Honeywell ACM 150 Manual To Installation, Operation, And Maintenance Download Page 16

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ACM 150

Figure 2. ACM 150 inside labels

Summary of Contents for ACM 150

Page 1: ...ACM 150 Air Composition Monitor Guide to Installation Operation and Maintenance ...

Page 2: ......

Page 3: ...ir sampling system 34 ACM 150 operating principle 40 Installation environment 43 Installation drawings 58 Operation 61 Setup menus 81 Shutdown procedure 98 Technical specifications 100 Maintenance 102 Manual tests and evaluations 126 Troubleshooting 135 Appendix A KBr MSDS 137 Appendix B ZnSe MSDS 142 Appendix C Glossary 150 ...

Page 4: ...ranty claims shall not in any event exceed the invoice price of the product claimed defective nor shall Honeywell Analytics be liable for delays in replacement or repair of product Honeywell Analytics makes no warranties or representation with regard to the information outlined in this manual and reserves the right to make changes in the specification s of the product described within at any time ...

Page 5: ...ics Inc 405 Barclay Blvd Lincolnshire IL 60069 USA Tel 1 847 955 8200 Toll free 1 800 538 0363 Fax 1 847 955 8208 detectgas honeywell com Asia Pacific Honeywell Analytics Asia Pacific 701 Kolon Science Valley l 43 Digital Ro 34 Gil Guro Gu Seoul 152 729 Korea Tel 82 0 2 6909 0321 Fax 82 0 2 2025 0388 analytics ap honeywell com Technical Services EMEAI haexpert honeywell com US ha us service honeyw...

Page 6: ...improper installation misuse abuse neglect or accident Components that are expendable in normal use are not covered by this warranty If the Seller determines that failure of its products is not due to defective materials or workmanship or in the event that the failure occurs after expiration of the warranty period Seller s standard charges for labor materials expenses and transportation shall be p...

Page 7: ...ect as of publication date Honeywell Analytics is not responsible for product application including but not limited to compatibility with other equipment The end user and their subcontractors must be responsible to assure that their respective employees receive hazardous communication training which meet or exceed OSHA 29CFR 1910 120 hazardous waste operations and emergence response End users and ...

Page 8: ... are not intended to restrict sections of the manual to specific users The purpose of the levels is to limit decisions and tasks to users that have the responsibility experience and or training to make the decisions and perform the tasks All users All of customer s employees who have a responsibility to install operate program service or use the ACM 150 are defined as All Users Authorized users Th...

Page 9: ...on those observations Danger Electrocution can occur when dealing with electrical circuits Under no circumstances shall an untrained person be permitted to access test touch or remove any electrical circuits plates or shields in the ACM 150 monitor Refer to Lockout Tagout Procedure before servicing the ACM 150 monitor danger L électrocution peut se produire lorsqu ils traitent avec des circuits él...

Page 10: ...s and procedures Refer to section 9 for further details Process compatibility All components are compatible with the materials in the ACM 150 monitor All sample wetted materials are PFA PTFE PVC acrylic stainless steel anodized aluminum or glass The normal operating pressure of the sample wetted components is a vacuum however most of these materials are designed to withstand a maximum pressure of ...

Page 11: ...ut power isolation box is installed on the top of the monitor s enclosure Before any electrical repair work is started turn the knob to the 0 position to isolate main power to the monitor To return power to the monitor turn the knob to the 1 position If it is necessary to enter any electronic areas electrical energy may be stored within the system Allow sufficient time for any power to discharge a...

Page 12: ...be isolated by ensuring that during installlation or setup of the ACM 150 monitor compressed air isolation valves for the supply have been installed Since each site s requirements vary it is up to the end user to provide this isolation Compressed air stored energy can be removed by first shutting off the air supply and then allowing time for the pressure to bleed down Under normal automatic operat...

Page 13: ...system level safety interlocks and administrative controls Potentially hazardous maintenance activities When performing maintenance on the ACM 150 monitor especially for those installations that have had hazardous gas alarm incidents purge all sample lines with air or nitrogen to prevent exposure to hazardous chemicals Also when performing maintenance on the sample cell or any components that may ...

Page 14: ...ly the end user can decide if those emissions should pass through an acid scrubber or alternatively untreated through a general exhaust system It is up to the end user to abide by all local safety procedures ACM 150 labels The exterior and interior labels for the ACM 150 monitor are shown on the following pages These labels are applied by the factory prior to shipment NOTE If any label is absent o...

Page 15: ...ACM 150 15 Figure 1 ACM 150 outside labels ...

Page 16: ...ACM 150 16 Figure 2 ACM 150 inside labels ...

