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This instruction has to be stored for future working processes with the analyser at

an appropriate place and has to be always accessible and available for the
personnel!

Instruction Manual

RHADOX AMS 7300


ATEX Ex II 3G IIB+H2 T3
Analyser for Wobbe Index,
Air Demand,
Specific Gravity (SG),
and Calorific Value
*Options

Technical Description
General information for installation, start-up, and measuring mode

Warning: Please wait 60 minutes after disconnecting power supply before


open the housing.

AMS Analysen-, Mess- und Systemtechnik GmbH


Industriestrasse 9
D-69234 Dielheim
Tel. +49-6222-78877-0
Fax. +49-6222-78877-20

Software:V1.035
Version:V1.35_R0

e-mail: info@ams-dielheim.com
web-site: www.ams-dielheim.com

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Instruction Manual
RHADOX AMS 7300
ATEX Ex II 3G IIB+H2 T3

Page 2

Table of Contents
page
1. INTRODUCTION .......................................................................................................................................... 3
1.1 PHYSICAL PRINCIPLES OF THE ANALYSER RHADOX 7300 ......................................................................... 3
1.2 MEASURING PRINCIPLES ........................................................................................................................... 5
1.3 AS BUILT .................................................................................................................................................. 7
1.4 TECHNICAL DATA RHADOX 7300............................................................................................................. 8
2. INFORMATION FOR THE OPERATOR .................................................................................................... 10
2.1 HOW TO USE THE INSTRUCTION MANUAL.................................................................................................. 10
2.2 APPROVED USE ...................................................................................................................................... 11
2.3 SAFETY INFORMATION............................................................................................................................. 12
3. RELEVANT INFORMATION FOR INSTRUMENTS PROTECTED AGAINST EXPLOSIONS ................. 13
3.1 IGNITION PROTECTION TYPE EEX-P (PRESSURISED ENCLOSURE) .............................................................. 13
3.2 GENERAL INFORMATION .......................................................................................................................... 15
3.3 PURGE UNIT F840 / BY GNNHEIMER .................................................................................................. 15
3.4 CATALYTIC COMBUSTION OF BYPASS-GAS................................................................................................ 16
3.5 IN CASE OF PURGE AIR FAILURE .............................................................................................................. 16
4. INSTALLATION AND START-UP ............................................................................................................. 17
4.1 TECHNICAL DRAWINGS RHADOX 7300 .................................................................................................. 17
4.2 ELECTRIC CONNECTIONS ........................................................................................................................ 17
4.2.1 Supply Voltage ............................................................................................................................ 17
4.2.2 Signal Outputs ............................................................................................................................ 18
4.3 PNEUMATIC CONNECTIONS ..................................................................................................................... 19
4.3.1 Gas Inlets .................................................................................................................................... 19
4.3.2 Gas Outlets ................................................................................................................................. 20
5. START-UP ................................................................................................................................................. 21
5.1 GENERAL OPERATION AND OPERATION/SERVICE CODES.......................................................................... 21
5.2 STARTING THE ANALYSER ....................................................................................................................... 23
5.3 TEMPERATURE MONITORING OF THE PNEUMATIC UNIT (*OPTION) ............................................................. 24
5.3.1 Setting the Cabinet Temperature.................................................................................................. 24
5.4 MEASURING MODE ................................................................................................................................. 24
6. SETTING THE USER PARAMETERS ...................................................................................................... 25
6.1 ANALYSER OPERATION ........................................................................................................................... 25
6.2 SETTING THE SECOND LINE..................................................................................................................... 26
6.3 SUBMENU DIAGNOSIS ............................................................................................................................. 27
6.4 SUBMENU PARAMETER ........................................................................................................................... 27
6.5 SUBMENU ANALOGUE OUT ...................................................................................................................... 28
6.6 SUBMENU CALIBRATION .......................................................................................................................... 29
6.6.1 Adjusting of Auto-calibration ......................................................................................................... 33
6.6.2 Start of Auto-calibration ................................................................................................................ 33
6.6.3 Calibration Errors .......................................................................................................................... 33
6.7 SUBMENU SERVICE................................................................................................................................. 34
6.7.1 Fixed Density (*Option)................................................................................................................ 37
6.7.2 Service Request .......................................................................................................................... 37
6.7.3 Cabinet Temperature (*Option) .................................................................................................... 38
6.7.4 Expert Mode.................................................................................................................................. 38
7. SERIAL INTERFACE ................................................................................................................................. 39
8. ERROR MESSAGES ................................................................................................................................. 40
I. GAS ALARM (*OPTION) ............................................................................................................................ 41
II. MEASURING CABINET COOLER (*OPTION) ......................................................................................... 42
III. SERVICE SOCKET (*OPTION) ................................................................................................................ 42
IV. EXTERNAL CATALYTIC COMBUSTION OF BY-PASS GASES (*OPTION) ........................................ 43
V. INSIDE CATALYTIC COMBUSTION OF BY-PASS GASES (*OPTION) ................................................ 44

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1. Introduction
1.1 Physical Principles of the Analyser RHADOX 7300
Due to environmental protection and as a cost-saving alternative to natural gas fuelling, more and
more gases used in industrial combustion processes that produced in other operations, such as in
coking plants. However, the composition of these exhaust gases is often subject to strong
variations due to their generating process.
On the other hand, a constant energy supply at the combustion of the off-gases is an economic
necessity and minimizing the emission desired. The reliable and continuous measuring of the air
demand and the Wobbe index of the gas used is necessary in order to adjust the combustion
process to the changing gas qualities and to the specific operating conditions.

Field of Application

Utilization of off-gases of furnaces, chemical plants and refineries as well as of sewage


digesters and bio-gas plants: in the combustion control for gas-fired boiler plants and
industrial furnaces in power production plants, the chemical and petrochemical industry

In plants producing blended gases of a given quality

For the production of synthetic gases, even with a very low Wobbe index

The gas flame as a tool: quality assurance in the glass industry

Systems Characteristics

RHADOX - measuring systems for air demand, Wobbe index, and calorific value,
specific gravity
Customized systems
Burner or catalytic reactor for adjusting to the measuring gas quality
Calibrateable with the PTB certification (special model)
Automatic and manual 2-point calibration
ZrO2 sensor for the oxygen measurement
menu-driven parametrizing
Diagnostic system for the instrument functions and alarms
Continuous operating mode

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RHADOX
7300
The RHADOX 7300 is a compact system for the continuous and reproducible determination of
the air demand at a total combustion of a gas. The instrument built into an insulated wall cabinet.
The mixing cell consists of two separated gas chambers, i.e. the mixing chamber and the fitting
chamber. This mixing cell plays a key part in the homogenous and reproducible process of the
sample gas with the combustion air. Due to built-in gas jets (Venturi-jets) for the probe gas and
the combustion air, the simple measuring method makes use of the law of Bernoulli (see
measuring principles).

