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ABB ACF-NT, Operator'S Manual

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42/23-572 EN Rev. 5 

Operator’s Manual ACF-NT, ACF-NT V0309 

3 

Contents 

  

Page 

  
Foreword 

4 

Important Safety Information 

5 

Safety Tips for Handling Electronic Measurement Devices 

6 

Safety Tips for Handling the FTIR Spectrometer 

7 

Safety Tips for Handling the VOC Analyzer 

8 

Safety Tips for Handling Harmful Gases 

8 

Special Information about the System Design for Measurement of HF 

9 

Chapter 1 

Startup 

Restart 

10 

Chapter 2 

Operation 

Display/Control Unit 

11 

“Measured Values” Screen 

12 

“Control Panel” Screen 

13 

“Diagnosis” Screen 

15 

“Ranges” Screen 

16 

“ASP Module” Screen 

17 

“Multi-FID” Screen 

18 

“Flow” Screen 

19 

Changing the Password 

20 

Chapter 3 

Maintenance 

Safety Notes 

21 

Cleaning Hints 

21 

Visual Inspection 

22 

Seal Integrity Check 

23 

Wear Part Replacement 

24 

Replacing the Filter Element in the Probe 

25 

Cleaning/Replacing the Sample Gas Filter in the SC Block 

28 

Replacing the Air Purifier Inlet Filter 

30 

Replacing the Air Conditioner Filter Mesh 

30 

Calibration 

31 

FTIR Spectrometer Zero Calibration 

33 

FTIR Spectrometer Span Check 

35 

Oxygen Analyzer Calibration 

36 

VOC Analyzer Calibration 

37 

Status Messages 

38 

Taking the Analyzer System Out of Service 

39 

Appendix  

Operating Specifications 

40 

Index 

41 

Summary of Contents for ACF-NT

Page 1: ...ACF NT ACF NT V0309 Multicomponent Analyzer Systems for Emission and Process Monitoring Operator s Manual 42 23 572 EN Rev 5 ...

Page 2: ......

Page 3: ...n 13 Diagnosis Screen 15 Ranges Screen 16 ASP Module Screen 17 Multi FID Screen 18 Flow Screen 19 Changing the Password 20 Chapter 3 Maintenance Safety Notes 21 Cleaning Hints 21 Visual Inspection 22 Seal Integrity Check 23 Wear Part Replacement 24 Replacing the Filter Element in the Probe 25 Cleaning Replacing the Sample Gas Filter in the SC Block 28 Replacing the Air Purifier Inlet Filter 30 Rep...

Page 4: ...red from your authorized ABB representative or from ABB Automation GmbH Analytical Marketing Communication Telefax 49 0 69 7930 4566 E mail analytical mkt deapr de abb com Additional Information on the Internet Additional information on ABB Analytical products and services is available on the Internet at http www abb com analytical indicates safety information to be heeded during analyzer system o...

Page 5: ...bserve the safety labels affixed to the analyzer system Safety Labels Affixed to the Analyzer System Consult Documentation Hot Surface Temperature 60 C Risk of Electric Shock National Regulations The regulations standards and guidelines cited in this operator s manual are applicable in the Federal Republic of Germany The applicable national regulations should be followed when the analyzer system i...

Page 6: ... with an Open Analyzer System The analyzer system must be disconnected from all power sources before being opened for any work All work on an analyzer system that is open and connected to power should only be performed by trained personnel who are familiar with the risks involved Charged Capacitors The capacitors in the analyzer system can retain their charge even when it is disconnected from all ...

Page 7: ...ditions the FTIR spectrometer can be operated in complete safety Class 1 Laser Product see rating plate Do not open the spectrometer enclosure during normal operation no user serviceable parts inside However since the instrument contains a laser and uses high voltages accessible only when the spectrometer enclosure is open observe the following warnings WARNING The enclosure of the spectrometer is...

Page 8: ...ck must be performed with a leak detector thermal conductivity when the device is reassembled CAUTION The combustion gas path inside the VOC analyzer is checked for leaks at the factory No seal integrity testing is required during normal operation Safety Tips for Handling Harmful Gases WARNING Some of the gases measured with the analyzer system are harmful to health Therefore the sample gas must n...