Page 17: ...chemicals and to alert workers should a leak spread into their breathing zone The ACM 150 samples the air in these locations and analyzes it for a large number of gaseous chemicals The samples are transferred to the ACM 150 monitor by 3 8 inch Teflon tubing or polypropylene At or near the sample pick up locations tube inlets an air filter is installed to keep the sample lines free of particles As ...

Page 18: ...ese assemblies 1 Main Power Switch 2 Sample Valve Manifolds 3 Sample Valve Control Panel 4 Touchscreen Computer Assembly 5 FTIR Bench and Gas Cell Assembly 6 Pumps and Pump Cabinet 7 Cycle Valves and Cycle Valve Control Panel 8 Router 9 Relay Output Control Panel 10 Relay Outputs Figure 3 General arrangement ...

Page 19: ... anodized to provide an inert surface Each manifold holds 10 valves These are 3 way solenoid valves operated by 24 VDC One way flows to a bypass header and the other to a sampling header that connects to the cycle valves and the FTIR gas cell The valves mount upside down They are secured by screws and o rings seal them to to the manifold Figure 5 10 Sample valve manifold One to four manifolds are ...

Page 20: ...ch area number is also a momentary test switch which may be pressed and used for test purposes when the ACM 150 monitor is in the Front Panel Mode In other modes the switches are inactive Figure 7 Sample valve contol panel A column of LEDs on the left and right sides indicate the vacuum measured in psia in the bypass flow Bypass Vacuum and in the sample flow Sample Vacuum They are a troubleshootin...

Page 21: ...panel Mode on the touchscreen Comm Active Flashes when the computer and the control panel are communicating Frequent communication is normal Figure 8 Control panel status LEDs Cycle valves When a sample area is selected by the computer the corresponding sample valve diverts the flow path from bypass to sample The boost pump draws the air sample in and pumps it to the gas cell The boost pump connec...

Page 22: ...e the Sample Valve Control Panel Status indicators include Sample Pressure This scale is psia or absolute pressure as measured at the gas cell The pressure is lowest during the Evacuation cycle It peaks during the Analyze and Background cycles atmospheric or 14 7 psia The scale is used to confirm proper operation of the pumps and cycle valves Cycle Status LEDs light to show the stages of the scan ...

Page 23: ...rrespond to valves S1 S6 with S7 and S8 provided for future use When the ACM 150 monitor is in the Frontpanel Mode press the buttons to activate the momentary test switches for test purposes In other modes the switches are inactive Figure 10 Cycle valve control panel Pump assemblies Venturi Pumps The ACM 150 monitor has two air driven eductors venturi pumps One is the Bypass Venturi Pump It draws ...

Page 24: ... to be pneumatically coupled to common bypass and gas cell vacuum lines This allows either one to provide the suction to draw the flow The mechanical pump switches on automatically when the venturi pumps fail to provide adequate vacuum The check valves permit flow in one direction only This prevents the pump in use from drawing on the idle pump Mechanical pumps The pumps are isolated in the bottom...

Page 25: ...turi pumps under these conditions When the air supply is restored or the problems are corrected the user manually switches the ACM 150 monitor from the automatic mode into the manual mode and back to automatic mode using the Diagnostic menu to use the venturi pumps again The Boost Pump speeds up the sampling cycle It is a dual head diaphragm pump with Teflon coated internal parts It is always on I...

Page 26: ...to each gas type The beam exiting the gas cell is focused by mirrors on the Optics Bench to a detector where the signal is collected for analysis Most ACM 150 applications are for TLV TWA level monitoring which require higher sensitivity The level of detection is at the low ppm and sometimes sub ppm levels As the pathlength increases more gas molecules come in contract with the infrared beam For t...

Page 27: ... Touchscreen The computer has an integral touchscreen on the front This serves as the user interface at the ACM 150 monitor A typical display is shown below Remote users have the same display on their computers and use the mouse instead of touch Figure 14 Touchscreen Keyboard For the entry of alphanumeric characters the ACM 150 monitor has a keyboard mounted on a slideout drawer below the computer...

Page 28: ... to 40 They are activated whenever any gas monitored at the specific Area exceeds the Alarm 2 set point The user has the option of reprogramming the function of each relay changing the activation level assigning specific gases and sample areas or groups of gases and sample areas Relays 81 to 86 indicate the following 81 Power fail 82 Watchdog timer 83 Manual mode 84 General malfunction 85 General ...

Page 29: ...ACM 150 29 Figure 15 Relay output board ...

