1、BE-150Installation and Maintenance ManualPreface Be sure to read this manual completely before installing the BE-150 in a gas analysis system. Make certain that this manual can be accessed whenever necessary. Warranty and Responsibility The product delivered to you is covered by HORIBAs warranty for
2、 a period of one (1) year. If any malfunction or damage attributable to HORIBAs responsibility should occur during this period, necessary repairs or replacement of parts shall be made free of charge by HORIBA. The warranty does not cover the following: z Any malfunction attributable to improper oper
3、ation z Any malfunction attributable to repair or modification by any party not authorized by HORIBA z Any malfunction attributable to the use in an improper environment z Any malfunction attributable to natural disasters, or accidents or mishaps not involving HORIBA z Any malfunction attributable t
4、o violation of the instructions in this manual z Any malfunction attributable to operations in the manner not specified in this manual z Any deterioration in appearance attributable to corrosion, rust, and so on. z Consumables and replacement of consumables z Products of other companies For the repa
5、ir or replacement under warranty, necessary information about the instrument should be provided for HORIBA. HORIBA shall not be liable for any damages resulting from any malfunctions of this product, any erasure of data, or any other uses of this product. Organization This document explains installa
6、tion procedure for BE-150. Target This document is intended for manufacturers of gas analysis systems in which the BE-150 shall be installed. Trademarks Generally, other company names and bland names are either registered trademarks or trademarks of the respective companies. Contents 1 OUTLINE 1 1.1
7、 Overview .1 1.2 Configuration.2 1.3 Block Diagram.3 2 INSTALLATION AND CONNECTION 4 2.1 Environmental Conditions .4 2.2 Utilities.5 2.2.1 Power supply 5 2.2.2 Calibration gases 5 2.3 Mounting in System.5 2.4 Connections 6 2.4.1 Gas piping.6 2.4.2 Power line .6 2.4.3 RS-232C line.7 2.4.4 Other signa
8、l lines 7 3 BASIC OPERATION 8 3.1 Power On 8 3.2 Status Output.8 3.3 Concentration Output 8 3.4 Zero Calibration.9 3.5 Span Calibration10 3.6 PEF Output 11 3.7 Analog Input and Engine Revolution Signal 11 3.8 Parallel I/O. 11 4 MAINTENANCE . 12 4.1 Error and Alarms for Analyzer Status 12 4.1.1 Error
9、 status .12 4.1.2 Alarms.13 4.2 Problems of Usage or Hardware.14 4.2.1 Troubleshooting 14 4.2.2 Cleaning of the gas cell.15 4.2.3 Replacements parts list for overhaul.17 5 REFERENCE . 18 5.1 Measurement Principle of the BE-150.18 5.2 Specification 19 5.2.1 System outline 19 5.2.2 Configurations/cond
10、itions20 5.2.3 Function and performance20 5.2.4 Options22 5.3 Command and Operation23 5.4 Problem Reporting Sheet25 5.5 Related Drawings26 1 OUTLINE BE-150 11 OUTLINE 1.1 Overview The BE-150 is the palm-top sized NDIR sensor that can measure CO, CO2and HC in automotive exhaust gases. The BE-150 comm
11、unicates with external CPU by RS-232C interface. It has the analog ports to connect with NO and O2sensors, and readings of the external sensors can be output with those of the BE-150. Fig 1 BE-150 1 OUTLINE HORIBA 2 1.2 Configuration Fig 2 Outline of the BE-150 Table 1 Name and function of the parts
12、 No. Names Descriptions Remarks 1 CPU board BE-CPU-01 2 Light source board BE-LSC-02 3 Detector board BE-PRE-02 4 NO connecting board (optional) For connecting an electrochemical cell NO sensor BE-NOX-01 5 Gas Inlet 6 mm O.D. 6 Sample cell 7 Gas outlet 6 mm O.D. 8 Fuse 1A (T) 9 Pressure sensor For b