Page 9: ...er Vapour Cross Sensitivity Checking the water vapour cross sensitivity must be ensured see also section Calibration page 31 during initial start up by the manufacturer s or the supplier s qualified personnel in the annual functional tests by an accredited measurement institute as per EN 17025 Use of FFKM Probe Seals The filter on the gas sampling probe has FFKM seals When they are replaced see se...

Page 10: ...ir is sufficiently dry Activating the Power Supply Make sure all circuit breakers fuses are deactivated Turn on the main switch Activate the circuit breakers fuses starting with those for the FTIR spectrometer Connecting the Filtered Air Check the filtered spectrometer purge air flow rate and set it to approx 200 l hr if necessary Checking the Temperature Check the temperature of the heated compon...

Page 11: ... cancel a function or menu item and to return to the previous menu level Allows the operator to cancel a function or menu item and to return to the measured value display in measurement mode Only entries confirmed with ENTER are stored unconfirmed items are not accepted Softkeys Allows the operator to scroll to the next display page This key only allows forward scrolling Appears in measurement mod...

Page 12: ...creen Values measured by the analyzer system i e the FTIR spectrometer the O2 ana lyzer and the VOC analyzer FID are displayed on pages 1 to 3 of the Measured Values screen Up to six measured values are displayed on one page The actual number of pages depends on the number of measurement components config ured in the analyzer system ...

Page 13: ...e controls are operated in the following manner Press the number key that corresponds to the position of the control and is indi cated above the control In the following screen press the corresponding function key Thereby the system switches back to the control panel screen and the func tion just activated is indicated by means of a filled rectangle Password Protection All control panel functions ...

Page 14: ...g e g for restarts SHUT DOWN Manual activation of purge air for the gas sampling probe AVERAGE TRIGGER FTIR Control Acquisition of average values e g for LOD or standard deviation SAMPLE GAS Sample gas supply normal operation ZERO LOCAL ZERO PROBE Zero gas activation Supply directly to the sample cell or via the probe TEST LOCAL Flow Control TEST PROBE Test gas activation Supply directly to the sa...

Page 15: ...how the relation of the current spectral inten sity to the initial one for 4 spectral regions of a reference spectrum Increasing values correspond to a loss in spectral intensity The lower two indications show the H2O and CO2 background values The indicated values are updated with each recording of the reference spectrum every 12 hours For further explanations see section FTIR Spectrometer Zero Ca...

Page 16: ... Screen Figure 5 Ranges Screen Indication The Ranges screen displays the number of the activated measurement range 1 or 2 for measurement components with two measurement ranges Note MRF Measuring Range Feedback Measuring Range 1 High range Measuring Range 2 Low range ...

Page 17: ...e values of the ASP module temperature and pressure regulators Parameter Default T Co D Temperature controller sample conditioning block 180 C T Co E Temperature controller sample cell 180 C Input Sample cell pressure 850 hPa Output Injector pump pressure 800 hPa Note The Multi FID 14 T Co D value actually belongs to the Multi FID screen see page 18 ...

Page 18: ...ure and pressure regulators Parameter Default T Co D Detector temperature on ASP Module screen 180 C T Co E Sample gas port temperature 180 C Flame Flame temperature 260 300 C A Pres Combustion air pressure 725 hPa H2 Combustion gas pressure 1100 hPa Input Instrument air pressure at combustion chamber inlet 700 hPa Output Instrument air pressure at combustion chamber outlet 600 hPa ...

Page 19: ...en Figure 8 Flow Screen Indication The Flow screen displays the various sample gas flow values Parameter Default Multi FID 14 Sample gas flow through the VOC analyzer 60 l h FLOW Ges Total sample gas flow 260 l h ASP Module Sample gas flow through the ASP module 200 l h ...

Page 20: ... password 2 Use the arrow keys to select the user group for which the password is to be changed for example Maintenance ENTER 3 Use the numeric keypad to enter the old 6 digit password for example 471100 ENTER 4 Use the numeric keypad to enter the new 6 digit password for example 471200 ENTER Changing the Password 5 Re enter the new password for example 471200 ENTER ...

