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ABB ACX, Commissioning Instruction

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42 

ACX Analyzer System Commissioning Instruction 

CI/ACX-EN Rev. D 

Program Sequence 

  

PFE2 

Digital output: 

-D08 
DO2 

-D08 
DO3 

-D08 
DO1 

-D08 
DO4 

-D08 
DO5 

-E05 
MV1 

Display 

Status 
signal 

Valve: 

-Y1.1 

-Y2.1 

-Y3.1 

-Y4 

-Y5

 6)

 

-Y01 

Message 
“Purge 
back 
active“ 

Maint. 
Mode 

Step  Duration  Function 

Impulse 
Compr. 
Air 

Filter 
Back-
purging 

Tube 
Back-
purging  Venting 

Sample 
Gas 
Valve 

Position 
Calibr. 
Valve

 5)

 

0 

4 hrs

 1)

 

Measure 

closed 

closed 

closed 

open 

open 

Measure  off 

off 

1 

10 sec

 8)

 

Back-purging 
probe filter 

Impulse  open 

closed 

closed 

closed 

Calibrate  on 

on 

2 

14 sec

 9)

 

Back-purging 
probe tube 

Impulse  closed 

open 

closed 

closed 

Calibrate  on 

on 

3 

6 sec 

Venting 

closed 

open 

closed 

open 

closed 

Calibrate  on 

on 

4 

150 sec

 2)

  Post-purging  closed 

closed 

closed 

open 

open 

Measure  on 

on 

0 

4 hrs

 1)

 

Measure 

closed 

closed 

closed 

open 

open 

Measure  off 

off 

  

PFE3, Probe 2, 
Probe F, Probe 
Tube 40W 

Digital output:  

-A01 
DO1 

-A01 
DO2 

-A01 
DO3 

 

-E05 
MV1 

Display 

Status 
signal 

Valve: 

 

-Y12

 7)

 

-Y11 

-Y07 

 

-Y01 

Message 
“Purge 
back 
active“ 

Maint. 
Mode 

Step  Duration  Function 

 

Filter 
Back-
purging 

Tube 
Back-
purging  Venting   

Position 
Calibr. 
Valve

 5)

 

0 

4 hrs

 1)

 

Measure 

 

closed 

closed 

closed 

 

Measure  off 

off 

1 

2 sec 

Switch over 

 

closed 

closed 

closed 

 

Calibrate  on 

on 

2 

4 sec

 3)

 

Back-purging 
probe filter 

 

open 

closed 

closed 

 

Calibrate  on 

on 

3 

8 sec

 4)

 

Back-purging 
probe tube 

 

closed 

open 

closed 

 

Calibrate  on 

on 

4 

6 sec 

Venting 

 

closed 

closed 

open 

 

Calibrate  on 

on 

5 

150 sec

 2)

  Post-purging   

closed 

closed 

closed 

 

Measure  on 

on 

0 

4 hrs

 1)

 

Measure 

 

closed 

closed 

closed 

 

Measure  off 

off 

 
1)  Cycle time factory-set to 4 hours 
2)  Post-purging time factory-set to 150 sec. For an analyzer system with Probe F,  

this period must be as short as possible (to be determined during start-up) 

3)  1x pressure impulse 2 sec, 1x interrupt 2 sec 
4)  1x pressure impulse 2 sec, 1x interrupt 2 sec, 1x pressure impulse 4 sec 
5)  Calibration valve on = “Measure”, calibration valve off = “Calibrate” 
6)  Only in version with VOC analyzer AO2000-Fidas24: 

open = sample gas path open, closed = relaxation against atmosphere 

7)  not in a system with Probe 2, Probe F 
8)  3x interrupt 2 sec, 2x pressure impulse 2 sec 
9)  3x interrupt 2 sec, 2x pressure impulse 2 sec, 1x pressure impulse 4 sec 
 

Continued on next page 

Summary of Contents for ACX

Page 1: ...ing from probe heated lines sample conditioning to reliable and time tested analyzers of the Advance Optima series It can be operated from the outside The system is available in various variants tailored to your measuring tasks emission monitoring cement applications and process gas measurements It is especially designed for easy service and maintenance Additional Information Additional documentat...

Page 2: ......

Page 3: ...is operator s manual is protected by copyright The translation duplication and distribution in any form even in a revised edition or in extracts in particular as a reprint by photomechanical or electronic reproduction or in the form of storage in data processing systems or data networks are prohibited without the consent of the copyright holder and will be prosecuted under civil and criminal law ...

