensors’ robustness, speed and high dynamics enable the reliable monitoring, control and/or optimisation of dynamic combustion processes in accordance with the emission edge regulation .

Figure 5: Curve of the CarboSen 1000 ST

CarboSen ST

Electronics Probe Dimensions: 111x111x87 mm³ Principle of measurement: Solid-state electrolysis

(Non-Nernst) Power supply voltage:

13-30V Measuring range: up to 3000 ppm CO/H2

Analogue output: 0/4- 20mA, 0mA = error Burden 300 Ohm

Power consumption electronic & probe

max. 8W (without accesoires) (probe up to 6W)

Cross-sensitivity: H2O none Temperature very low Volumetric flow very low

Scaling of analogue output:

100mV to +900mV Response time t (sensor element):

<1s

Housing Operating temperature: Type NT: up to 150°C (Low temperature) Type HT: 150°-400°C (High temperature)

Material: Die-cast aluminium Sensor temperature 630°C Temperature: -40°C ... +100°C Cold resistance sensor 7,0Ω≤ R20°C ≥ 11Ω Proportion resistance Rhot/ R20°C: 2,5 Max. resistance „HOT“ 35 Ohm

(above this value, it will be accepted „broken wire“)

Average life: Blue flame burner,

Fuel: oil / gas approx. 3 years

Wood combustion, Fuel: clean fire wood or pellets approx. 2 years

All others wood fuels, depending on pollutant concentration (e.g. wood chips, bark)

< 1 year

Protection class in acc. EN 60529: IP 67

CarboSen ST

* = 190 mm when the closure head is open

Length „L“:

Iten no. 658 R 0010 150 mm (HT)

658 R 0012 250 mm (HT)

658 R 0030 150 mm (NT)

Connector A1

Circular plug-in connector, 4-pins • Pin 1 supply voltage 0V • Pin 2 supply voltage +24VDC • Pin 3 analogue output – • Pin 4 analogue output +

Connector A2

Circular plug-in connector, 5-pins • Pin 1 24VDC-output + • Pin 2 24VDC-output - • Pin 3 CAN-GND (LSB • Pin 4 CAN-L (LSB) • Pin 5 CAN-H (LSB)

} only for programming unit

Connecting cable, shielded, max. cable diameter 1mm2 .

The max. line length should not be longer than 100m.

CarboSen ST

Service

Setting the parameters via programming unit

• Programming unit, incl. connecting cable Item No. 658 R 0932

• Supply voltage 24VDC / 2,5W (from CarboSen ST) • Protection class in acc. with EN 60529 IP40

Panel mounting (option)

• Panel mounting frame for programming unit Item No. 663R0932T

• Protection class in acc. with EN 60529 IP54

CarboSen ST

Accessories Analogue output module with module address 19 for the output of the measure signal

• 4 analogue outputs 0…10V (non floating) Item no. 663 R 4025

or • 4 analogue outputs 0…20mA (non floating)

Item no. 663 R 4029 • for output of :

- Sensor voltage averaged - Sensor voltage 1 - Sensor voltage 2 - Heating power - Internal resistance of the heating Rki-HZG - Pulse-width heating - Internal resistance of the sensor Rki - COe Can be setted in parameter 810...825 of the CarbosSen ST.

x1x1

0

1-1+

L (D-)

H (D+)

- (A2)

+ (A1)

28

67

453

76

9

98

4

105

3

102

2+ 2-

4+4- 3- 3+

Analog output modulAnalogausgangsmodul

L (D-)

H (D+)

- (A2)

+ (A1)

Technical datas module

• Rated voltage UN

• Current consumption • Power consumption • Operating voltage range • Operating temperature range • Storage temperature range • Suppressor circuit • Function indicator • Operating indicator

24 V DC 50 mA 1.2 W 0.8 ... 1.1 x rated voltage UN

0°C ... +55°C -25°C ... +70°C Polarity reversal protection for operating voltage Green LED for BUS activity and power supply Red LED for BUS error message

Analog Outputs (Voltage)