Figure 1.1:
RHADOX 7300
Basic Gas Flow Diagram

From the mixing chamber, the gas/air mixture flows to the fitting chamber, which might design as
a supersonic jet or a flame barrier (depending on the application involved). Hence, a reaction from
the burner on the performance of the mixing chamber has prevented and the ultimate mixing of
the two gases will achieved.
Gas and air supplied to the corresponding apertures located in the mixing cell.
The electronic controller ensures that the pressure of both gases in the two separated gas
volumes is equal and constant (controller accuracy + 0,01 mbar). For this purpose, a pressure
controller for the combustion air as well as a differential pressure transmitter is used in the
instrument.
The front panel features two pressure meters: the controller to adjust the correct pressure of the
combustion air and a meter for the sample gas pressure. The latter will adjust to the correct air
pressure via the electronic controller.
Programming and operating the instrument needs only three push buttons: one for the operation
mode (measurement, calibration, and signal outputs), two for the cursor. A display with two LCD
rows indicates the corresponding values and user fed data (alarms, residual Oxygen). A key
operated switch locks the programming level if required.

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Using the semi-automatic calibration mode a given and correct value compared to the
corresponding measuring value of the test gas via the electronic controller. Deviations show on
the display.
If a two-point calibration is need, a second calibration point can obtain via an auxiliary airflow to
dilute the reference gas properly. Of course, also two different reference gases can use to cover
the measuring ranges. The actual calibration mode depends on the specific AMS application.

1.2 Measuring Principles


The combustion gas to analyze via the
RHADOX measuring system will completely
oxidize with air in surplus (approx. 3-10 fold). The
mixture of the measuring gas with the burner air
has to be constant and reproducible. Hence, the
residual Oxygen is a reliable measure for the Air
Demand of the oxidized gas. Once the
instrument has been calibrated the corresponding Wobbe
Fig. 1.2
Index can be determined.
Design and construction of the mixing cell for combustion gas and air meet Bernoullis law, taking
into account the viscosity of the compound (Reynolds Number Re):

With: p

= A * v = A * 2 * p / p = Const.

(1)

p = [1 + f (Re)] + * v 2 / 2

(2)

Re = . v . D/

(3)

pressure loss in the reduction


Density
Volume flow
Dynamic viscosity

D
V
A

diameter of the restriction


flow speed in the restriction
restriction area

Apart from temperature and pressure, the volume flow depends only on the density and the
viscosity of the gas considered.
For Re < 2000 a laminar gas flow can be assumed, the function f(Re) tends to zero. This
prescription will met through the corresponding layout of the gas jets for measuring gas and air as
well as by maintaining pressure and temperature of both the components sufficiently constant and
equal:
p
T
p
T

~
~
~
~

0.2 mbar
0.25 C
100 mbar
2 C

The dimensions of the aperture(s) in the mixing chamber in order to achieve Reynolds number
following eq. (3) are set during the application at AMS GmbH.
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The stoichiometric Air Demand l at the combustion process has defined as


lstoichio. = [air supplied - res. O2] / gas

(4)

and the corrected stoichiometric air demand as


lcorrr. = stoichio. /

rel.

(5)

with the specific gravity defined as


drel. = gas / air
Values for the relative density may take from the literature, or more precisely determined via a
specific measurement of the actual gas mixture.
The measuring procedure featured by the RHADOX reduces the determination of lcorr.to a single
measurement, i.e. to the residual Oxygen concentration or Air Demand. The residual Oxygen
concentration will display.
Within reasonable concentration ranges, a linear relationship exists between the (corrected)
stoichiometric Air Demand and the Wobbe Index, the latter of major importance for burner control
units.
To determine this relationship for a given gas matrix is a further major task of the AMS application
lab. The corresponding calibration enables the determination of the Wobbe Index WI via the builtin computer:
WI = f(lkorr.)

(6)

The Wobbe-Index WI has related to the Calorific Value H as


WI = H /

(7)

The instrument computer can determine the calorific value of a gas with the help of an additional,
separately installed density measurement.
There are two systems for the oxidation of a measure gas, a burner with a flame resp. with a
catalytic reactor. If the sample gas cannot burn in a stable flame due to its physical or chemical
characteristics, the catalytic reactor developed by AMS will installed instead of the burner.
The reaction chamber will fill and heat with a noble metal functioning as catalytic converter.

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1.3 As built
The analyser consists of the following main components:
1. two-part housing,
Left side Pneumatic for gas mixing and analyse
Right side power supply, electronic, evaluation
2. Electronics, wiring terminal, Display und Functional keys
3. Solenoid Valve(s) for Gas shut-off / change
4. Pressure reducer for Instrument Air / Process Gas
5. Oxygen analyse in raw Gas (*Option)
6. Analogue solenoid Valve and Gas mixing with Pressure monitoring
7. Measuring catalyst followed by residual oxygen analysis
8. Density measuring cellblock
9. Catalytic combustion for bypass gas (*Option)
10. Purge Gas Unit for Ex-Zone 2

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1.4 Technical Data RHADOX 7300


Voltage Supply

110230VAC / 50/60Hz

Power Consumption

max. 1000 VA

Ambient Temperature

-5 up to +45C

Influence of Temperature

20 up to 40C: 0,04% /C

Display

2*16-digit back-lit LCD

Analogue Outputs

4-20 mA, ohmic load max. 500 Ohm


max. 4 outputs, possible settings: WI, CARI, LCV, SG
(Please refer to the test report)
*Option: measuring ranges galvanically isolated

Measuring Ranges(s)

according to the application, programmable

Accuracy

depends on the quality of the test and references gases

Repeatability

Wobbe index
Air Demand
Gas Density
Calorific Value

Noise
Drift

0,3% of the current value


0,5% of the current value / month

Response Times
Wobbe Index and
Air Demand

T90%

:10-40 sec.
depending by application

Specific Gravity and


Calorific Value

T90%

: 10-40 sec.
depending by application

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: 1,0% of the current value


: 1,0% of the current value
: 2,00% of the current value
: 2,00% of the current value

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Analyser Messages
Analyser State

4 messages signalising the analyser state


Potential-free pins
max. load: 24V/0,3A ohmic load

1x

Status message (measuring values available (Yes/No))

3x

indicating the operating status


1. Service Request
2. Calibration active
3. Service active

(YES / NO)
(YES / NO)
(YES / NO)

Serial Interface

RS 232 C (please refer to chapter # 9: cable and protocol)

Calibration

semi-automatic calibration with two bottled gases


Manual start of the calibration
Manual switching between the calibration cal gases
(*Option Automatic calibration
Automatic monitoring of the calibration

Dimensions

W x H x D ca. 900*1.000*350 mm

Weight

ca. 150 kg

:
:
:

max. 250Nl/hr at 2,0 6 bar-g


max. 100Nl/hr during application
max. 100Nl/hr during application

Flow Rates
Instrument Air
Measuring Gas
Calibration Gas

II. Ex-relevance Data corresponding nameplate


Labelling

ATEX Ex II 3G IIB+H2 T3

Ambient Temperature

+ 5 Temp + 55 C

Housing protection

IP65

Purge gas

instrument quality air (oil- / dust free) / Inert gas

min / max purge air pressure

2 / 6 bar (g)

min / max protection over-pressure 0,8 / 15 mbar (g)


min. purge air flow

100 l/h (during operation)

AMS GmbH, 2012, subject to modification

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2. Information for the Operator


2.1 How to use the Instruction Manual

Please read this Manual before the start-up of the instrument!