Page 4: ...on Point 17 Test Gas Connection at the Gas Sampling Probe or upstream of the Sample Gas Cooler Test Gas Inlet Conditions 17 AO2000 Magnos27 Test Gas Inlet Conditions 18 AO2000 Fidas24 Supply Gas and Test Gas Inlet Conditions 18 Back Purging Unit Installation Site and Air Supply Requirements 19 Power Supply Requirements 20 Weight Sound Level 22 Items Delivered 23 Materials Needed for Installation n...

Page 5: ...Up 53 Transportation Restraints Release 54 Reagent Fill 55 Analyzer System Start Up 56 AO2000 Fidas24 VOC Analyzer Start Up 57 Warm Up Phase 61 Analyzer System Seal Integrity Check 62 AO2000 Air Pressure Correction 64 AO2000 Air Pressure Value Correction 65 Dynamic QR Code 66 Analyzer System Operation 68 Display Control Unit 68 Measured Values Screen 69 Control Panel Screen 70 Menu Tree 72 Setting...

Page 6: ...ls and Technical Documentation CD ROM Spare Parts Catalog for Analyzer Technology Information on the Internet Information on ABB Analytical products and services is available on the Internet at http www abb com analytical Service Contact If the information in this manual does not cover a particular situation ABB Service is prepared to supply additional information as needed Please contact your loc...

Page 7: ...apable of such work should work on the system Special Information and Precautions These include The content of this manual The safety labels affixed to the analyzer system The applicable safety precautions for installing and operating electrical devices Safety precautions for working with gases acids condensates etc Safety Labels Affixed to the Analyzer System Observe the safety labels affixed to ...

Page 8: ... Working 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 f...

Page 9: ...l integrity check must be performed with a leak detector thermal conductivity when the device is reassembled The bulkhead connector with integrated flow limiter for connection of the combustion gas line is a safety relevant part It must not be removed modified or replaced It is recommended to check regularly the seal integrity of the combustion gas line outside the analyzer system WARNING Combusti...

Page 10: ... often acidic Neutralize condensates and follow the prescribed measures for disposal Safety Tips for Handling Harmful Gases CAUTION Some of the gases measured with the analyzer system 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 Th...

Page 11: ...n ABB Automation Products GmbH and its affiliates are not liable for damages and or losses related to such security breaches any unauthorized access interference intrusion leakage and or theft of data or information Digital communication The ABB guidelines prevent communication through unsecured communication protocols provided that the operator does not explicitly allow this These communication p...

Page 12: ...s warning center to shut down the power supply in the event of a fault is not installed in the analyzer system in the factory delivered condition The gas warning center must be installed outside the analyzer cabinet in a non hazardous area in a distribution cabinet or similar It must be electrically connected to the gas sensor see the order specific set of drawings in this regard The solenoid valv...

Page 13: ...commissioning parameterization operation signal evaluation and maintenance of the supplied gas warning center are the responsibility of the operator WARNING If the above mentioned instructions are not observed or the hydrogen monitoring of the analyzer cabinet is installed incorrectly a hydrogen explosion may occur in the event of a malfunction Operation of this safety device should be checked dur...

Page 14: ...ke sure the enclosed accessories are not lost see the Items Delivered section page 23 Keep the packaging material for future shipping needs Installation Overview Step Action Page 1 Prepare the gas sampling probe installation site 15 2 Prepare the analyzer cabinet installation site 16 3 Install the gas sampling probe and filter unit 25 4 Install the sample gas line 35 5 Install the back purging uni...

Page 15: ...nd removed see Figure 1 The sampling probe tube must be easily accessible to allow maintenance work to be performed Align the boreholes of the mounting flange in relation to the flow direction of the process gas see Figure 1 Observe the separate instructions for installation of probe tube type 40W on page 27 Figure 1 Wall Tube Installation Dimensions in mm Brickwork Brickwork with metal sheeting α...

Page 16: ...rotect the analyzer cabinet against Water spray Contact with chemicals Strong sunlight and heat radiation Strong air currents Heavy dust load Corrosive atmospheres Vibration Installation Indoors or Outdoors The sheet steel cabinet and the mounting plate are only suitable for installation indoors An air conditioned room is recommended The GRP cabinet is suitable for installation indoors and outdoor...