Page 30: ...ntacts rated for maximum 30 VDC 2 A Figure 16 Relay schematic Relay shown in normal position Deenergized with no alarm present This diagram is typical of all 86 relays Relay number 81 Power Fail and relay number 82 Watchdog are inverted power is always on and drops upon a trouble condition Relays number 1 to 80 are programmed by software relays number 81 through 86 are fixed in function See Progra...

Page 31: ...ACM 150 31 Figure 17 Typical relay layout Relay number 1 is shown Typical of all 86 relays See Figure 15 for layout and relay locations ...

Page 32: ...ars or the relay is reset The 80 alarm relays have a momentary test switch which is active in the Front Panel Mode Relays 82 86 can only be tested from the computer in the Manual Mode In other modes the switches are inactive Figure 18 Relay control panel The Control Panel Status LEDs for Power On Manual Mode and Comm Active have the same functions as the other control panels Refer to Control panel...

Page 33: ... on when the Primary Pump failes A fault message is activated ACTIVATING SECONDARY PUMP Twelve unswitched 120 230 VAC receptacles for all of the powered subassemblies Figure 19 Power distribution panel Interconnecting cables On request Honeywell Analytic can provide a wiring diagram showing all of the power cords and other interconnecting cables in the ACM 150 monitor and the connection points for...

Page 34: ...nto the gas cell This replaces sample from the last area scanned with fresh sample from the current area Fill cycle The valve to the Gas Cell Venturi Pump is shut and the gas cell fills with the new air sample until it reaches atmospheric pressure The gas cell is allowed to equilibrate to atmospheric pressure before analysis begins The calibrations for the measured components used to develop the a...

Page 35: ...cted for each analysis the scans are compared to the latest Background If the air samples were exactly the same as the Background gas the result would be a flat baseline along the x axis of the ratioed spectrum But the gases are never exactly the same because the air samples always contain some infrared absorbing gases such as water vapor and carbon dioxide The water vapor in the air will always b...

Page 36: ...r decreased to get good sampling and analysis results in the minimum amount of time Both the timing and the frequency of the Background mode may also be changed in the configuration software CDA panel The panel shown below sets and controls the pressure of clean dry air CDA It splits to two air set regulators one for the Venturi Pump air supply and one for Line Leak Test Solenoid valve S9 is norma...

Page 37: ...el 1 Line Leak to Sample Rail 2 Line Leak Gauge 3 Line Leak Needle Valve 4 CDA In 5 To Venturi Pumps 6 Line Leak and Venturi Regulators Gauges 7 Isolation Valve S9 Solenoid Valve S10 Solenoid Valve Figure 21 Venturi Supply Option ...

Page 38: ...omputer uses these readings for multiple purposes Identify a plugged sample line or an internal flow restriction Determine when the Backup Exhaust Pump is needed Optional Line Leak Test pass or fail In line sample filters HA supplies the initial set of inline filters one for each sample port on the ACM 150 monitor from 10 to 40 The filters are installed near the sample inlet They prevent a build u...

Page 39: ...cut by a contractor working in the facility The automatic Line Leak Test is built into all ACM 150s however it may be turned on or off in the configuration by Honeywell Analytics For every sample line in use the test requires a check valve installed near the sample tube inlets which is shown in the flow schematic that s available on request The check valve passes flow in one direction only It stop...

Page 40: ...a Wavenumber precision The wavelength location of any chemical s absorbance peaks is fundamental and never changes being fixed by the quantum mechanics of the molecule The FTIR analyzer is able to reproduce the exact wavenumber location for each gas Absorbance and gas concentration Absorbance is the extent to which the intensity of a beam of infrared radiation is decreased on passing through a sam...

Page 41: ...th and with cell path length For the weakest IR absorbing chemicals and long cell path lengths the non linearity may be insignificant over the range of 0 1000 ppm For the strongest IR absorbing chemicals readings over 100 ppm may be significantly non linear and less accurate Use of the background spectrum It is critical that calibrations taken on one ACM 150 are valid for computing accurate concen...

Page 42: ...h chemical The matrix uses more calibration data sets from other wavelength regions to improve on this computation The computation accuracy is further improved by the use of advanced data fitting statistical techniques known by the broader term of Chemometrics The technique of PLS partial least squares is employed in the ACM 150 monitor to fit a data set from the unknown air spectra to the trainin...

Page 43: ...en decide which of the chemicals contained in the method may actually be present at the sample area Those chemicals are selected as active The ACM 150 monitor will then monitor each sample areas for the all of the chemicals set active for that sample area Chemicals designated inactive are not reported by the ACM 150 monitor ZPD Value and Location The ZPD Zero Path Difference is a signal that is pr...