The manual contains important data and information. Observing this
information guarantees safe operation of the analyser and will result in
reliable measuring values.
This Manual describes the standard instrument. Deviations are marked
at the corresponding part of the documentation.
Of particular importance are the information and warning texts
identified by the appropriate pictograms. These symbols serve the
personal safety and provide useful tips on how to avoid malfunction.
This Manual comprises all necessary information for the applicationoriented use of the instrument. Therefore, only qualified and authorized
personnel may work with the instrument. The personnel should properly
train in measuring and control instrumentation for process automation.
This Manual is an integral part of the system supplied. For clarity
reasons this Manual cannot cover all details of the various versions
supplied. If it is intended to use the instrument in a different way as
described herein, please contact AMS GmbH, Dielheim before starting
the analyser.

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2.2 Approved Use


The product supplied has been developed, manufactured and tested
according to the relevant safety standards. It may used only as
approved by AMS GmbH, Dielheim. Proper transport, storage and
installation are a must, as well as careful operation and maintenance to
guarantee the safe and reliable operation of the instrument.
Only qualified and authorized personnel may install and operate this
instrument. The personnel shall be familiar with the safety concept of
this instrument. Severe injuries and/or substantial damage to property
may occur by not observing the warning texts in this manual or attached
to the analyser or if unqualified actions are carried out.
Intended use in the sense of this manual means that the instrument
may only use in applications described in this manual. Auxiliary
equipment or other components used in conjunction with this instrument
have to approve by AMS GmbH, Dielheim.
Observing the safety and operation rules described in this manual helps
to avoid personal and property damages during regular operation.

Warning
While opening the housing of the analyser please observe that certain
parts of this device may carry dangerous voltages. Therefore, only
authorized and qualified personnel may open the instrument.

Note
The conformity declaration of this instrument must renew if the operator,
e.g. using a different sensor type, has carried out modifications in this
instrument.

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2.3 Safety Information


The following information serves for your personal safety as well as to protect the described
product from damage.
Safety information and warnings to prevent danger to the life and health of users identified
by pictograms in this Manual matched to the significance of the accompanying text.

Note is important information on the product itself and its handling.

Danger means that death, severe personal injury and/or substantial


damage to property will occur if the appropriate safety precautions has
not observed.

Warning means that death, severe personal injury and/or substantial


damage to property can occur if the appropriate safety precautions has
not observed.

Caution with a warning triangle means that slight personal injury can
occur if the appropriate safety precautions has not observed.

Caution without a warning triangle means that damage to property can


occur if the appropriate safety precautions not observed.

Attention without a warning triangle means that an undesirable effect


or state can occur if the corresponding information has not observed.

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3. Relevant Information for Instruments protected against Explosions


Note For a safe application of the RHADOX 7300 the analyser features
an approved purge unit. Please read the instruction manual of this
purge unit as well as the instruction manual of the RHADOX itself
before the initial start-up of the RHADOX.
Danger Please read the separate manual of the purge unit and proceed
accordingly. Lack of knowledge of the purge units functioning and its
safety concept might cause substantial material damage of the
complete analysing system. Furthermore, disregarding the safety
instructions may lead to life-threatening injuries and/or death.
Note In addition to the purge unit, an optional catalytic combustion of
by-pass gas is available.

3.1 Ignition Protection Type EEx-p (pressurised enclosure)


Instruments with the ignition protection type EEx-p labelled according to the hazardous area (ExZone 1 or Ex-Zone 2).
The basic principle of the ignition protection type is to keep explosive gas mixtures clear of nonhazardous instruments. An excess pressure against the atmosphere inside the protected housing,
which has monitored, achieves this.
Gases (generally instrument air or Nitrogen) passed into the protected housings. Hereby a slight
excess pressure built up inside the tightly sealed housings reliably preventing the intrusion of
vapours of dangerous atmosphere. Therefore, the protective housings may only have opened
being in a voltage-free state.
For ensuring the permanent leak-tight containment is at least 1x per year to provide the evidence
on testing the tightness of the containment technology with 1.5 times the operating pressure. For
this, the standard EN 1127-1 should be considered.

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Please comply all of these technical formalities for the containment system:
Gas inlet pressure: max 5 bar (g)
Air inlet pressure: max. 5 bar (g)
Flow rates during operations
Air: app. 250 - 500 l/h
Gas: app. 50 - 150 l/h
For assessing and establishing, a tight containment considered the norm EN 1127-1 approach. As
permanently sealed containment, devices apply if:
I. They are constructive in such a way, that they remain tight due to technical, or
II. Their technical tightness is ensured by servicing / maintenance and monitoring
Please use only trained and qualified personal to check for leaks in the analyser suitable use in
hazardous areas.
The service and maintenance of the analyser includes the following measures:
1. Visual inspection of the equipment and check for savour, noise due
2. Review of devices with mobile leak detectors and portable gas detection devices
3. Overpressure test of the entire system at 1.5 times of the normal operating pressure
The operator of the system, at least monthly for point 1, shall determine the frequency of
testing. and 2., and quarterly for testing the entire system.

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3.2 General Information


The faultless and safe operation of the analyser and its optional catalytic combustion of by-pass
gas require careful operation and maintenance. Only qualified personnel may work on these
instruments.
The operator has to observe strictly the electric parameters of the label and of the test certificate.

Warning The housings of the measuring system (purge unit and calorific
value analyser) may only have opened in a voltage-free state.

Warning If there is explosive dust in the ambient you have to clean the
interior of the housings before closing the lids.

3.3 Purge Unit F840 / by Gnnheimer


To protect the analyser it is equipped with a purge unit by Gnnheimer. Please read the
Gnnheimer manual before the start-up and proceed accordingly.
Parameters Ex-Zone 2
The purge unit pre-sets by the manufacturer. The general parameters lined out in the separate
manual.
Attention The general settings has found in the corresponding manual.

After you have carefully read, the manual you may re-set all values. However, if the analyser used
in the Ex-Zone 2 please make sure that there is no hazardous atmosphere, which might lead to an
explosion.
The measures, which will take if the purge unit and/or purge air fail, are the sole responsibility of
the operator. These should be in accordance with the general regulations of the plant operator.
The purge unit of the analyser for calorific value AMS 7300 protects the analyser via instrument air
against intruding hazardous atmosphere. Further functions, such as shutting down in case of
failing purge air, has not intended.
We again refer to the safety concept of the plant operator. The operator has to guarantee the safe
operation and has to arrange in case of failing instrument air to protect the personnel and the plant
against explosions.