Page 17: ...ax 500 C 850 to 1100 hPa 0 85 to 1 1bar max 250 l h Kiln or Calciner Outlet T 900 C max 1300 C 850 to 1100 hPa 0 85 to 1 1bar 1 max 100 l h Calciner max 900 C 850 to 1100 hPa 0 85 to 1 1bar max 125 l h Wet Kiln Gas Outlet max 300 C 850 to 1100 hPa 0 85 to 1 1bar max 250 l h 2 Preheater CO Monitoring of ESP max 450 C 850 to 1100 hPa 0 85 to 1 1bar max 250 l h 3 Coal Bunker Coal Mill max 500 C 850 t...

Page 18: ...ent in N2 or air 1000 100 hPa 1 0 0 1bar 130 to 250 l h 1 Provide a shutoff valve with a pe 4 5 to 7 bar pressure gauge Instrument air is used as drive air for the air injector if installed combustion air emergency purge air 2 Separate combustion air supply is required if the analyzer system is not equipped with a combustion air conditioning module catalyst 3 Recommendation Provide two 40 l cylind...

Page 19: ...rse Conditions Protect the back purging unit against Water spray Contact with chemicals Strong sunlight and heat radiation Strong air currents Heavy dust load Corrosive atmospheres Vibration Pressurized air supply requirements dry dew point 3 C oil and dust free max 6 bar for back purging approx 4 bar as control air needed for 2 stage back purging with Type PFE2 filter unit and AO2000 Fidas24 VOC ...

Page 20: ...ter unit type PFE2 or PFE3 heated 250 W Probe 2 partially heated 255 W Probe F partially heated 400 W Back purging unit 150 W Sample gas line type TBL01 S TBL01 C heated regulated180 C 90 W m self regulating100 C 35 W m self regulating 30 C 15 W m Uninterruptible Power Supply Prepared for Uninterruptible Power Supply UPS 400 W 230 V AC or120 V AC 10 48 62 Hz L N PE Non floating PEN conductor is fo...

Page 21: ...nit test gas connection valves 10 A or 16 A or 6 A F03 Heated sample gas line 16 A F04 NO2 NO converter 6 A F05 AO2000 Fidas24 air catalyst 6 A F06 Sample gas cooler sample gas feed unit 6 A F07 AO2000 central unit power supply 6 A F11 Temperature controller T 2 A F12 Temperature controller T 2 A F13 Temperature controller T 2 A F14 Emergency purging AO2000 Fidas24 T 0 5 A F17 Test gas valve 1 T 0...

Page 22: ...000 mm 2 kg 1500 mm 3 kg Probe tube type 40W partially heated 3500 mm 13 kg 4000 mm 15 kg 4500 mm 17 kg Probe tube type 42 heated 1000 mm 8 kg 1500 mm 10 kg 2000 mm 12 kg Probe 2 with protective case 1200 mm 17 kg Probe F 1200 mm 10 kg Filter unit type PFE2 heated with protective case 20 kg Filter unit type PFE3 heated with protective case 17 kg Back purging unit 70 kg Sample gas line type TBL01 S...

Page 23: ...E3 with ring heater or heating sleeve 1 Sample gas line type TBL01 S or TBL01 C heated 1 Back purging unit 1 stage or 2 stage with compressed air hoses 1 Hydrogen switch over station with cylinder pressure reducers on mounting plate for AO2000 Fidas24 1 Reagent supply bottle 1 Condensate collection bottle 1 Wear parts set Hydrogen monitoring of the analyzer cabinet option Quantit y Description 1 U...

Page 24: ...g 5 x 6 mm2 5 x AWG 8 If applicable uninterruptible power supply wiring 3 x 2 5 mm2 3 x AWG 14 Cables to connect the heated gas sampling probe filter and sample gas line to the analyzer cabinet if applicable in a heat resistant version note the power requirements of these components page 20 Grounding cable with cross section 10 mm2 AWG 8 Signal Leads Shielded cable for analog outputs current outpu...

Page 25: ...00 1000 1500 mm Dimensions in mm G3 4 L1 16 12 6 ø 17 2 ø Special Steel Material No 1 4571 max 500 C Type 40 Probe Tube and Filter Unit Installation Step Action 1 Screw the probe tube into the internal thread of the filter unit 2 Insert the pre assembled probe tube with filter unit in the wall tube and screw the flange of the filter unit to the flange of the wall tube Use the green seal from the a...