Page 44: ...rical area Refer to Technical Specifications on page 97 Utility requirements The ACM 150 monitor requires the following utilities Line power 115V 60Hz 13 Amps or 230V 50Hz 6 Amps setup at factory Normal idle power consumption 8 amps 115 VAC Average power consumption 14 amps 115 VAC Peak power consumption 20 amps 115 VAC Clean Dry Air CDA 90 psig 12 SCFM 3 8 inch OD tube Nitrogen 5 psig 8 liters mi...

Page 45: ...e this mechanical pump backs up the venturi pumps to provide operation in the absence of CDA Available outputs The following output relays are dry contact double pole double throw DPDT rated for 3 amps 30 VDC Programmable Output Relays 80 Default programmable relay settings Relays 1 40 activate for any gas at the Alarm 1 level set point for areas 1 40 Relays 41 80 activate for any gas at the Alarm...

Page 46: ...of crates Report any signs of rough handling or damage during shipment to the transportation carrier Inspect all equipment and or parts after removal from shipping containers NOTE Report any broken damaged or missing parts immediately to Honeywell Analytics or your local Honeywell Analytics representative Figure 22 Floor Mounting Locations ...

Page 47: ...er or connecting line power verify that the external AC supply power is disconnected at the source in accordance with your company s Lockout Tagout procedures DANGER Dangers d électrocution Avant de retirer le couvercle de l interrupteur d alimentation principale ou de brancher l alimentation de la ligne vérifiez que le bloc d alimentation secteur externe est déconnecté à la source conformément au...

Page 48: ...is necessary only when the power terminal strip located inside the Main Power Switch is accessed The appropriate LOTO method depends on the AC wiring option that is used Follow your company procedures or if none are established follow these recommendations for circuit breaker or fused disconnect box turn the power off at the box and then close it and lock it typically using a padlock International...

Page 49: ...sumption less than 8 liters minute intermittent Air supply Compressed air is required to operate the venturi pumps It is also used for the optional Line Leak Test Source clean dry compressed air CDA or instrument grade air External Pressure Regulator Shut off locate near the ACM 150 monitor by installation contractor Quality filtered and oil free with a dew point of 20 F 29 C Pressure 65 70 psig s...

Page 50: ...of gases monitored by the ACM 150 monitor The requirements are Flow Rate 12 scfm 340 lpm Connection 1 1 2 inch male pipe thread per Figure 25 Figure 25 Nitrogen CDA and exhaust connections 1 Exhaust Pipe 2 Nitrogen 3 Air CDA NOTE Vent the monitor s exhaust properly in accordance with site or legislated safety policies governing the gases being monitored workplace safety and environmental requireme...

Page 51: ...n bent CAUTION Tygon polyethylene copper and aluminum absorb or react with many gases Use only the materials listed above Make no substitutions MISE EN GARDE Tygon le polyéthylène le cuivre et l aluminium absorbe ou réagir avec de nombreux gaz Utilisez uniquement les matières énumérées ci dessus Ne faites pas de substitutions Tubing run lengths The ACM 150 monitor should be located near the areas ...

Page 52: ...range of detection The following conditions may harm the ACM 150 monitor and may violate the warranty terms Continuous presence of oxidizing or corrosive gases at one or more sample point at levels exceeding 10 PPM particularly if the air is humid High PPM level leaks that saturate the ACM 150 monitor with oxidizing or corrosive vapors Liquids water solvents or oil present in the sampled air that ...

Page 53: ... Honeywell Analytics supplies one filter for each sample port Install the filters at the sample pick up point when the tubing is run to each port If a port in not currently used leave the cap over the inlet tube fitting If there is no cap install a short run of tubing with the filter at the inlet This keeps particulates out of the bypass orifice which draws all on ports used or not Check valves fo...

Page 54: ...e The relays are numbered on the board which is shown in Figure 28 Standard output relays There are 80 programmable relays They have a default setup providing 40 Alarm 1 level and 40 Alarm 2 level outputs for up to 40 sample areas Each relay is independently programmable The user can change configure set points sample areas and gases in any combination or grouping Six status relays are on the Rela...

Page 55: ...E If you use the fail safe configuration all of the ACM 150 monitor output relays will activate on loss of power which is likely to cause wide spread alarms and gas shut downs Even a reboot of the computer will cause this to occur It is essential that a bypass switch be utilized to maintain power in the wire loop so that the ACM 150 monitor can be shutdown for service or when loading new software ...

Page 56: ...50 monitor The alarm will soon clear and reset the relay restarting the flow of gas and the leak will be detected again ATTENTION Cette séquence peut à plusieurs reprises le cycle et peut entraîner une exposition à des gaz toxiques tandis que le personnel de l EIU sont la réparation de la fuite Si les ACM 150 relais de sortie du moniteur sont utilisées pour arrêter la source de gaz et interrompre ...