13、arometric pressure 10 Switch 1: OFF (for the electrochemical cell NO sensor connection: ON) 2 to 7: OFF, 8: ON 11 LED For CPU status check 12 +12 V connector For power supply (CN107) 12 V DC 13 RS-232C connector For host communication (CN105) 14 PIO connector For parallel I/O (CN104) In: 4 channels
14、Out: 4 channels 15 REV connector For engine revolution signal (CN103) Pulse signal 16 O2connector For O2sensor connection (CN102) 17 AIO connector For analog input (CN101) 4 channels, 0 V to 5 V 18 NO connector For BE-220FS sensor or BE-NOx-01 board connection (CN1) 19 SENS connector (optional) For
15、the electrochemical cell NO sensor connection on BE-NOX-01 121314 15 16 1718198 910 111 2 345 6 71 OUTLINE BE-150 31.3 Block Diagram REFCOCO2HCGainLPFFourelementspyro-sensorDetector BoardO2 SensorDriverCircuitAmp. & LPF16bit8chADCAnalog input(4 ch)Parallel Input(4ch)NO SensorAmbient Press.Gas Temp.M
16、PXEngine Rev.Light sourceLight Source BoardCPUParallelOutput(4ch)CPU BoardFig 3 Block Diagram 2 INSTALLATION AND CONNECTION HORIBA 4 2 INSTALLATION AND CONNECTION This chapter describes the environmental requirements and connections of the power/signal lines and gas piping. 2.1 Environmental Conditi
17、ons The BE-150 shall be installed in a gas analysis system. The environmental requirements for the BE-150 are listed below. Temperature: Environmental temperature shall be stable and within the range of 0C to 50C. A filtered air stream of 1 m/s to 3 m/s shall cool the light source of the BE-150. Hum
18、idity: Relative humidity shall be stable and less than 90%. Ambient pressure (Altitude): Ambient pressure shall be stable and within 75 kPa to 106 kPa (corresponding to the altitude of -300 m to 2500 m above sea level). Location: Install the BE-150 inside the system housing. Do not expose it to corr
19、osive gases, oily mists, organic solvents and/or water. Vibration: Do not expose the BE-150 to strong vibration and/or mechanical shock. Electromagnetic field: Do not expose the BE-150 to a strong electromagnetic field. Power: Assure that stable power from 9.6 V to 14.4 V DC (fluctuation: within 0.6
20、 V in this range) is supplied from the analyzer system. Particulate and drain: Particulate and drain in sample gas for the BE-150 shall be removed by adequate filters and drain separators. Sample gas pressure: The outlet of the BE-150 shall be opened in the atmospheric pressure. The sample flow rate
21、 shall be 1 L/min to 3 L/min under this condition (fluctuation: within 0.2 L/min in this range). 2 INSTALLATION AND CONNECTION BE-150 52.2 Utilities 2.2.1 Power supply The power supply specification for the BE-150 is as follows. Table 2 Power supply Connector Voltage Capacity +12V connector (CPU boa
22、rd) 12 V DC (2.4 V) Voltage fluctuation: within 0.6 V Approx. 6 W 2.2.2 Calibration gases The calibration gases required by the BE-150 and connected sensors are as follows. Table 3 Calibration gases Gas Specification Remarks Zero Gas N2(purity more than 99.99%) or purified air (O215.0%vol to 25.0%vo
23、l/ N2) Span Gas CO 1.2% vol to 15.0% vol/ N2, CO23.0% vol to 20.0% vol/ N2, C3H81200 ppm vol to 20000 ppm vol/ N2NO 300 ppm vol to 5000 ppm vol/ N2(for NO sensor)Mixed gases of CO+CO2+C3H8/ N2or CO+CO2+C3H8+NO/ N2are available. Note When an O2sensor is also connected to the system, purified air shou
24、ld be adopted as zero calibration gas. In this case, the purified air will be used as a span gas for the O2sensor, and the mixed span gas without O2will be used to calibrate zero point of it. Note Hexane (C6H14) 600 ppm to 10000 ppm/ N2is also available as HC span gas. 2.3 Mounting in System The BE-
25、150 should be mounted on spring or rubber shock absorbers using 4 holes on the CPU boards. Screws/bolts in M3 size are available. Refer to page 2, “1.2 Configuration” for dimensional outlines of the BE-150. Note The light source of the BE-150 should be cooled by a filtered air stream at flow rate of