Page 26: ...obe Tube Dimensions in mm 160 40 1000 1500 2000 mm Type 42 Probe Tube and Filter Unit Installation Step Action 1 Insert the probe tube in the wall tube and screw the probe tube flange to the wall tube flange Use the green seal from the accessories pack to seal the space between the flanges 2 Screw the filter unit to the flange of the probe tube Use the green seal from the accessories pack to seal ...

Page 27: ... 0 m or 4 5 m it can be necessary to make a hole in the roof above the smoke chamber in order to install the probe tube as well as the protection pipe Installation of the protection pipe is preferably carried out during a shut down of the kiln The opening should be closed with a blind flange until the installation of the probe tube takes place Type 40W Probe Tube and Filter Unit Installation Step ...

Page 28: ...28 ACX Analyzer System Commissioning Instruction CI ACX EN Rev D Type 40W Probe Tube and Filter Unit Installation continued Figure 3 Type 40W Probe Tube Installation in the Smoke Chamber ...

Page 29: ...tion 29 PFE2 Filter Unit Installation Figure 4 PFE2 Filter Unit Mounting of Probe Protective Case α X Minimum distance xmin of the mounting flange wall tube flange from the wall depending on mounting angle α α 10 15 20 25 30 35 xmin mm 229 248 268 287 307 324 ...

Page 30: ...Air Y1 2 5 Instrument Air Inlet Bulk Head Union 12 mm 6 Test Gas Inlet Bulk Head Union 6 mm 7 Control Air Inlet Bulk Head Union 6 mm 8 Pt100 Connection 9 Heated Sample Gas Line E13 10 Power Supply 11 Heated Check Valve Y5 12 Solenoid Valve Aeration Y4 13 Diaphragm Valve Cleaning Filter Surface and Probe Tube Y3 2 14 Pilot Operation Valve Cleaning Filter Surface and Probe Tube Y3 1 15 Protection Bo...

Page 31: ...nit Installation Figure 6 PFE3 Filter Unit Mounting of Probe Protective Case Dimensions in mm 25 min 680 min 150 2 7 0 330 Minimum distance xmin of the mounting flange wall tube flange from the wall depending on mounting angle α α 10 15 20 25 30 35 xmin mm 229 248 268 287 307 324 ...

Page 32: ...be Compressed Air CU 15x1mm 3 Terminal Box X1 IP66 4 2 x M12x1 5 Cable Connectors 5 3 x M20x1 5 Cable Connectors 6 2 x M20x1 5 Cable Connectors 7 Tube Compressed Air CU 15x1mm A Test Gas Connection with Check Valve Bulkhead Fitting 6 mm B Back purging of Filter max 6 bar Bulkhead Fitting18 mm C Back purging of Filter Surface Probe Tube max 6 bar Bulkhead Fitting18 mm D Sample gas connection male f...

Page 33: ...ts spring washers and washers Harting connector degree of protection IP55 Protective box option degree of protection IP54 CAUTION Danger of breakage The ceramic inlet filter of probe 2 is fragile Assembly of the Ceramic Inlet Filter First of all assemble the ceramic inlet filter as shown in Figure 8 Please note that the compression spring 4 has to be compressed by approx 15 mm Figure 8 Probe 2 Cer...

Page 34: ...0 35 xmin mm 133 138 143 147 151 153 Probe 2 Installation Step Action 1 Align the probe so that the protection shield is directed towards the process gas flow 2 Insert the probe in the wall tube and screw it to the wall tube flange with the enclosed screws M12 x 70 3 Connect the sample gas line to one of the two gas ports 5 by means of a clamp ring screw fitting 4 If 1 stage probe back purging is ...

Page 35: ...ine see page 51 Otherwise the measurement values would drift for a prolonged period of time Fundamentals for Laying the Sample Gas Line Do not lay the heated sample gas line in a thermowell When laying the sample gas line avoid the formation of water locks particularly at the sampling points Do not lay the heated sample gas line in a cable tray together with other electrical or pneumatic lines esp...

Page 36: ...s or other thermally insulating materials from soiling the heated sample gas line Otherwise overheating will occur at these points If soiling occurs clean the materials and remedy the cause Heat can be conducted away again as a result Avoid heat accumulation through wrapping the heated sample gas line with other materials otherwise the sample gas line will overheat at these points Do not cover the...