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3.4 Catalytic combustion of Bypass-gas


The optimized mixture of combustion air and sample gas leads to an increased production of fuel/air mixture more that could burn in the measuring catalyst. Therefore, an optional catalytic
afterburner is available. The catalytic afterburner integrated in the housing and in use in
hazardous areas.
Without the catalytic afterburner, a costly disposal of the fuel-/air mixture is necessary. The
disposal should carefully planned by the operator of the analyser to protect the exhaust pipes for
explosion in hazardous areas.

3.5 In case of Purge Air Failure


Note In case of purge air failure, the EEx-p controller automatically
shuts down the complete measuring system from the mains. In addition,
it closes the sample gas valve. This will protect the analyser as well as
the catalytic oven combustion of by-pass gas.

Danger After disconnecting the instrument or after a purge unit failure


you have to wait at least one hour until you open the housings. The
internal parts have to cool down to the maximum surface temperature.
Please observe the temperature class, which has indicated on the type
label.

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4. Installation and Start-Up


ATTENTION: Strictly follow all working steps / control measures described below. The
operator may not change anything concerning the operation, used components, and may
not alter the control electronics in any way. Otherwise, the certificate is not valid anymore!

4.1 Technical Drawings RHADOX 7300


The controls of the analyser RHADOX 7300 as well as the electric and gas connections has
outlined in the technical drawings in the appendix.
Please refer to the corresponding drawings in the appendix.

4.2 Electric Connections


4.2.1 Supply Voltage
Concerning the terminal assignment of the power supply line, please refer to the corresponding
AMS GmbH technical drawing in the appendix.
Power Supply: 110230 VAC ; 50/60Hz ; max. 1000 VA, please refer to the test report and
the technical drawings in the attachment.

Danger Only trained personnel may connect the power supply line
since an inappropriate connection may harm the personnel and the
systems. Under certain conditions, the internal parts may carry
hazardous voltages.
Note Always operate the instrument after applying instrument air. This
allows ventilating the catalyst and the optional catalytic combustion and
diminishes the preheat sequence of a cool catalyst as well as the
heating time of the complete system.

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4.2.2 Signal Outputs


The terminal assignment of the terminal row X4 has outlined in the appendix.
A.) Analogue Outputs
Terminal

Assignment

Description

01 02

Analogue Output 1

420 mA current loop, measuring value freely


programmable

03 04

Analogue Output 2

420 mA current loop, measuring value freely


programmable

05 06

Analogue Output 3

420 mA current loop, measuring value freely


programmable

07 - 08

Analogue Output 4

420 mA current loop, measuring value freely


programmable

B.) Serial Interface RS232


Terminal

Assignment

09
10
11

RS232

Description
RXD
TXD
GnD

please refer to # 6 of the Instruction Manual

C.) Messages via the relay contacts


Termina
l

Assignment

Switch
Position

12 - 13

SYSTEM
STATUS

12 - 13

Measuring values available


Measuring values not available
FAIL SAFE [NC]

12 - 14

Service Mode

open
12 - 14

12 - 15

Calibration

open
12 - 15

12 - 16

Service Request

open
12 - 16

Measuring Mode
Service Mode
[NO]
Calibration inactive
Calibration active
[NO]
Message inactive
Service request
[NO]

17 -19

Relay 5

Back-up relay, not assigned

20 - 22

Relay 6

Back-up relay, not assigned

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4.3 Pneumatic Connections


In order to connect the calibration gases please refer to the corresponding AMS GmbH drawing in
the appendix.
1. Gases for the measuring mode:
Instrument Quality Air
Air pressure:
2,0 - 6,0 bar-g, dust-free and clear of hydrocarbon
Flow rate:
max 250Nl/hr
Non-condensing process gas
Gas pressure: according to the application
Flow rate:
ca. 100Nl/hr
2. Gases for the calibration:
Instrument Quality Air
Air pressure:
2,0 - 5,0 bar-g, dust-free and clear of hydrocarbon
Flow rate:
max 100Nl/h
2 calibration gas bottles with different gas compositions
Gas pressure: according to the application
Flow rate:
max. 100Nl/h

4.3.1 Gas Inlets


Note All gas inlets outside of the analyser cabinet labelled in plain
text!
1. Instrument air

"Instrument Air"

2. Sample gas

"Process Gas"

3. Calibration Gases

"Cal. Gas high"


"Cal. Gas low"

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4.3.2 Gas Outlets


Note The following indications of the gas connections can found at the
outlet fittings!

4. "Bypass" combustor
Danger This is an inflammable gas/air mixture (ca. 300 Nl/hr)

The by-pass gas has to be disposed of via a back-pressure-free and safe conduit!
Disposal

pressure-free and pressure-fluctuation-free

We recommend leading off the by-pass gas via a stainless steel conduit of 1-2 m with the
appropriate connection size of the lines. If the by-pas gas is lead off via a longer conduit, the
diameter of the lines has to be enlarged.
5. Reference air + purge gas OUT "PurgeGas"
The reference air and purge gas may be discharged freely to the ambient atmosphere.
6. Off-gas "Exhaust/Condensate"
Lead the off-gas away via a continually sloping 1 - 5 m conduit or hose. If the off-gas is lead
off via a longer conduit the diameter of the line has to be enlarged accordingly. The off-gas
conduit leads away max. 20 Nl/hr of a combusted water-saturated gas mixture. On falling
below the dew point, the resulting water has to be disposed of to the rule. The off-gas
temperature at the exhaust fitting of the analyser is below 60 C.

While installing the off-gas conduits make sure that the condensed water can flow off
freely. A congested off-gas conduit can shut down the complete instrument.

Remark:
If you want to install an upward off-gas conduit you have to connect a condense separator
with a corresponding condensate separation at the analysers exit.

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5. Start-up
Note Before the start-up, all electrical and pneumatic connections have to
connect according to their use. Make sure all pneumatic lines are gas-tight.

Attention strictly follows all working steps / control measures


described below. The operator may not change anything concerning
the operation and use components and may not alter the control
electronics in any way. Otherwise, the certificate is not valid anymore!

Note If the analysing system features a catalytic combustion of by-pass gas


it is important that the combustion reach its operating temperature before
the RHADOX start-up since the catalytic combustion will provide the release
signal for the RHADOX

Note The inlet valve closed during the preheating time of the pneumatic
unit, of the catalyst, and of the ZrO2 sensor. Please set the gas inlet
pressures to the correct values after all components have reached their
operating temperature and after the main valve has opened. The required
pressure values noted in the test report and next to the manometers.