Page 21: ...m are harmful to health Therefore the sample gas must not escape from the gas path during normal operation and maintenance works A seal integrity check of the analyzer system has to be performed at regular intervals The diluted exhaust gas must be drained out of the installation room of the analyzer cabinet Cleaning Hints Cleaning Hints Never use water or any solvents to clean parts inside the ana...

Page 22: ...2 in N2 Combustion gas VOC analyzer H2 Zero gas VOC analyzer N2 or zero gas for O2 analyzer Span gas VOC analyzer Propane in N2 1 2 0 1 bar 1 2 0 1 bar 1 2 0 2 bar 1 2 0 2 bar A Air conditioning unit Filter mesh White B Air purifier Moisture indicator Green Display Measured values temperatures pressures flows Page 12 to 19 C Temperature controllers of heated probe tube heated filter and heated sam...

Page 23: ...e FID will increase immediately and will decrease relative fast to normal measurement values Do not let stream the gas from the lighter too long to the connections especially when testing the SC block This would result in a cloud of hydrocarbons and because of the short distances it would be difficult to decide which connection has the leak The seal integrity check of the SC block should be perfor...

Page 24: ...rts Air conditioning unit filter mesh 0999765 every 3 months see Page 30 Use of FFKM Probe Seals in the System Version for Measure ment of HF The filter on the gas sampling probe has FFKM seals When they are replaced see section Replacing the Filter Element in the Probe page 25 FFKM seals must also be used For quick replacement it is recom mended that a complete preassembled filter element be kept...

Page 25: ...tone is obviously damaged replace it with a new one To avoid a prolonged down time of the analyzer system the complete filter insert Part No 0730683 should be changed The disassembling cleaning and assembling of the used filter stone and O rings should be done separately Figure 10 Filter Element 1 T handle 2 Bridge 3 Detaching disk 4 Locking screw 5 Removal screws 6 Flange 7 O ring seals 8 Filter ...

Page 26: ...t of the casing 10 2 Turn bridge 2 until it can be pulled off from the bridge holding device 9 through the elongated holes 3 Pull out filter element 8 with bridge 2 and detaching disk 3 4 Turn detaching disk 3 until it can be pulled off from the hexagon screws 5 via the elongated holes Replacing the Filter Element Never loosen or tighten the hexagon screws 5 They have been adjusted at the factory ...

Page 27: ...Re install the filter element 8 Steps 1 to 4 in reverse order or 5 Screw off locking screw 4 with open end spanner NW 22 6 Screw out the hexagon socket screw 12 underneath locking screw 4 7 Take out the filter stone 8 Insert a new filter stone Part No 0730682 with new O rings from the accessory set Replace seals 7 O rings from the accessory set Re lubrication is not necessary even after replacing ...

Page 28: ...To avoid a prolonged down time of the analyzer system the complete gas filter ACF NT Part No 0768914 should be changed The disassembling cleaning and assembling of the used filter should be done separately CAUTION The sample conditioning block is hot approx 180 C Step Action 1 Turn off the sample gas supply Loosen the three mounting screws 1 4 mm hex key and remove the sample gas filter cover 2 fr...

Page 29: ...emoved to avoid drift of the VOC analyzer Replace the O ring 3 in the sample gas filter cover 2 Replace the O ring on the back of the bottom plate 4 not visible in the photo and the two PTFE profile gaskets 5 5 Always use new O rings and gaskets with a cleaned sample gas filter Contaminated or damaged O rings and gaskets will reduce sample gas path seal integrity and lead to erroneous measurement ...

Page 30: ...ter by slowly unscrewing the filter housing collar 3 Unscrew the filter housing collar and lower the filter bowl Remove the filter element retainer disc at the base of the cartridge Replacing the Air Purifier Inlet Filter 4 Replace the exhausted cartridge Part No 0999755 set of 3 and re assemble the filter Replacing the Air Conditioner Filter Mesh When is filter mesh replacement needed The cooling...

Page 31: ...rator 4 H2O in air from evaporator Test Gases for FTIR Spectrometer Span Check 5 HF H2O air from evaporator Supplied directly to sample conditioning block or sample gas line Before each test gas change purge the test gas paths with the zero gas for at least 10 minutes In case of NH3 span check use this test gas as the last to avoid reactions with other gases Setting and checking the water cross se...