Page 37: ...ate cooling of the sample gas line Avoid bundling or laying several heated sample gas lines so that they touch each other This results in overheating at the contact points Lay several heated sample gas lines separately with a distance of at least 2 5 cm and provide adequate ventilation Heat can be conducted away as a result Do not squeeze the heat insulation in mounting brackets tightly together s...

Page 38: ...NO unheated PTFE max 20 m recommended with SO2 NO heated Type TBL01 C self regulating 100 C 0 C Wet Kiln Gas Outlet 0 C w o SO2 NO unheated PTFE max 10 m recommended with SO2 NO heated Type TBL01 C self regulating 120 C 0 C Preheater CO Monitoring of ESP 0 C w o SO2 NO unheated PTFE max 10 m must not be exceeded with SO2 NO heated Type TBL01 C self regulating 120 C 0 C Coal Bunker Coal Mill 0 C un...

Page 39: ... the Com pressed air Hoses to PFE2 Filter Unit Connect the compressed air hoses for purge air and control air to the respective ports at the PFE2 filter unit see Figure 5 page 30 Connecting the Com pressed air Hoses to PFE3 Filter Unit Connect the compressed air hoses for purge air filter and filter probe tube to the respective ports at the PFE3 filter unit see Figure 7 page 32 Connecting the Com ...

Page 40: ...equired gas flow will increase to such a high value that several unfavorable effects will emerge and can finally be accepted no longer Filter Cleaning If the suction exceeds a limit of about 300 mbar accordingly the absolute pressure falls below 700 mbar the sampling system filter has to be cleaned The PFE2 and PFE3 filter units can be cleaned automatically by a back purging procedure with compres...

Page 41: ...led by Event A flow fault during normal measuring operation will start the automatic back purging procedure After back purging was started by event the procedure will run only once If the procedure is finished waiting time 30 sec and the starting event flow fault is still active the back purging procedure will not start again even not controlled by time and a status message Probe or line is plugge...

Page 42: ...ep Duration Function Filter Back purging Tube Back purging Venting Position Calibr Valve 5 0 4 hrs 1 Measure closed closed closed Measure off off 1 2 sec Switch over closed closed closed Calibrate on on 2 4 sec 3 Back purging probe filter open closed closed Calibrate on on 3 8 sec 4 Back purging probe tube closed open closed Calibrate on on 4 6 sec Venting closed closed open Calibrate on on 5 150 ...

Page 43: ...for 6 sec and finally the calibration valve Y01 1 is switched back from position Calibrate to position Measure This venting time removes an internal remaining pressure which might be still present in the pneumatic system and so avoids a damage of the analyzer s measuring cell Post Purging Period The calibration valve switch back to position Measure will not finish the back purging procedure becaus...

Page 44: ...ost purge time factory set to150 sec no measurement can be made The optimum time will have to be found out by operational experience Cycle Time Minimum Value The cycle time should not be below a lower limit The back purging procedure with cold compressed air causes a cooling of the heated probe filter and the filter temperature regulation needs some time to correct this temperature decrease As the...

Page 45: ...actory set Guide for the Post Purge Time A guide for the needed post purge time is given in the table below Please add the times for the pneumatic system the analyzer and the sample gas line Response time 3 x T90 approx for sample gas flow 60 l h 100 l h 200 l h Bypass Pneumatic system without sample gas line 45 sec 27 sec 20 sec plus analyzer Uras26 23 sec 20 sec 23 sec plus for each10 m sample g...

Page 46: ...IG TIMER CYCL is shown with the parameters of this function block 6 Select the parameter Low time The window PASSWORD ENTRY is shown if the password is not already active 7 Enter the password using the numeric keys The factory set password is 325465 The window CONFIG TIMER CYCL with indication of the parameter Cycle time is shown 8 Change the shown value factory set 4 hrs to the new value required...

Page 47: ... lugs can be bent or the analyzer cabinet can be warped It is strongly recommended that the analyzer cabinet is transported by a specialist firm transported in a horizontal position as far as possible and not set upright until immediately before the installation Unpacking the Analyzer Cabinet Lift out the analyzer cabinet from the shipping box Do not remove the plastic sheet in which the analyzer ...

Page 48: ...ansport crates Open the transport crates and lift out the system components Do not remove the plastic foil in which the system components are shrink wrapped Unpacking cold system components could cause condensation Do not remove the plastic foil until the system components have reached room temperature This takes at least 24 hours Installing the System Components Installation site requirements see...

