1633 Combustion Controller Manual - Novatech Controls

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Replace the link on the burner between the gas control valve and the air control damper with a new linkage thatincludes the linear actuator. The actuator should not be required to use more than 50mm of travel.Use the MANUAL mode of the 1633 to set the travel of the actuator to the required distance using the offset and spanadjustments on the linear actuator. If the offset and span adjustments are set correctly, the actuator will not be able todrive past the required air rich position. However the auxiluary position switches can be used to warn the operator of amalfunction in the actuator.Motor Increase / Decrease Driven ActuatorThe 1633 controller can drive a motor style actuator. The “Motor Inc” and “Motor Dec” outputs from the 1633controller will provide power to the actuator.The feedback potentiometer in side the linear actuator is used by the 1633 controller to determine the actuator positionwhen the 1633 is operating in the NEUTRAL mode.Replace the link on the burner between the gas control valve and the air control damper with a new linkage thatincludes the linear actuator. The actuator should not be required to use more than 50mm of travel.After the linear actuator has been mounted on the burner, use the MANUAL mode on the 1633 controller to run theactuator from the fully withdrawn position to the 50mm extended position.Use set-up function 63 (Trim Pot Span) to set the full scale output of the feedback pot. Measure the voltage betweenscrew terminals 8 and 9 when the motor is in the air rich extended position. Enter this voltage into set-up 63. The trimmotor position can be displayed on the lower line of the analyser. See set-up 29, or for more details see appendix 7.3.2.LinearActuatorMotor IncMotor CommonMotor DecResistor **Feedback pot HighFeedback pot wiperFeedback pot Low43 Motor Inc (Mains Active)44 Motor Inc (Power Neutral)45 Motor Dec (Mains Active)46 Motor Dec (Power Neutral)7 +12V8 Trim feedback signal9 & 11 CommonMotor Driving Trim Actuator ConnectionsThe resistor in series with the trim feedback pot must be chosen to allow a maximum trim feedback signal of 4VDC.Select the trim motor pot resistance-** Trim motor Pot Resistance Series Resistor Value135 ohms 270 ohms1 k ohms 2.2 k ohmsAugust 200932 1633 Combustion Controller
3.18 CONNECTING POWERCOMMISSIONINGBefore commissioning the probe, sensor or transmitter, read the CAUTION paragraphs at the front of this manual.Check that the mains supply voltage switch is set for the correct supply voltage, and that the green / yellow EARTHwire MUST be connected to earth.3.19 COMMISSIONING – SET-UP MODEPress the SET-UP button to select the ‘SET-UP’ mode. Most of the default settings of the functions will be correct, orwill have been pre-set at the factory. Refer to Section 5.5 for more details.Check the following set-up functions -1 to 5 Date / time6 to 9 Reference voltages10 Probe offset20 Oxygen Sensor type22 & 24 Output channel #126 to 27 Output channel #234 to 36 Auto purge37 to 42 Auto gas calibration checking70 to 78 Alarm set-up3.20 COMMISSIONING – RUN MODEWhen the analyser is turned on it will go to RUN mode. The SET-UP / RUN button will toggle between the twomodes. The upper line of the display will now read ‘% OXYGEN’. If the probe temperature is not above 650°C(1200°F), a “Probe Low Temperature” message is flashed on the lower line. The probe temperature can be checked onthe lower line of the display.3.21 BURNER BY-PASS SWITCHHeated probes and sensors should have their heater supply interlocked. If the combustion appliance is not running,then power will not be supplied to the heater. To commission an oxygen probe when the main burner is turned off,switch power off the analyser, remove the probe from the flue or the flue connection from the 1234 sensor.Re-apply power to the analyser, press the BURNER BY-PASS switch into the ‘DOWN’ or ‘ON’ position. This willapply power to the probe heater even when the plant is not running. The offset can now be set and calibration checkedwith appropriate calibration check gases (typically 2% oxygen in