5.1 General Operation and Operation/Service Codes


The analyser operates via three keys. The F-key takes you to the menu. You can toggle through
the menu via the two arrow keys and you can makes settings according to the direction of the
arrows.
Note After you have changed values and/or settings via the arrow keys, you
have to confirm the new values with the F-key. If the new values has not
approved by the F-key, the former values remain valid.

Note The display will light as soon as you press any key. The lightning will
go out if no key has pressed during the next 20 sec.

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Via pressing the F-key, you will reach the menu from which you can choose by pressing the F-key
and/or the arrow keys. Sensitive data have protected by codes in the submenu.

1. Operation Code

111

2. Service Code

1111

The chapter submenu outlines when to enter which code. The entered code is valid until you
switch back into the measuring mode.

Software pattern:
Measurement Mode

Menu

Submenu

Measure
Diagnosis

F-key

Submenu, please refer to # 6.3

Parameter

F-key

Submenu, please refer to # 6.4

Analogue Out

F-key

Submenu, please refer to # 6.5

Calibration

F-key

Submenu, please refer to # 6.6

Service

F-key

Submenu, please refer to # 6.7

Note Via pressing the F-key you will get from the measurement mode to the
menu. Now you can select the corresponding submenu via the arrow keys.
After you have quit the submenu by pressing return, select Measure and
you will reach the measurement mode.
Note If you do not press any key for ca. 250 sec. the analyser automatically
switches back to the measurement mode regardless of the menu level.

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5.2 Starting the Analyser


Note After starting the RHADOX 7300 the automatic start process follows
as described like below.

Note The RHADOX 7300 only reaches its normal operating status if all
gases (air, process gas) has connected to the corresponding gas lines.
Please refer to # 5 of the instruction manual!

Note The inlet valve has shut off during the preheating time of the
measuring catalyst and of the ZrO2 sensor. Only after both components
have reached their operating temperature and the main valve is open,
please set the gas pressures of the inlets to the correct values. These
required pressure values can be found in the test report and are marked
next to the manometer.
Display

Description
After powering on the analyser, the start menu displayed.
Among others, the system identification and serial
number has shown.

AMS 7300
Ser.Nr.
Warmup

##,## h

Catalyst Temp.

### C

Startup
Checking

##,## min

Version: V1.35_R0

During the pre-heating time, the sample gas catalyst has


heated up to 400 C. Simultaneously the ZrO2 sensor is
pre-heated.
Now further sensors are checked and the system levels
out to the current measuring value = process gas

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5.3 Temperature Monitoring of the Pneumatic Unit (*Option)


The analyser features a temperature monitoring of the pneumatic unit. It can display as cabinet
temperature in the second line.
The cabinet temperature protects mounted parts and monitors the condensation formed by
temperatures below dew point.
Note The measurement will stop if previously set temperature limits has
exceeded or fallen below to protect the mounted parts. The operator can
set the temperature limits. The factory-set limits has noted in the test
report.
Note If the temperature inside the pneumatic unit is > 50 C, special parts
have to use. These are optionally available at AMS GmbH.

5.3.1 Setting the Cabinet Temperature


The possibilities of settings of the temperature evaluation has described in # 6.7.3.

5.4 Measuring Mode


After the pre-heating sequence, the analyser automatically starts the intake of the measuring
values. The current Wobbe index shows in the first line of the display. The second line of the
display may be set by the user (choose from a list).

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6. Setting the User Parameters


6.1 Analyser Operation
The analyser has operated via three buttons. Via the F-key (=function key) you can choose menu
items of the main menu. In addition, the F-key confirms altered values and parameters. Via the two
arrow keys
and
(=justifying keys) you can change values according to the keys symbols
(increasing/decreasing).
Note Please confirm any changes of values or parameters via the F-key.

Main Menu
Display

Description

Measure
Diagnose
Parameter

Analog Output

Possible error messages are displayed


Parameters are displayed (cannot be altered in the
measuring mode)
Assignment of the analogue outputs and setting the
measuring range limits, aligning the mA-signal to the
evaluation unit

Calibration

Read in the calibration values, carry out the calibration


(Wobbe index and calorific value)

Service

Parameter list (for sensor exchange), setting the relay


outputs, expert modus

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6.2 Setting the Second Line


Note You can choose the parameters for the second line by pushing the

resp.
.
List of choices for the second line
Display
SG

CARI

LCV [MJ/m] / [MJ/kg] /


[kWh/m]
WI [MJ/m]
O2Air [%]

Description
Specific Gravity (*Option)

Air demand

Lower Calorific Value (*Option)

Wobbe - Index

Oxygen value of the reference sensor for SG


measurement

O2Mix [%]

Oxygen value of the reference sensor subsequent to the


density mixing chamber

O2Gas [%]

Oxygen value in raw gas for correction of Wobbe and SG


measurement (*Option)

O2ZrO2 [%]

dp [mbar]

CAT AB [C]

CAT [C]

Cabinet Temp [C]

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Oxygen value Wobbe measurement

Pressure difference at the gas and air nozzles

Temperature catalytic combustion (*Option)

Temperature sample gas catalyst

Temperature pneumatic unit (*Option)

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6.3 Submenu Diagnosis


Note The submenu diagnosis indicates all pending errors (which e.g.
caused the shutdown of the analyser).

Note Errors cannot delete as long as their reasons have not been
resolved. Only the message Service Request may delete via the F-key.

Second line
Display

Description
No error message

NO ERROR

Note During measuring, the upper message has indicated. Possible error
messages have described in the corresponding error message chapter.

6.4 Submenu Parameter


Note All parameters may show in this submenu. The operator cannot
change any parameters. The submenu intends to outline quickly the
corresponding parameters in case of an error message.

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6.5 Submenu Analogue Out


The analyser RHADOX 7300 features max. 4 independent 4 20 mA analogue outputs, which can
be freely scaled:
Note To choose and set the analogue output, please select the sub item
Analog Out of the main menu via the F-key. You will reach the following
submenu.
Note During the calibration, all analogue outputs are frozen to the latest
valid values. They will be active again after the purge sequence has
completed.
Note You can choose from values for the analogue outputs which are
displayed in the second line (please refer to # 7.2).
Submenu Analogue Out
Display
return
Analog out 1-4

Description
Back to the main menu

Choose between analogue out 1-4 via F-key

extended parameter

A1 ####

A1 420 mA / 0...20 mA

Please select from the list below which measuring value should
be assigned to the analogue output, e.g.
Wi Wobbe Index MJ/m
LCV Lower calorific value[MJ/m] / [MJ/kg] / [kWh/m] / [kcal/kg]
LHV Lower heating value[kcal/kg]
O2 Gas [Vol%] Oxygen concentration in the raw gas
Via the F-key you can choose the limits at the output:
420 mA
420 mA ( E ), user defined constant current in case of error
020 mA
020 mA ( E ), user defined constant current in case of error
020 mA ( C ), with adjustment [value has to be programmed]
OFF output is turned off
frozen, output is frozen to the latest value
Const. I, constant current at the output

Analog Min

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Measuring range limit, 20 mA

Analog Max

Const. Curr

Constant current at the analogue output, adjustable via the


arrow keys

Error Current

Current in case of error at the analogue output, adjustable via


the arrow keys
Note According to the test report, the analogue outputs 14 are
galvanically isolated.