Page 57: ...field and offer this service to their customers Networks Direct questions concerning network interfacing to your Honeywell Analytics representative Interfacing to a PLC Combining Relay Outputs and Remote Computer If you are connecting the ACM 150 monitor to a PLC Programmable Logic Controller you can connect the relay outputs and or the network Many users connect only the relay outputs to the PLC ...

Page 58: ...M 150 58 Installation drawings In addition to the drawings in this section drawings may be separately provided to clarify the installation of special or modified assemblies Figure 29 Installation diagram ...

Page 59: ...ACM 150 59 Figure 30 Installation diagram ...

Page 60: ...m 1 Sample point matrix ACM 150 Port Gases Monitored Sample Point Name or Equipment ID Installation Notes 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 ...

Page 61: ...ACM 150 monitor MISE EN GARDE Avez dispositifs RF générant pas usée tels que les radios bidirectionnelles ou les téléphones cellulaires moins de 10 m de l installée ACM 150 moniteur Laser and exterior label Within the FTIR optics bench is a Class 1 laser A laser product label is displayed on the exterior door of the optics cabinet of the ACM 150 monitor Laser and interior labels The front door of ...

Page 62: ... optics bench and service the components inside with AC power applied DANGER Haute tension et le laser source de courant alternatif à l intérieur de l optique FTIR banc peut causer un dommage à la vue ou d électrocution Étiquettes d avertissement ont été appliquées à le banc optique FTIR par le fabricant Lire et se conformer à ces étiquettes Seul le personnel qualifié y compris des ingénieurs de s...

Page 63: ...nd configuration of the ACM 150 monitor Typically the scan rate is 15 seconds per sampled area A longer scanning rate may be used to enhance lower detection sensitivity Background Every two hours the ACM 150 monitor stops normal scanning and acquires a new Background spectrum A message may display on the monitor while this occurs After it the background spectrum is complete normal scanning resumes...

Page 64: ...eans the A and that are e details sho rea scanned ew referenc e Backgroun ates in norm for test serv hey are sele matic Mode nt Scan Res seconds on etermined by nge refer to 64 M 150 monit condition re s change M 150 monito omatic Mod ACM is curre ea has been ow as the Re d Every two ce is establis nd mal scanning vice purpos ected norm e to Manual ults It upda n a standard y the Setup o Setup Men...

Page 65: ...unlikely to have any meaning to the operator the ACM 150 monitor software allows you to enter the name or equipment ID Active Gases The gases actively monitored at that area If a gas is not shown as active it is not being monitored at that area Concentration Concentration of each active gas Usually the ACM 150 monitor confirms zero gas present shown as 0 In most cases the scale is ppm parts per mi...

Page 66: ...play OK Indicates the gas concentration is lower than the warn level set point Warn Indicates the gas concentration is above LDL Alarm 1 Indicates the gas concentration exceeds the Alarm 1 level but is lower than the Alarm 2 level Alarm 2 Indicates the gas concentration exceeds the Alarm 2 level set point Changing the mode of operation Figure 33 Sidebar menus ...

Page 67: ... along with the infrared spectrum The data is available for graphical trending These incidents along with the normal scan data are available for interfacing to a PLC or network computer Ethernet or Lonworks Network or remote computers connected via Internet protocol may be set to print each incident as it occurs Alarm 1 Alarm 2 incident log Press Alarm 1 Alarm 2 to access the incident log Shown be...

Page 68: ...ory is displayed press Backup this list to generate the al_back csv file After the file has been created locally you may export it to a USB memory stick or to your Desktop PC if you are operating remotely Figure 36 Alarm event backup Every time Backup list is pressed the complete history is appended to the end of the existing file Older data is not overwritten and cannot be lost ...

Page 69: ...level relay per area Relays 41 80 activate when the Alarm 2 level is exceeded for any active gas at areas 1 40 with one Alarm 2 level relay per area Example For area 1 relay 1 and relay 41 are preassigned for Alarm 1 and for Alarm 2 level activation This progression continues through to area 40 Programming relays The ACM 150 monitor output relays are all programmable The relays may be configured b...

Page 70: ...CM 150 monitor relays be changed to latch This is a simple configuration change in the ACM 150 monitor software When set to latch the relays must be manually reset to open This is done by selecting Reset in the alarms log DANGER Resetting a latching relay could cause a leak to restart and expose employees to hazardous conditions Make certain that the leak causing the initial alarm event has been c...