nitrogen).Ensure that the burner by-pass switch and the power are turned off before the probe is re-installed. An alarm willoccur if the BURNER BY-PASS switch is turned on (down) during normal operation.3.22 CHECKING THE ALARMSIf any alarms are present the alarm LED will be lit, either flashing or steady. To interpret the alarms, press the alarmbutton until all alarm functions have been displayed. Rectify the cause of each alarm until no further alarms appear onthe display. For details on the operation of the alarm button and the alarm functions refer to Section 4.3.23 PROBE CALIBRATIONThe zirconia sensor provides an absolute measurement of oxygen partial pressure. There are no calibration adjustments,apart from ‘SENSOR OFFSET’, for the probe. The zirconia sensor EMF is either correct or a replacement is required.To check that the probe is functioning correctly, firstly check that the high impedance alarm, ‘SENSOR FAIL’, is notactive. The actual impedance can be displayed on the lower line. It should be less than 9 KΩ at 720°C (1320°F).Once it has been established that the impedance is normal, the offset may be set using the millivolt level marked on theoxygen probe. Refer to Section 5.5.10. The probe offset can be tested on site. A small flow of air must be admitted toboth the ‘REF’ and ‘CAL’ ports when testing the probe offset. If the probe is in the process, the air must fully purgethe probe sensor to avoid interference from the process gas sample. Novatech probes can easily achieve this with orwithout a probe filter and a gas flow of only 1 to 5 litres / minute (120 to 600 scfm) for a 1231 probe and up to 20 litres/ minute (2400scfm) for an unheated probe.August 20091633 Combustion Controller 33
Page 1: Combustion ControllerModel 1633Augu
Page 6 and 7: REF1.1 MODEL 1633 COMBUSTION CONTRO
Page 8 and 9: Range of Indication, Upper Line•
Page 10 and 11: NOVATECHCONTROLSEXHAUSTGAS INLET 1/
Page 12 and 13: OXYGEN PROBE SPECIFICATIONSMODEL 12
Page 14 and 15: The external components required fo
Page 16 and 17: 2.1 THE ZIRCONIA SENSORDESCRIPTIONT
Page 19 and 20: 2.11 RS 485 MODBUS NETWORK & RS 232
Page 21 and 22: 3INSTALLING &COMMISSIONINGSectionNu
Page 23 and 24: REFPreferred mounting angle ifthere
Page 25 and 26: 3.5 ELECTRICAL CONNECTIONSAll wirin
Page 27 and 28: 3.6 HEATER INTERLOCK RELAYSCAUTIONE
Page 29 and 30: 3.7B CONNECTING A 1234 SENSOR CABLE
Page 31 and 32: 3.13 CONNECTING THE DUAL FUEL INPUT
Page 33: 3.16 CONNECTING THE BURNER FEEDBACK
Page 37 and 38: 4OPERATOR FUNCTIONSSectionNumber4.1
Page 39 and 40: NOTE:1. The run time will be the pe
Page 41 and 42: 25. Alarm HornThis is not an alarm
Page 43 and 44: 5SETTING UP THETRANSMITTERSectionNu
Page 45 and 46: 46. Low oxygen alarm level47. Low o
Page 47 and 48: 58 Oxygen% SetPointCharacterised *P
Page 49 and 50: 11. 4-20mA Calibration Options, Cha
Page 51 and 52: 27. Transmitter Span Channel 2Outpu
Page 53 and 54: 38. Maximum Acceptable Positive Err
Page 55 and 56: 55. Data to PrintAny or all of the
Page 57 and 58: 65. Enter Characterisation Point #U
Page 59 and 60: 83. Fuel Number 2 ‘N’ Value‘N
Page 61 and 62: 6MAINTENANCESectionNumberTRANSMITTE
Page 63 and 64: The analyser maintains its accuracy
Page 65 and 66: 6.9 TESTING A PROBEWith the probe h
Page 67 and 68: APPENDIX 2PROBE OR SENSOR EMF TABLE
Page 69 and 70: APPENDIX 3% OXYGEN SCALE TO LOGARIT
Page 71 and 72: APPENDIX 5CIRCUIT SCHEMATICSAugust
Page 73 and 74: 87654321970123561783691524783517212
Page 75 and 76: 876A A5Ch#1 +12Ch#1 com432131876543
Page 77 and 78: 87654321123456789256934782468135791
Page 79 and 80: A A8B B7654321654387654321141110121
Page 81 and 82: Read/Write Configuration Variables*
Page 83 and 84: List of Alarms in Alarm MatrixIndex
Page 85 and 86:
WARNING:It must be recognised that
Page 87 and 88:
7.3.0 INSTALLATION7.3.1 THE OXYGEN
Page 89 and 90:
7.7.0 SET THE OXYGEN TRIM LEVEL AND
Page 91 and 92:
APPENDIX 81633 COMBUSTION CONTROLLE
Page 93 and 94:
PPower ............................
Page 95 and 96:
Novatech Controls Pty. Ltd. ABN 57
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1633 Combustion Controller Manual - Novatech Controls

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