26、 1 m/s to 3 m/s. Note To prevent the water accumulation in the cell, it is recommended to mount the BE-150 so that the gas inlet and outlet face downward. 2 INSTALLATION AND CONNECTION HORIBA 6 2.4 Connections 2.4.1 Gas piping The specification of the piping for gas inlet/outlet is as follows. Table
27、 4 Gas piping Ports Tubes Remarks Gas Inlet 5 mm I.D. flexible tube, made from less HC adhesive materials such as Nylon or Urethane (Flow rate: 1 L/min to 3 L/min (fluctuation: 0.2 L/min) Flow rate should be regulated at the same level for both calibration gas and sample gas Gas Outlet 5 mm I.D. fle
28、xible tube The outlet should be opened to the atmospheric pressure PFZero GasBE-1502 L/minSample GasDSSpan Gas(AtmosphericPressure)Fig 4 An example of gas flow for the BE-150 2.4.2 Power line The power line should be connected to a power supply that satisfies the specification in Table 2 (page 5). T
29、he pin No. of the power line connector (CN107) is listed below. Table 5 Power line Connector Pin Line Description Remarks 1 +12 V +12 V DC +12V (Power) 2 COM Ground Connector type: VHR-2N (JST Mfg., Co., Ltd.) 2 INSTALLATION AND CONNECTION BE-150 72.4.3 RS-232C line The RS-232C line should be connec
30、ted to a host PC. The pin No. of the connector (CN105) is listed below. Refer to page 2, “1.2 Configuration” for the location of the connectors. Table 6 RS-232C line Connector Pin Line Description Remarks 1 SD Send Data 2 RD Read Data RS232C 1 (Host PC) 3 COM Ground Connector: Molex 5051-03 2.4.4 Ot
31、her signal lines Connect other signal lines if necessary. The pin No. of the connectors are listed below. Refer to page 2, “1.2 Configuration” for the location of the connectors. Table 7 Other signal lines Connector Pin Line Description Remarks 1 AI0 Channel 1 2 AI1 Channel 2 3 AI2 Channel 3 4 AI3 C
32、hannel 4 AIO (Analog input) 5 ACOM Ground 0 V to 5 V DC, Connector: Molex 5051-05 1 O2+ O2output (+) 2 - - O2(O2sensor) 3 ACOM O2output (Ground) Connector: Molex 5051-03 1 REV Engine revolution 2 - - REV (Engine revolution) 3 COM Ground Pulse signal (1 Hz = 120 rpm), 200 rpm to 10000 rpm, Connector:
33、 Molex 5051-03 1 DI0 Channel 1 2 DI1 Channel 2 3 DI2 Channel 3 4 DI3 Channel 4 5 COM Ground 6 DO0 Channel 1 7 DO1 Channel 2 8 DO2 Channel 3 9 DO3 Channel 4 PIO (Parallel I/O) 10 COM Ground Connector: Molex 5051-10 1 NO NO output (+) 2 ACOM NO output (Ground) 3 +12V Power 4 ACOM Ground NO (BE-220FS)
34、5 -5V Power For BE-220FS NO sensor or BE-NOx-01 board 1 VOUT+ Power (+) 2 NO- NO output (-) 3 COM Ground 4 NO+ NO output (+) SENS (NO sensor) 5 - For an electrochemical cell NO sensor Connector: Molex 5051-05 (Optional) Note Input impedance of analog input (AIO) port is 200 k. 3 BASIC OPERATION HORI
35、BA 8 3 BASIC OPERATION All operations of the BE-150 will be performed through RS-232C host communication. Refer to the manual “BE-150 Communication Protocol” for detailed information about commands. 3.1 Power On The BE-150 will be powered on by simply supplying 12 V DC to the power connector. It can
36、 not accept action commands and data transmission requests for 20 seconds after turned on. During this period, the “warm-up” status is returned for the Analyzer Status Request ($01) command. The initial status of the BE-150 after warm-up is the “zero calibration coefficient is out of range” for all
37、components. Perform the zero calibration before starting sample measurements. Procedure: 1. Supply 12 V DC to the power connector. Start to introduce the zero calibration gas into the BE-150 at flow rate of 2.0 L/min 1.0 L/min (at the same flow rate with sample gas). 2. Warm-up the BE-150. 3. Perfor