Page 49: ...valve with a pe 4 5 to 7 bar pressure gauge in the instrument air supply system Installing the Combustion Gas Supply Clean the combustion gas line Pump cleaning agent alkaline cleaner solvent stainless steel pickling fluid through the tube Purge tube thoroughly with distilled water Purge tube for several hours at a temperature above100 C with synthetic air or nitrogen 10 to 20 l h Close off tube e...

Page 50: ...lines result in short lag times Connect the test gas lines to the bulkhead connectors provided for this purpose on the right wall of the cabinet Installing the Exhaust Gas Line Connect the exhaust gas line to the bulkhead connector provided for this purpose on the right wall of the cabinet using the shortest possible line with an I D 8 mm Allow the exhaust air to pass freely and do not install red...

Page 51: ...he heated sample gas line directly to the sample gas inlet of the AO2000 Fidas24 VOC analyzer see Figure 10 Make sure that the O rings are properly seated and the sample gas line is fully inserted in the sample gas port Fittings and O Rings The required fittings and O rings are supplied in the accessory kit Figure 10 Sample Gas Line Connection on AO2000 Fidas24 Heated Sample Gas Port 4 3 2 1 1 Hea...

Page 52: ...ads to the terminal strips Cable shielding should be connected according to local regulations Differences in potential and signal interference must be taken into consideration Connecting the Input Wiring Power supply requirements see page 20 Before connecting the power supply make sure the analyzer system operating voltage is set to match the line voltage The protective lead connector and protecti...

Page 53: ...Combustion Gas Line Purge the combustion gas line before analyzer system start up This should ensure that the combustion gas line is free of impurities especially containing hydrocarbons that could lead to erroneous measurement values Purge the combustion gas line for approx 20 seconds with a nitrogen flow of approx 100 l h Transportation Restraints Release see Transportation Restraints Release se...

Page 54: ...on air conditioning is mounted underneath the sample gas cooler use an offset screwdriver to release the transportation restraints If no offset screwdriver is at hand the Zero Air Generator must be dismounted according to the following instructions 1 Loosen the nuts of the hose fittings on the left and right side of the Zero Air Generator and pull the hoses out of the fittings 2 Loosen the mountin...

Page 55: ... measurement task involved reagents can be used to eliminate interfering gas components or to stabilize the desired sample components Reagent Fill Fill the reagent supply bottle optional with the reagent needed for the measurement task Mixture Ratio Reagents concentrate are used in the following mixture ratios Phosphoric Acid H3PO4 Hydrogen Peroxide H2O2 Concentration 85 30 Mixture ratio in10 lite...

Page 56: ...00 central unit power supply Function Check The following events will occur after the power supply is turned on Phase Description 1 The three Power Maint and Error LEDs light up 2 The different booting phases are displayed on the screen Also the software version is displayed 3 After a brief time the screen switches to measurement mode 4 The STATUS MESSAGE softkey appears on the screen This indicat...

Page 57: ...s by means of the variables Input Instrument air at combustion chamber inlet Output Instrument air at combustion chamber outlet Air Combustion air H2 Combustion gas H2 Random values may be displayed at first for the variables The values are updated for the first time approx 30 seconds after selection of the menu item and thereafter approx every 30 seconds Pressure control continues to run in the b...

Page 58: ...the pilot pressures must be changed 6 Instrument air Use the external pressure regulator to set the Output variable to approx 60 max 70 Variable too large reduce pressure Variable too small raise pressure The Input variable depends on the sample gas flow rate 7 Combustion air Use the external pressure regulator to set the Air variable to approx 50 max 60 Variable too large raise pressure Variable ...

Page 59: ...on coil switched off Combustion air pressure raised steadily Flame on Analyzer module goes into stand by mode No Yes Yes No Adjust supply gas pressures to set points Warm up phase continues Menu Maintenance Test Analyzer spec adjustm Restart FID Flame ignition may take up to10 minutes depending on the number of ignition attempts The flame temperature is displayed in the Flame parameter under the A...

Page 60: ...t Temperature limit value 1 2 The temperature of the detector T Re D and possibly of the heated sample gas port T Re E is above or below the upper or lower limit value1 2 Pressure limit value 1 2 The pressure at one of the internal pressure regulators for instrument air Input Output combustion air Air or combustion gas H2 is above or below the upper or lower limit value1 2 Reading The reading and ...