• Output current (10 V DC) • Resolution • Output voltage • Response time • Recovery time

5 mA 9.9165 mV/digit 0 ... 10 V DC 15 ms 550 ms

CarboSen ST

Analog Outputs (Current)

• Output current • Accuracy • Load • Response time (receive to transmit) • Recovery time

0....20mA 1% Max. 300 Ohms 15 ms 550 ms

Housing

• Degree of protection (EN 60529)

• Relative humidity range to IEC60721-3-3

• Connection cross-section for output terminals

• Connection cross-section for screw-type plug-in terminals (BUS, supply)

• Weight • Dimensions

Housing: IP50 Terminals: IP20

Ambient class 3k3 2.5 mm²

1.5 mm²

95 g W x H x D = 35 x 68 x 60 mm

CarboSen ST

Digital output module with module address 03

• 4 relay outputs 250 V/AC, 6 A Item no. 663 R 4027

• Output 1 – Limit 1 Output 2 – Limit 2 Output 3 – Non measure Output 4 – Fault

• Emergency manual operation level: Position "1" Output contact always closed Position "A" Output contact switches via LAMTEC SYSTEM BUS Position "0" Output contact always open

x1x1

0

1413

L

H

-

+

28

67

453

76

9

98

4

105

3

102

23 24

4443 33 34

Digital output modulDigitalausgangsmodul

0

A

11 2 3 4

+

H

L

-

4x normally open contacts

Technical datas output module

• Rated voltage UN • Current consumption • Power consumption • Operating voltage range • Response time

(receive – relay switches) • Release time

(receive – relay switches) • Recovery time • Operating temperature range • Storage temperature range • Suppressor circuit • Relay status indicator • Function indicator • Operating indicator • Features

24 V DC 100 mA 2.4 W 0.8 ... 1.1 x rated voltage UN

15 ms 15 ms 200 ms 0 °C ... +55 °C -25 °C ... +70 °C Polarity reversal protection for operating voltage LED Green LED for BUS activity and power supply Red LED for BUS error message Manual operating level with checkback via BUS

CarboSen ST

Digital Outputs

• Output contact / material • Switching voltage • Max. input/output current • Continuous current • Contact fusing • Mechanical lifetime • Electrical lifetime • Permissible operating freq. • Insulation to VDE 0110 • Rated voltage • Overvoltage category • Contamination level • Test voltage for coil/contact • Test voltage for contact/contact

4 NO contacts_ / AgNI Max. 250 V/AC 12 A / 4 s at 10 % ED 6 A/relay, but max. 12 A/module 6 A 1x107

switching cycles 1x105

switching cycles 360/h at rated load C 250 V/AC II 2 4000 V AC 50 Hz 1 min 1000 V AC 50 Hz 1 min

Housing

• Degree of protection (EN 60529) • Relative humidity range to IEC60721-3-3 • Connection cross-section for output terminals • Connection cross-section

for screw-type plug-in terminals (BUS, supply)

• Weight • Dimensions

Housing: IP50 Terminals: IP20 Ambient class 3k3 2.5 mm² 1.5 mm² 95 g W x H x D = 35 x 68 x 60 mm

CarboSen ST

Digital input module with module address 11

• 4 digital inputs 24 V DC The inputs are electrically isolated 24 V DC voltage inputs.

Item no. 663 R 4028 • Input 1 – RESET limit 1 & 2

Input 2 – reserved Input 3 – starting sensor test Input 4 – RESET fault / warning

• Emergency manual operation level: Position "1" Input is always HIGH Position "A" Input switches externally via contact Position "0" Input is always LOW

Digital Input module

24V DC Supply voltage

CAN-H CAN-L

1+ input 1

1-

2+ input 2

2-

3+ input 3

3-

4+ input 4

4-

24V DC

0V

CarboSen ST

Technical datas input module

• Rated voltage UN • Current consumption • Power consumption • Operating voltage range • Operating temperature

range • Storage temperature range • Suppressor circuit • Function indicator • Operating indicator • Features • Test voltage input/BUS