6.6 Submenu Calibration


After the calibration process of the analyser RHADOX 7300 has started, the operator has guided
through the menu.
Note On request, please enter the corresponding code. Please refer to #
5.1.
Note The calibration has started manually but the calibration process
itself is automatic and has monitored.
Note Each calibration has preceded and completed by a purge sequence.
The purge sequence allows purging the lines and keeping the
measurements stable.
Note During the calibration the analogue outputs are frozen. The
analogue outputs activated again after the final purging.
Note valid for Ex-versions with EEx-p-controller of the RHADOX housing:
The instrument may only calibrate with closed housing doors and active
purge unit observing the excess pressure inside the housing. I.e. that after
starting the calibration the housing doors have to shut and the by-pass of
the purge unit Gnnheimer has to deactivate.
Note After starting the calibration, the calibration parameter and the
calibration status will display in turns.
Note for Option AUTO CAL.:
In case of Error during the auto cal.-Routine, the relay contact
Service Requesthas switched and the operator can see by toggle the
menu Diagnosiswhat happens during the calibration. Anyway, the error
only appears if the analyser gets a right calibration.

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Submenu Calibration
Display
return

Wi LO POINT
Wi HI POINT
SG LO POINT

SG HI POINT

Description
Return to the main menu

Lower calibration point of Wobbe index in [MJ/m]


Upper calibration point of Wobbe index in [MJ/m]
Lower calibration point specific gravity

Upper calibration point specific gravity

CV Low Cal.

Starts the calibration of the lower calibration point; follow


the instructions displayed

CV High Cal.

Starts the calibration of the upper calibration point; follow


the instructions displayed

Show last Cal.

Displays latest calibration; verifies latest calibration

Submenu Extended
Parameter
return
Set the purge time which
starts and terminates each
calibration
Choose between active and
frozen, i.e. analogue out
status during calibration
Suppresses the monitoring
during the calibration; only
perform if directed

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Purge Time

Analog Out

Service Cal.

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OFF
Auto-calibration is switched off
Low
Auto-calibration starts with
calibration of the lower
calibration point
High
Auto-calibration starts with
calibration of the higher
calibration point
Low-High
Auto-calibration starts with
calibration of the lower and
higher calibration point
High-Low
Auto-calibration starts with
calibration of the higher and
lower calibration point

Adjusting the time-interval


between two auto-calibrations

Page 31

Auto Cal. Mode

Auto Cal. Time

Submenu O2 Gas Sensor


(*option)
return

Oxygen concentration of the


lower calibration point Gas
Sensor

O2 Low Gas

Oxygen Sensor for the upper


calibration point Gas Sensor

O2 High Gas

Starts the calibration of the


lower calibration point; follow
the instructions displayed

Lo Gas Calib.

Starts the calibration of the


upper calibration point;
follow the instructions
displayed
Displays latest calibration;
verifies latest calibration

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Hi Gas Calib.

show last Cal.

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Note Any calibration can abort via the F-key.


Note After you have started the calibration; please do proceed according
to the displayed directions.
Note After the sampling sequence (sequence of the measurement
reading), the result of the calibration will displayed.
Note for Option AUTO CAL.:
In case of Error during the auto cal.-Routine, the relay contact
Service Requesthas switched and the operator can see by toggle the
menu Diagnosiswhat happens during the calibration. Anyway, the error
only appears if the analyser gets a right calibration.
Cal. successful

Result of calibration displayed after sampling sequence,


calibration successful

6.6.1 Adjusting of Auto-calibration


Auto-calibration is available as option. It includes the possibility to pre-select the type of calibration
and the time interval by using the counter in the time range of max. 9999 h between two
calibrations. AMS recommends setting the time range at 600 1000 h.

To set the times please proceed as follows:


1. Press the F-key and select the submenu Calibration
2. Select Extended Par. via the arrow keys and choose the following sub item:

Auto-calibration
mode

Press the F-key and set the desired


calibration. OFF indicates that Autocalibration is deactivated.

Auto-calibration
time interval

Press the F-key and set the time


interval between 2 calibrations. 0000
h indicates that auto-calibration is not
active. In this setting the autocalibration can be started at any time
with an external actuator.

Version: V1.35_R0

The counter shows the


remaining time until the next
auto-calibration in the second
line of the display.

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6.6.2 Start of Auto-calibration

Note: The Auto-calibration will starts after the adjusted time-interval.


Note for Option AUTO CAL.:
In case of Error during the auto cal.-Routine, the relay contact
Service Requestswitched and the operator can see by toggle the
menu Diagnosiswhat happens during the calibration. Anyway, the error
only appears if the analyser gets a right calibration.

Additional start of the Auto-calibration:


Via potential-free contact: after press the contact longer than 3 seconds the autocalibration will start, according Auto-calibration mode
Abort of the Auto-calibration:
Via potential-free contact: If you press the contact for longer then 10 seconds the
auto-calibration aborts
Via F-key pressed at the analyser
6.6.3 Calibration Errors
Note The semi-automatic calibration requires the user to monitor the
calibration process. The automatic calibration needs no monitoring but
also there can be an error. The calibration result will show after the
calibration has completed; the following messages may displayed:
Note for Option AUTO CAL.:
In case of Error during the auto cal.-Routine, the relay contact
Service Requesthas switched and the operator can see by toggle the
Menu Diagnosiswhat happens during the calibration. Anyway, the
error only appears if the analyser gets a right calibration.
Display
Cal. Scale ERR

Cal unstable

Version: V1.35_R0

Description
Calibration point and actual measuring value too distant,
indicating wrong cal gas
Troubleshooting: apply correct cal gas, check calibration
parameters
Fluctuations during sampling sequence are too high, no
calibration possible
Troubleshooting: prolong purge sequence, prevent
pressure fluctuations

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6.7 Submenu Service


After you have exchanged the Oxygen sensor for the Wobbe measurement, you can set the
sensors parameters with the help of the menu. The analyser will electrically adjust to the new
sensor. Furthermore, special settings allow adjusting the analyser to the complete system.
Note On request, please enter the corresponding code. Please refer to #
5.1.
Note If you have ordered the sensor at AMS GmbH, you will receive the
calibration parameters ibidem.
Note The electric adjustment of the system after a sensor exchange does
not replace the calibration as described in # 7.5.
Note The menu items listed below are always visible; however, they will
only be analysed if the according option has ordered previously.
Note Optional parameters are marked with (*

Submenu Service
Display
return

O2 Air Offset
O2 Air Span
O2 Mix Offset
O2 Mix Span
O2 Gas Offset
O2 Gas Span

Description
Return to the main menu

You receive the value of the reference sensor of the SG


measurement (*Option)

You receive the value of the sensor of the SG


measurement (*Option)

Sensor to determine the Oxygen concentration in raw gas


(*Option)

ZrO2 Offset
ZrO2 Span
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Sensor to determine the Wobbe Index

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Fixed Density #.### kg/m

Relay Set.