Page 71: ...ees go to the sample point to check for the source of the leak You can communicate with the ERT employees and report the readings to them if they start to change The Lock on Mode can help ERT determine when it is safe for workers to re enter an area The Lock on Mode is also used to introduce a test chemical while the ACM 150 monitor is locked onto the area Lock on Mode data is archived Figure 37 L...

Page 72: ...s the point a ates to show s scanning t 0 minute tim s terrupts nor scanning re or the follow ns of monito azardous ga mical compo a monitored ectrum of th ater time e igure 40 is Only areas w e selected 72 the same ra area numbe w the latest the locked a e out autom rmal scannin esumesauto wing uses oring any are ases presen osition of un d componen e air sample e g using sp identical to with gre...

Page 73: ...re 41 The concentration readings and status of each active gas at the sample point are displayed Programmable relays activate if Alarm 1 Alarm 2 set points are exceeded Normal area scanning resumes in the background as soon as the Demand Scan is completed Nevertheless the display remains until another mode is selected on the touchscreen Figure 41 Demand scan results ...

Page 74: ...dent from start to finish Trend Graphs are available in the menu shown in Figure 42 You must enter a date a starting hour and an ending hour Only one date may be selected The minimum time interval is one hour and the maximum is 24 hours Time entries use the 24 hour clock You can not enter minutes Use the number keys to make the entries Then press one of the scanned areas green box for trending Fig...

Page 75: ... the three Scan Types and then the desired Status Results The following rules apply to the Scan Types Normal Scans collected in the normal scan mode Generally only the Alarm 1 and Alarm 2 normal scans are important to the user Validate some of these Alarm 1 Alarm 2 incidents by reviewing the spectra or emailing spectra to Honeywell Analytics for review and comment If you press Load Data the data f...

Page 76: ...tically Operator interface is only needed when an incident is detected by the ACM 150 monitor In all cases such incidents are noted on the Status Bar Figure 31 and they activate one or more of the output relays Nevertheless it is important to remember that the system is installed for the purpose of detecting chemicals which may be dangerous to workers and or harmful to the environment For this rea...

Page 77: ...d spectra and send it to Honeywell Analytics The application chemist will use this information to make adjustments to the analytical methods If necessary new methods will be generated and sent to the user or installed by HA or its agent The user should also collect and the spectra generated during any of the following events Demand Scans Used when a chemical level is suspected or unknown odor chem...

Page 78: ... Form 2 Plan for ACM 150 incidents Port Active Points Sample Point Name or Equip ment ID Actions for Warn Alarm 1 Alarm 2 Incidents 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Form 3 Details of alarms problems or non spec performance ...

Page 79: ...eading of gas1 caused by an innocuous interfering gas2 For example if the following noise areas are chosen for SNR calculation with an SNR setpoint of 100 Sample Background RMS Noise Area 1 968 1008 100 Sample Background RMS Noise Area 2 2480 2530 100 Sample Background RMS Noise Area 3 4380 4430 100 RMS root mean square The ACM 150 monitor software will check the RMS SNR over these regions and if ...

Page 80: ... all liability resulting from customers enabling signal to noise ratio on samples DANGER Activation du rapport signal sur bruit sur des échantillons peut inhiber la détection de gaz Honeywell Analytics ne recommande pas ce paramètre Le client permet le rapport signal sur bruit sur des échantillons à leurs propres risques Honeywell Analytics décline toute responsabilité découlant de clients permett...

Page 81: ...ent status The chart below explains the status indicators and what they mean Only the points having a filled blue circle may be scanned by the ACM 150 monitor However the filled circle does not indicate that the point is currently scanned Points can only be scanned if they are listed in the Order of scan Points with a blank circle have been configured but they are on hold until they are enabled Su...

Page 82: ...Order of Scan Inactive Indicates the point is configured but not active Scan must be enabled before the point can be included in the scan cycle Named Non Configured A name Gas Cab 2 is assigned to the point but it has not been configured Non Named Non Configured Indicates a name has not been assigned to the point and it has not been configured ...

Page 83: ...ethods are displayed If the ACM 150 monitor monitors only a short list of gases you may have only one method If you have a large number of gases you will have multiple methods installed NOTE A method is a group of gases A Honeywell Analytics application chemist reviews the list of gases you want the ACM 150 monitor to monitor at each sample point arranges them into logical groups and develops the ...

Page 84: ... the sample point that identifies the specific equipment or location in your facility Form 1 may be used as your master list of sample point names 2 Scroll down the list of methods and select one that includes all of the gases you want to monitor at that point NOTE If one method does not contain all of the gases for that point choose gases from multiple methods ...