24 V DC 50 mA 1.2 W 0.8 ... 1.1 x rated voltage UN

0°C ... +55°C -25°C ... +70°C Polarity reversal protection for operating voltage Green LED for BUS activity and power supply Red LED for BUS error message Manual operating level with checkback via BUS 2500 V AC 50 Hz 1 min

Digital Inputs

• Input voltage (control input) • Input current (24 V DC)

(control input) • High signal recognition • Low signal recognition • Response time

(receive to transmit) • Recovery time

30 V DC 6 mA >7 V DC <3 V DC 15 ms 550 ms

Housing

• Degree of protection (EN 60529)

• Relative humidity range to IEC60721-3-3

• Connection cross-section for input terminals

• Connection cross-section for screw-type plug-in terminals (BUS, supply)

• Weight • Dimensions

Housing: IP50 Terminals: IP20 Ambient class 3k3 2.5 mm²

1.5 mm²

95 g W x H x D = 35 x 68 x 60 mm

CarboSen ST

Power Supply

Ext. power supply unit 230VAC/24VDC – 1,5A (35W) for supply of the CarboSen ST, the programming unit and the LSB-modules

• Item number 658 R 0109 • Range of input voltage 85…264 VAC, 47…63 Hz • Typ. current consumption 0,48A • Installation on DIN-rail TS35 • Range of temperature

during operation -20…+60°C • Weight 270gr • Protection class IP 20

CarboSen ST

Item Numbers

• 658 R 0010 CarboSen ST-HT, Immersion depth 150mm, temperature conditions during operation 150...400°C

• 658 R 0012 CarboSen ST-HT, Immersion depth 250mm, temperature conditions during operation 150...400°C

• 658 R 0030 CarboSen ST-NT, Immersion depth 150mm, temperature conditions during operation up to 150°C

• 658 R 0932 Programming unit, for setting the parameters of the CarbonSen ST

• 663 R 0932T Panel mounting frame for programming unit

• 663 R 4025 Analogue output module 0...10V with address 19

• 663 R 4029 Analogue output module 0...20mA with address 19

• 663 R 4027 Digital output module, for output of: - Limit 1 / 2 - „not measure“ - Fault

• 663 R 4028 Digital input modul, for release of: - RESET limit 1 / 2 - Starting sensor test - RESET fault/warning

• 658 R 0109 Ext. power supply 230VAC/24VDC – 1,5A, for voltage supply of the CarboSen ST, programming unit and modules

Spare parts • 658 R 0013

Spare sensor for 658 R 0010, 150mm • 658 R 0022

Spare sensor for 658 R 0012, 250mm • 658 R 0031

Spare sensor for 658 R 0030, 150mm • 658 R 0105

Spare elektronik XC164 in the head of the CarboSen ST • 663 R 0430

Spare connecting cable of the programming unit • 658 R 0426

Spare adapter cable of the programming unit

CarboSen ST

Connection diagram

CarboSen ST

Order example

1 pc. CarboSen 1000 ST for detection of oxidizable gas, constituents (CO/H2) in flue gases, integr. in a housing of stainless steel Type C, length 150 mm, maximum flue gas temperature at 400°C, single channel electronic XC 164 integrated in the sensor head, 1 analog output 4 to 20 mA, 0 mA = error CANBUS interface, power supply 13 to 30 V DC,

658 R 0010

1 pc. Programming unit for CarboSen ST, incl. connection cable 2m

658 R 0932

1 pc. Panel mounting frame for programming unit

663 R 0932T

1 pc. LSB-output module with 4 digital outputs, isolated relay contacts

663 R 4027

1 pc. Additional power supply unit for CarboSen ST 230 V AC / 24 V DC / 1,5 A, 30 W

658 R 0109

LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co KG Impexstraße 5 D-69190 Walldorf Tel. (+49) 06227 6052-0 Fax (+49) 06227 6052-57 Internet: http://www.lamtec.de e-mail: info@lamtec.de

Presented by: Publication No.: D LT5800 -10-aEN-008 Printed in Germany