Page 32: ...at test gas port Test Gases for O2 Analyzer Calibration Span Gas Clean air from the air purifier Permanently connected to system VOC Analyzer Calibration The VOC analyzer is automatically adjusted at the officially established mainte nance interval every 14 days The VOC analyzer zero and span calibration is described in detail in the VOC Analyzer Calibration section see page 37 Zero Gas N2 or oxyg...

Page 33: ...ponse When should a zero spectrum be measured Since over time the instrument response can change a new zero spectrum must be recorded at regular intervals This procedure is called zero calibration or zero ing the analyzer Naturally the analyzer must be zeroed or referenced before it can be used Since over extended periods of time the infrared source can change and this includes the mirror in conta...

Page 34: ...pletely digital Zero calibration thus has nothing to do with the signal drift seen in analog circuits it is just a matter of correcting the instrument response Self Test During each zero calibration the analyzer automatically performs a self test This test compares current instrument response with the initial instrument response data The test also establishes the quality of the zero gas since it m...

Page 35: ...hus a device capable of producing a specific steam concentration in a continuous flow must be used Since the calibration mix dew point is above room temperature the calibration gas must be supplied directly to the air injector in order to avoid noticeable cooling of the H2O air mix Step Action 1 Set the Maintenance Mode via the Control Panel screen and switch the Flow control to either Test gas lo...

Page 36: ...ntrol signals for zero and span alignment and for the switching of the solenoids The FTIR controller also controls the purging times which are needed to ensure that the proper gas is at the analyzer sensor Calibration Method Common Calculation Method Offset Zero Calibration Data Test Gas Concentration 1 to 4 Vol O2 in N2 Calibration Method Common Calculation Method Amplification Span Calibration D...

Page 37: ...e span calibration n Propane in nitrogen from a test gas cylinder is used Maintenance Interval According to the officially established maintenance interval zero and span calibra tion have to be performed every 14 days Calibration Control The VOC analyzer calibration is performed as externally controlled automatic calibration The FTIR controller triggers the start of the automatic calibration Enabl...

Page 38: ... probe pipe sample gas line 10001 Message back purge X 10002 FTIR Failure X Contact service 10003 FTIR Maint Req X Contact service 10004 FTIR Maintenance X 10005 Temp MGL X Temp error sample gas line 10005 Temp Pipe X Temp error pipe 10005 Temp Probe X Temp error sample probe 10007 Flow spectrom X Flow to FTIR is too low 10008 Service X Key Service is activated 10009 Enablir failure X Contact serv...

Page 39: ...w Control to Zero gas probe see page 14 VOC analyzer option Shut off the combustion gas supply 2 Purge the analyzer system with air from the air purifier for at least 15 minutes Temporarily Taking the Analyzer System Out of Service 3 Leave the FTIR spectrometer FTIR controller and air purifier power supplies on Turn off the power supply to all other components ...

Page 40: ...t H2O 0 40 Vol 0 01 Vol CO2 0 30 Vol 0 01 Vol VOC Analyzer 2 Smallest Meas Range Detection Limit VOC 0 15 mg m3 0 3 mg m3 O2 Analyzer Measuring Range Detection Limit Sample Components and Measuring Ranges O2 0 25 Vol 0 2 Vol Measuring ranges within ignition limits cannot be provided 1 The values are based on a data acquisition time of 120 seconds a standard deviation of 3 and a cell path length of...

Page 41: ... zero calibration 33 HF measurement 9 24 31 Inspection 22 Instrument air supply Activating 10 Maintenance control 14 Operating specifications 40 Oxygen analyzer calibration 36 Page Password Changing 20 Power supply Activating 10 Raw spectrum 33 Reference spectrum 33 Restart 10 Safety precautions 5 6 7 8 21 Sample gas filter in the SC block cleaning replacing 28 Screens ASP Module 17 Control Panel ...

Page 42: ...uct improvement and the right is reserved to modify the information contained herein without notice Printed in the Fed Rep of Germany 03 10 ABB 2010 42 23 572 EN Rev 5 ABB Automation GmbH Analytical Stierstaedter Strasse 5 60488 Frankfurt am Main Germany Phone 49 69 7930 40 Fax 49 69 7930 4566 E Mail analytical mkt deapr de abb com ...

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