Page 85: ...dy to monitor the point select SCAN ENABLED A check mark indicates it is enabled 7 After you complete your selections press SUBMIT CHANGES to make them active Order of scan The Order of Scan defines the sequence of point scanning Points may be scanned in any order and points may be repeated in the sequence It is also possible to have points in the sequence without making them active Reviewing the ...

Page 86: ...nts When editing Order of Scan follow the steps in Table 3 Figure 51 Editing the order of scan Table 3 Order of scan editing steps 1 Decide on the scan sequence you want to use before you make any changes Note that points may be scanned in any sequence If you want the ACM 150 monitor to spend more time scanning one or more critical points you can repeat the point s in the sequence Order of Scan al...

Page 87: ...points on temporary hold 6 Press RESET FIELDS if you make a mistake and want to recover the prior sequence 7 After you complete your selections press SUBMIT CHANGES to make them active Composite points Up to 4 points may be sampled together by the FTIR to speed up the scan rate The disadvantage of composite sampling is that the lower detection limit is raised because the sample from one point is d...

Page 88: ... de tubes courts tirages ce qui peut causer un déséquilibre dans le composite mélange 2 Points Groupe qui ont identiques Configurations point unique à savoir le même méthode avec les mêmes gaz actives et la même Alarmes 1 et 2 ensemble des points Programmable relays The ACM 150 monitor has 80 programmable relay outputs The functions and uses of the relays are described in section Alarm 1 Alarm 2 i...

Page 89: ...ACM 150 89 Figure 52 Review programmable relays default Selecting the relay program Follow the steps in Table 4 when assigning levels points and gases to a relay ...

Page 90: ... the activation point number s for this relay Note that a relay may be assigned to one point or multiple points up to a maxi mum of 10 4 Press the Next button after entering your selection for point numbers This takes you to the activation gas es screen shown below The active gases are listed for each point that you assigned to this relay Now select a gas or group of gases you want to assign to th...

Page 91: ... control functions properly Virtual relay setup You can connect the ACM 150 monitor to a PLC or facility computer without hard wired relays Virtual relays are available for this purpose They are accessed using the advanced key which brings up the SQL Direct Entry display as shown below This is for advanced programmers only Figure 54 Virtual relay setup ...

Page 92: ...er Code may be changed by the user and that code may be used for multiple monitors in the same facility When assigning a code set enter the name of the employee or group assigned to that code set Passwords require a length of at least 8 digits and must contain at least one lower case character one numeric character one of the following special characters To further grant or deny access to differen...

Page 93: ...ve scans on one point Level 1 Level 0 Reset Alarms Reset Service Events Lock On Scan Level 2 Level 1 Change Point Configuration Change Order of Scan Level 3 Everything except Access Codes Only the Administrator may change Access Codes and Levels Level 99 Administrator using Master Code This access level cannot be changed ...

Page 94: ... from the USB Drive and confirm by pressing OK NOTE If the Master Code on the target ACM 150 differs from that on the source ACM 150 you will have to manually change the Master Code on the target ACM 150 directly after importing the password there The Administrator may choose to increase the number of access levels by assigning higher values for individual screens and users For enhanced security t...

Page 95: ... methods and to delete meth ods no longer used The menu is shown in Figure 57 Figure 57 Method files Save load configuration After you setup the ACM 150 monitor and each time you change the setup you want to save the configuration to the ACM 150 monitor hard disk Also you should backup the configuration to a USB flash drive Then if the software should get corrupted or the hard disk fail you can sa...

Page 96: ... the Alarms screen of the ACM 150 user interface Simulated alarms show up as auto cleared alarms and do not trigger the red Alarm icon on the title bar In the screenshot below the top four alarms are simulated while the lower two alarms are for real Clicking any Remove from List button for simulated alarms will delete all simulated alarms at once Figure 59 Warn and alarm screen To simulate alarms ...

Page 97: ...k either Go to activate the alarms or Cancel to abort A summary listing all simulated alarms is displayed see Figure 61 Figure 61 Simulated alarms summary Click Reset Alarms to reset the gas concentrations sent via Modbus TCP to 0 0 or click Back to choose another point to simulate alarms on You may reset all simulated alarms from the Alarm Sim main screen anytime later on ...

Page 98: ...ng down the ACM 150 monitor may have on your facility and prepare for it e g fail safe relays that activate alarms on loss of power or shut off gases automatically when this system is not on line Use appropriate precautions to avoid unscheduled interruptions of production Turn off the Main Power Switch Figure 62 located on top of the ACM 150 monitor Follow Lockout Tagout Procedure when shutting do...