Page 35

Calculation of the calorific value from the Wobbe index,


without the option SG measurement, only available with
the corresponding option (*
Set the relay to report the analyser status (NC/NO)

Submenu Relay Set


Return to the main menu via
the F-key

return

Choose the operation of the


relays via the arrow keys

Service Relay
is not failsafe / is failsafe

Choose the operation of the


relays via the arrow keys

Calib. Relay
is not failsafe / is failsafe

Choose the operation of the


relays via the arrow keys

S.Req. Relay
is not failsafe / is failsafe

Reserve Relay 5

Relay 5
is not failsafe / is failsafe

Reserve Relay 6

Relay 6
is not failsafe / is failsafe

Service Request

Count down, can be set 099999 hr between two


services

Parameter

Direct parameter input sets subjacent layers of the


analyser; please contact AMS GmbH

Cab. Temp

Setting the monitoring of the housing temperature


Select the corresponding parameters via the F-key

Submenu Cabinet
Temperature (*Option)
Return to the service menu via
the F-key

return

The temperature sensor can


be selected via the F-key

LM 35 installed / not installed

Adjusting the Temperature


Deviation

LM 35 Offset (normally = 0)

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Temperature Monitoring on/off

Check CT ON/OFF

Temperature approval for the


sample gas solenoid valve

Cab. Temp. ON/OFF

Setting the lower temperature


limit to avoid condensate

Cab. Temp. LO

Setting the upper temperature


limit to protect mounted parts

Cab. Temp. HI

Expert Mode

This mode is exclusively reserved for AMS GmbH experts

Restart

After you have changed the parameters, AMS GmbH


recommends a restart of the analyser. Please confirm with
the F-key

The following message is displayed (alternating with the


previously set second row)

Wi ##,## MJ / m
Service Request

Note The relay Service Request 12 -16 is active according to the adjusted
operation; please refer to # 7.6 of the manual.
Note An active message does not influence the measurement.
Deleting the active message
The operator can delete the active message in the submenu diagnosis at any time. Please select
the menu diagnosis via the arrow keys; now confirm the message Service Request via the F-key.
The timer is re-set to the chosen time interval and the countdown is re-started.
Remark: The active message serves as an indication for the operator of maintenance work at the
instrument (e.g. filter exchange or absorber replacement).

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6.7.1 Fixed Density (*Option)


Note If the SG varies within a very small range, a fixed value for SG can
used for converting the Wobbe index into the calorific value. The
calculation based on the measured Wobbe index and the fixed SG value.

6.7.2 Service Request


Note The operator may set a timer to adjust the service request. After the
set time has elapsed, the instrument displays a message for service
request. The operator also requests to check the gas sampling and gas
conditioning.
Note If you reset the timer to zero, the message will deactivate.

The following message is displayed (alternating with the


previously set second row)

Wi ##,## MJ / m
Service Request

Note The relay Service Request 12 -16 is active according to the adjusted
operation; please refer to # 7.6 of the manual.
Note An active message does not influence the measurement.

Deleting the active message


The operator can delete the active message in the submenu diagnosis at any time. Please select
the menu diagnosis via the arrow keys; now confirm the message Service Request via the F-key.
The timer is re-set to the chosen time interval and the countdown is re-started.
Remark: The active message serves as an indication for the operator of maintenance work at the
instrument (e.g. filter exchange or absorber replacement).

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6.7.3 Cabinet Temperature (*Option)


The temperature monitoring / indirect heating of the pneumatic unit and therefore the monitoring of
the cabinet temperature prevent the mounted parts from overheating. Further, they avoid
formation of condensate resulting from undershooting the dew point in the gas lines using humid
gases. The lower temperature limits (Cab. Temp. Lo) should choose such as the formation of
condensate normally prevents. The upper temperature limits (Ca. Temp. High) protects the
mounted parts and allows a max. temperature of 50 C. Only if special parts for temperatures
above 50 C have previously ordered (please refer to your order and the test report) a higher
cabinet temperature allowed.

Attentions do not expose the analyser to direct sunlight at any time.


The installation site should protect from wind and weather
conditions.

6.7.4 Expert Mode


Note This sub item protected by a code, which is only available for AMS
GmbH experts.

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7. Serial Interface
Terminal assignment at terminal-row -X4:
In order to locate terminal-row -X4 please refer to the drawing in the appendix.
Terminal

Name

9
10
11

RS232

Description
RXD
TXD
GnD

Only potential-free units may connect to the serial interface, these are e.g. battery-driven laptops
or galvanically isolated PCs.

Configuration of the RS 232-interface:


8 data-bits
1 start-bit
1 stop-bit
parity-none
BAUD-rate: 19200 BPS
no hard nor software handshake
Voltages that are fed into the analyzer externally (e.g. RS232) must been
idle with appropriate equipment during maintenance and in cases of
switching off the analyzer.

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8. Error Messages
Note The instrument features an extensive self-monitoring. In case of an
error message the second line will display the cause of the shutdown.
Note In case of an error, message the instrument switches to the standby mode. The main valve has shut. The combustion air down regulated
and the catalyst(s) is/are shut off.

The following error messages might cause a shutdown of the system

System is OFF
AB < 250C ERROR

System turns off since the temperature of the catalytic


burner for low calorific gases is too low.

System is OFF
CAT < 250C ERROR

System turns off since the temperature of the measuring


catalyst is too low.

System is OFF
APP Over Range

System is at the measuring range limit, i.e. the


measurement is substoichiometric.

System is OFF
CAB TEMP ERROR

System is turned off due to temperature error of


pneumatic unit

Note The instrument can restart any time. Before a restart the operator,
however, has to troubleshoot the error cause or to contact AMS GmbH.
System restart

Calibration
Service
* Restart

Enter the main menu via the F-key. Now choose the
message Restart via the arrow keys. Confirm via the Fkey. The system has restart.