Page 61: ...side the ranges specified in the data sheet End of the Warm Up Phase The warm up phase is over when the temperature and flow status messages are gone and the measured value drift is acceptable The latter depends on the size of the measurement range Readiness Sample Gas Supply At the end of the warm up phase the analyzer system is ready for operation and automatically activates the sample gas suppl...

Page 62: ...r when no VOC analyzer is installed in the analyzer system Step Action 1 Interrupt the sample gas supply 2 Close the sample gas outlet 3 Disconnect the sample gas line from the sample gas inlet and connect a tee fitted with a shut off valve 4 Connect a U tube manometer half filled with water to the free end of the tee 5 Blow air or nitrogen through the shutoff valve to a gauge pressure of pe 100 h...

Page 63: ... leak detection spray It is recommended to check regularly the seal integrity of the combustion gas line outside the analyzer system The combustion gas path inside the VOC analyzer is checked for leaks at the factory No seal integrity testing is required during normal operation Seal Integrity Check of Back Purging Unit Step Action 1 Close the water precipitator outlet part of the pressure regulato...

Page 64: ...Magnos27 Fidas24 cannot be installed Use the MENU Diagnostic Information System overview menu item and select the appropriate analyzer module to determine if a pressure sensor is installed Air Pressure Values Operating Altitude Mean Air Pressure meters above mean sea level hPa mbar psi mm Hg Torr in Hg 200 1037 15 04 778 30 63 100 1025 14 87 769 30 28 0 1013 14 69 760 29 92 100 1001 14 52 751 29 5...

Page 65: ...is calibrated to1013 hPa This is the reference pressure for the test gas concentration when measuring the calibration cells If the air pressure value needs to be changed the following items are also required Calibrate the sample components with test gases and then Measure the calibration cells Air Pressure Value Correction The current atmospheric pressure can be entered as a correction value for e...

Page 66: ...s an innovative way of customer s communication which allows for instance improved case specific support by ABB resulting in an increased availability of analyzer assets Dynamic QR Code is compatible with the ABB application my Installed Base as well as with standard QR code scanner applications Handling The QR code is selected in the gas analyzer s diagnosis menu and displayed on the gas analyzer...

Page 67: ...h Back The diagnosis menu can be selected directly from the status messages overview The QR code can also be selected in Remote HMI and scanned from the computer screen Recommended QR code scanner applications ABB recommends the use of the following QR code scanner applications available free of charge for iOS and Android my Installed Base by ABB Download in App Store Download in Google Play QR Sc...

Page 68: ...ator to cancel a function or menu item and to return to the previous menu level Meas 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 STATUS MESSAGE...

Page 69: ... Figure 13 Measured Values Screen Indication Values measured by the analyzer system are displayed on 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 configured in the analyzer system ...

Page 70: ...d off Maintenance Mode activated on Operation The controls are operated in the following manner Press the number key that corresponds to the position of the control and is indicated above the control In the following screen press the corresponding function key Thereby the system switches back to the control panel screen and the function just activated is indicated by means of a filled rectangle Pa...

Page 71: ...ging manually PURGE OFF Disable back purging MPS Control Measuring Point Switchover AUTOM Automatic measuring point switchover MP 1 Select measuring point 1 manually MP 2 Select measuring point 2 manually Gas Control SAMPLE Sample gas supply normal operation PROBE Test gas supply at the probe CABINET Test gas supply at the analysis cabinet Test Gas Control TESTGAS 1 Select test gas 1 TESTGAS 2 Sel...

Page 72: ...alyzer specific i e they only appear when particular analyzer modules are integrated into the analyzer system Password Levels For each menu item its password level 0 1 2 3 is shown in the table For some menu items individual sub menu items are on a higher password level These applies especially to those sub menu items which allow access to function block applications Note The Change password menu ...

Page 73: ..._ Sample system 3 _ Calibration Correction 3 __ System _ Date Time 2 _ Language 2 _ Change password _ Setup system modules 2 _ Save configuration 1 _ Status signals 2 _ Network 2 _ Display 2 _ Maintenance Test __System _ Atm pressure 2 _ Display test 0 _ Keyboard test 0 __Analyzer spec adjustm _ Pump 1 _ Atm press anlz 2 _ Calibration reset 1 _ Basic calibration 2 _ Measure cal cell 1 _ Optical ad...