38、m the zero calibration by sending the Zero Calibration ($20) command. 4. By sending the Analyzer Status Request ($01) command, confirm that the “zero calibration coefficient is out of range” status has been reset. Note The warm-up time of BE-150 for accuracy is 10 minutes (for OIML class 0) or 15 mi
39、nutes (for BAR-97) in stable environmental condition. Note The zero calibration of an O2sensor (if connected) should be done separately, by sending the O2Sensor Zero Calibration ($35) command. 3.2 Status Output The status of the BE-150 can be confirmed by sending the Analyzer Status Request ($01) co
40、mmand. Refer to the manual “BE-150 Communication Protocol” for detailed information. 3.3 Concentration Output The Data Transmission Request ($40) command returns the readings of CO, CO2and HC of the BE-150, as well as O2and NO input data. The concentration data in the BE-150 CPU are updated in every
41、 0.5 seconds. Refer to the manual “BE-150 Communication Protocol” for detail information. 3 BASIC OPERATION BE-150 93.4 Zero Calibration The BE-150 needs the zero calibration periodically. The “zero calibration is required” status is returned for the Analyzer Status Request ($01) command if more tha
42、n 30 minutes past after the latest zero calibration. When this status is output, perform the zero calibration in advance of the sample measurements. Procedure: 1. Start to introduce the zero calibration gas into the BE-150 at flow rate of 2.0 L/min 1.0 L/min (at the same flow rate with sample gas).
43、2. Wait until the residual gas inside the gas cell of the BE-150 is completely replaced by the zero gas. 3. Perform the zero calibration by sending the Zero Calibration ($20) command. 4. By sending the Analyzer Status Request ($01) command, confirm that the BE-150 is not in the “zero calibration coe
44、fficient is out of range” status. Note For approx. 15 minutes after warm-up, the interval from the zero calibration to the next “zero calibration is required” status is shorter than 30 minutes. The interval is 1, 3 or 6 minutes depending on the timing of the latest zero calibration. Note When the en
45、vironmental condition or operating condition of the BE-150 changes drastically, perform the zero calibration for more accurate measurements. Note If the zero calibration fails by some reasons, the “zero calibration coefficient is out of range” status will be returned for the Analyzer Status Request
46、($01) command. In this case, the zero calibration coefficient(s) is/are not updated. Perform the zero calibration again. Note The zero calibration of an O2sensor (if connected) should be done separately, by sending the O2Sensor Zero Calibration ($35) command. 3 BASIC OPERATION HORIBA 10 3.5 Span Cal
47、ibration The span calibration of the BE-150 and connected sensors can be performed by the Span Calibration ($11) command. Both one-point calibration and two-point calibration can be carried out. Calibration method and step in the two-point calibration are specified in the command as well as span gas
48、 concentration. Refer to page 5, “2.2.2 Calibration gases” and the manual “BE-150 Communication Protocol” for detailed information. Procedure (1 point calibration): 1. Start to introduce the span calibration gas into the BE-150 at flow rate of 2.0 L/min 1.0 L/min (at the same flow rate with sample g
49、as). 2. Wait until the residual gas in the gas cell of the BE-150 is completely replaced by the span gas. 3. Perform the span calibration by sending the Span Calibration ($11) command that contains span gas concentration value. 4. By sending the Analyzer Status Request ($01) command, confirm that the BE-150 is not in the “span calibration coefficient is out of range” status. Procedure (2 point calibration): 1. Start to introduce the span calibration gas for low point into the BE-150, at flow rate of 2.0 L/min 1.0 L/min (at the same flow rate