Note If the cause of the shutdown still exists, the instrument again
switches off the system right after the start-up sequence.
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I. Gas Alarm (*Option)


Optionally, the analyser can be equipped with a gas detector checking the analyser cabinet for
leaks resulting out of the system or monitoring the system for vapours of explosive gas mixtures
intruding from the environment.
If the measuring system is equipped with such a gas, detector this option encompasses the
analysis via a central gas warning GasFlagnotifying the user visually and acoustically that
explosive gases exist.
The measuring range of the gas detector is set according to the expected gas components;
therefore, the message is specific for the measure task. Furthermore, the central gas warning
shuts down the analyser and its by-consumers if the concentration of explosive gases is too high.
Only the visual/acoustic alarm remains activated. At the same time service personnel requested
since errors indicated via the Fail Safe circuit of the analyser.
ATTENTION: Quitting the alarms at the central gas warning only allowed if you have
previously checked with an external gas detector that there is no danger for any persons or
the instruments. Otherwise, persons and instruments may harm.
Structure of the gas alarm unit:
Gas detector:
Crowcon XGard Type 5
Measuring range: 0 100 % LEL Hydrogen
Central gas warning: Crowcon Type: GasFlag
Al1: 20 % LEL Hydrogen
Al2: 40 % LEL Hydrogen
REMARK: Please refer to the corresponding instruction in order to operate and service the
gas detector and its central gas warning; this instruction attached to the instruction
manual.
Actions triggered by transgressing the alarm limits:
Transgressing Al1:

- flashing light and horn are on

Transgressing Al2:

- flashing light and horn are on


- RHADOX 7300 turns off,
I.e. gas supply stops
- By consumer shut off

ATTENTION: After the measuring system has stopped by a gas alarm, you have to search
for the cause before restarting the analyser. Make sure that you eliminate the cause of the
error. The user has to undertake adequate measures for which he himself exclusively is
responsible!
Furthermore, you have to check the gas protector and its alarm features in a quarterly
interval. Please do not apply any cal gas corresponding with the alarm limits. Please refer
to the attached instruction for the calibration of the central gas warning and of the gas
detector.
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Instruction Manual
RHADOX AMS 7300
ATEX Ex II 3G IIB+H2 T3

Page 42

In order to check the gas protector with its central gas warning, a key switch has installed in the
inner electronic housing; a key switch bridges Al2 of the central gas warning, which means that
the gas alarms function can monitored although the Al2 limit has been crossed yet the analyser
not turns off.
However, before using the key switch you have to make sure that the atmosphere is nonexplosive during the deactivation of the alarm limit and during the monitoring.
For checking, switch the key switch to Pos. I. You are not able to take out the key in this position.
Now you can check the functions of the gas protector, of the central gas warning, of the horn and
of the flashing light (as described above with the help of the corresponding instruction manual
which has enclosed to the users manual).
After checking the functionality, set the key switch back to Pos. 0 and remove the key from
the lock! This is for your own safety and impedes unintended altering of any values!
Test gases necessary:
Alarm limit 1:
Alarm limit 2:

0,8 Vol% Hydrogen in air


i.e. 20% UEG of Hydrogen
1,6 Vol% Hydrogen in air
i.e. 40% UEG of Hydrogen

II. Measuring Cabinet Cooler (*Option)


The measuring cabinets temperature has to remain constant. In order to achieve this, the
measuring cabinet is equipped with a Vortex cooler that opens a valve (in housing 15) as soon as
the temperature is T > 15-20 C; through this valve streams air through the cooler; this keeps the
inner area at a set temperature.
As air use oil and dust-free compressor air. Please connect the air line at the right side of the
measuring cabinet.
Inlet pressure
Volume flow
Temperature switch

:
:
:

5,5 bar-g
max 100 m/hr at max. cooler power
> 15 C

The temperature switch has also installed into the housing (15). If you wish to reset the switching
point, please see below:

III. Service Socket (*Option)


For later services, a service socket has installed in the inner electronic housing.
Technical data:
Max. load:

110 or 230 VAC / 50/60Hz


60 VA

During the normal operating of the analyser, the socket must not used! It means only for a
temporary use.

Version: V1.35_R0

10/2014

Instruction Manual
RHADOX AMS 7300
ATEX Ex II 3G IIB+H2 T3

Page 43

IV. External Catalytic Combustion of By-pass Gases (*Option)


The option catalytic combustion comprises an additional catalytic reactor and an external control
unit working independently from the temperature controller of the RHADOX. The catalytic reactor
built into a separate housing.
Please read chapter 3 of the instruction manual and the enclosed separate manual for a safe
application of the catalytic combustion in the Ex protection zone 2.

FUNCTION DESCRIPTION:
If the excess bypass gas (sample gas mixed with air) cannot lead off into a safe and back
pressure-free tube, it has to be burntdue to environmental reasons. Please make sure that the
by-pass gas not burns via a naked flame due to safety reasons.
The catalytic reactor for the catalytic combustion has structured for a minimum flow resistance and
for a complete combustion of the by-pass gas. The off-gas consists only of carbon dioxide and
water at the outlet of the catalytic combustion. Therefore, the exhaust gas tube has to be sloping.
The separate temperature controller stabilises the temperature of the catalytic combustion at 400
C. The electronic unit monitors exceeding or falling below this temperature. If the temperature
constantly exceeds or falls below the alarm values, the RHADOX will turn off. No sample gas will
reach the analyser. Only instrument air still be applied and will be lead off via the catalyst
protecting the catalyst at the same time.

ELECTRIC CONNECTION
Please refer to the technical drawings in the appendix for the electric connection of the catalytic
combustion.
Please make sure that:
1. the cross section of the heat line measures min. 2.5mm
2. the temperature sensor is connected with thermal wire (suitable for thermo couple type
NiCrNi) to the heat controller.

START-UP OF THE RHADOX


As soon as the catalytic combustion has reached its operation temperature, the LED of the
heating control on the front panel flashes. Now the RHADOX can start by pressing the green start
button (or any other start button previously installed by the operator). For the connection of an
external start button, please refer to the technical drawings in the appendix of the instruction
manual.

Version: V1.35_R0

10/2014

Instruction Manual
RHADOX AMS 7300
ATEX Ex II 3G IIB+H2 T3

Page 44

V. Inside Catalytic Combustion of By-pass Gases (*Option)


The option catalytic combustion of low calorific gases comprises an additional catalytic reactor
built into the same housing as the pneumatic unit.
The catalyst has activated via the RHADOX electronic, too.
The system has fully configured and connected. No further working steps are necessary.
Failures will display and can solve after consultation with AMS GmbH.
The option catalytic combustion of low calorific gases features an additional gas outlet tube
mounted to the instrument. The amount of condensate depends on the energy content of the bypass gas.
While disposing the off-gas please make sure that the lines do not freeze and that the
accumulated condensate is being disposed of according to the Ordinance of Hazardous
Substances.
The current temperature of the catalytic combustion can display in the second line. Please choose
AB (afterburner) in the second row to display the current temperature.
The following message now displays:
Wi ##.## MJ/m
AB ### C

Current measuring value Wobbe index


Temperature of the catalytic combustion

Note The analyser monitors the catalytic combustion. Malfunctions have


displayed.

Note After a restart, the instrument checks the temperature of the


measuring catalyst as well as the temperature of the catalytic combustion
considering the current temperature. Therefore, after a short shut-off the
current temperature is immediately measured to determine the preheat
sequence.
Note The temperature of the catalytic combustion has to reach a certain
temperature range. Only then, the solenoid valve will open and the
sample gas will reach the analyser.

Version: V1.35_R0

10/2014