Page 74: ...t be entered in month day year format Enter year with 4 digits Time Time must be entered in hour minute second format Enter seconds too Daylight Savings Time The analyzer system is automatically set to daylight savings time Note This applies only when the time zone has been selected from the continent country city list and not from the GMT values list Factory Setting The analyzer system is factory...

Page 75: ...lecting User Interface Language Menu Path MENU Configure System Language Language Selection The user interface languages English and German are factory configured per order in the analyzer system In the menu item Language the user can switch between these two languages ...

Page 76: ...enance team 0 1 471100 Specialist team 0 1 2 081500 Function block specialist 0 1 2 3 325465 Procedure Select the Change password menu item select the user group enter the old password enter the new password 6 digits re enter the new password leave the menu item with Back Password level 0 is not displayed in the Change password menu item CAUTION After entering the password for password level 3 you...

Page 77: ...s Password Every user group set up in the system has a password The password consists of six digits which can be entered via the numeric keypad Passwords are pre assigned for the factory set user groups Factory Setting User group Access to password levels Password Every user 0 None Maintenance team 0 1 471100 Specialist team 0 1 2 081500 Function block specialist 0 1 2 3 325465 CAUTION After enter...

Page 78: ...ized to change any menu items accessible at the user s level Duration of the Change Privilege The change privilege remains in effect until The analyzer automatically switches to measurement mode if the user has not pressed a key for more than about 5 minutes time out Or the user presses the Meas key twice in succession The change privilege remains in effect if the user presses the Meas key only on...

Page 79: ... system i e entering the main menu and thus switching to the menu mode can be password protected After inhibition the analyzer system can only be operated when the level 1 password has been entered The level 3 password must be entered to configure the password protection Procedure Press the MENU ACCESS softkey in the Change password menu item and set the password protection ...

Page 80: ... communication is blocked on all Ethernet interfaces X8 X9 by default When communication is blocked a corresponding message is issued on the Remote HMI Image 1 Message on the Remote HMI example Release communication via the proprietary protocol Implement the following steps to release communication via the proprietary protocol 1 Select the Configure Network TCP IP Network menu 2 Select the Unsecur...

Page 81: ...ured protocol menu item and set the parameter to Permit 4 Confirm the information field by selecting BACK Communication via the proprietary protocol has now been released The proprietary protocol via port 8001 tcp is an unsecured protocol in the meaning of IT security or cybersecurity ...

Page 82: ...Implement the following steps to release communication via Modbus TCP IP 1 With the Modbus card installed select the Configure Network Modbus menu or The Configure Network Modbus menu is not available if the Modbus card is not installed In this case the Release menu is called up directly via Modbus TCP 2 Select the Modbus TCP Access menu item and confirm by selecting ENTER 3 Select the Modbus TCP ...

Page 83: ...eld by selecting BACK Communication via the Modbus TCP IP protocol has now been released The Modbus protocol is an unsecured protocol in the meaning of IT security or cybersecurity as such the intended application should be assessed before implementation to make sure that the protocol is suited ...

Page 84: ...en working with corrosive reagents note the hazard information and safety precautions contained in the applicable material safety data sheets Condensates are often acidic Neutralize condensates and follow the prescribed measures for disposal Harmful Gases CAUTION Some of the gases measured with the analyzer system are harmful to health Therefore the sample gas must not escape from the gas path dur...

Page 85: ...ent supply bottle and dispose of reagents according to applicable regulations Emptying the Conden sate Collecting Bottle Empty the condensate collecting bottle and dispose of condensates according to applicable regulations Make sure the analyzer system is free of residual moisture that can freeze if low temperatures are encountered during shipping and storage Transportation Restraints Activation S...

Page 86: ...ectrical distribu tion cabinet in foil 2 Put desiccating agent in the transport crate The amount of desiccating agent should be sufficient for the package volume and the expected shipping duration at least 3 months 3 Place the analyzer cabinet mounting plate electrical distribution cabinet on vibration dampers in the transport crate and fix with wedges 4 Mark the transport crate according to the r...

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Page 88: ...he contents of this document without prior notice With regard to purchase orders the agreed particulars shall prevail ABB does not accept any responsibility whatsoever for potential errors or possible lack of information in this document We reserve all rights in this document and in the subject matter and illustrations contained therein Any reproduction disclosure to third parties or utilization o...

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