Page 99: ...tors on the CDA Panel Figure 20 to ensure that they read zero This confirms that the pressure has bled down and that it is safe to continue MISE EN GARDE Ceci est un risque de sécurité à haute pression L air comprimé CDA offre pression dépasse normalement 100 psig 7 kg cm2 Après arrêt de l externe fournir vanne vérifier les régulateurs de pression internes sur le panneau de CDA figure 20 afin d as...

Page 100: ...e Up to 2 000 m 6 562 ft Temperature range 5 C to 30 C 41 F to 86 F Relative humidity 80 at temperatures up to 31 C 88 F decreasing linearly to 50 RH at 40 C 104 F Main supply voltage 10 of the nominal voltage Overvoltage Category II Pollution degree 2 Ingress protection IP 20 Facilities Requirements Sample Line Tubing 1 4 ID x 3 8 OD polypropylene Sample Line Inlets 3 8 Swagelok connector Electri...

Page 101: ...viewing control ODBC access Touchscreen user friendly interface point and click Optional Outputs and Communications via Gateways Interface LonWorks Allen Bradley Modbus Profibus OPC drivers others on request Options and Accessories Automatic sample line leak test user settable ...

Page 102: ...be followed for both the integral Lockout Tagout switch and any external disconnects that the user may have DANGER Dangers d électrocution L interrupteur d alimentation principal est le point de puissance de la ligne de partage des voix qui se connecte à bornes à l intérieur du commutateur Avant de retirer le couvercle ce commutateur pour accéder à ces bornes la puissance de la ligne de déconnexio...

Page 103: ...gen supply has been relieved Disconnect both the CDA and nitro gen supply lines 6 Remove and disconnect all electrical power and communications lines 7 Remove and replace the sample filter located in the lower pump cabinet The panels of the lower cabinet are removable for access 8 Inspect and clean the optics bench components such as the sample cell win dows and mirrors 9 If moving the ACM 150 mon...

Page 104: ...ese relay outputs for immediate notification that a service problem has been detec ted Monthly service It is highly recommended to reboot the ACM 150 monitor computer monthly This ensures proper operation and avoids unexpected behaviour Quarterly inspection It is recommended that the ACM 150 monitor be inspected every 3 months more frequently if desired and that service be performed if any problem...

Page 105: ...d pass inspection there is no need to replace them during the annual service Three year service These services are recommended at least once every 3 years FTIR Optics Bench The infrared source HeNe laser and laser power supply have a limited operating life HA can provide a reconditioned bench to exchange for your used bench which is returned to HA for reconditioning Five year service These service...

Page 106: ... from a remote computer pulls up the left column of Diagnostic Menus shown in Figure 63 This menu offers numerous diagnostic choices enabling you to evaluate the performance and make adjustments to improve performance Selecting the MANUAL MODE OP key pulls up the right column of manual mode selections In Manual Mode Operation you can test all of the valves and relay outputs General access Diagnost...

Page 107: ... readings as they change ZPD Trends A diagnostic tool which is useful for evaluating the signal trends of the FTIR analyzer and for identifying problems Background S N Drift Diagnostic tools which evaluate the performance of the FTIR analyzer and its optical alignment Acquire Background Not the periodic automatic background but an on demand background scan initiated by the user Hardware Servicing ...

Page 108: ...lows the user to simulate gas concentrations at the Modbus TCP interface Service log Reviewing service events The Service log key pulls up the menu shown in Figure 64 All of the incidents currently stored in memory are displayed starting with the most recent This list may be limited to a shorter time period e g 1 day or 2 days by selecting the number of days using the arrow keys and then pressing ...

Page 109: ...andard activation sequence is explained in ACM 150 flow cycles and the standard cycle timing and pressures are given in Table 1 2 way valves shown blank i e with no color fill are not activated In this state they are closed and block the flow path 2 way valves shown with green color fill are activated and open Sample flow passes through these open valves The three graphs indicate the current absol...

Page 110: ... nitrogen is consistent the graph should be relatively flat Between service intervals the trend is usually in the direction of a decreasing ZPD A decreasing ZPD is an upward trend on the graph because ZPD is a negative number Following a service where the magnitude of the ZPD increases or following an upset condition where the ZPD is reduced you can expect a step change in the trend Sample point Z...

Page 111: ...e before it reaches unacceptable levels The upper graph in Figure 67 labeled Background S N Ratio shows the average daily S N and how it drifts over a 15 day period Ideally this will be a flat line however you should expect a downward trend over time as the S N degrades between service intervals The lower graph labeled Background Factory Drift is also a measure of the S N and its drift over time h...

Page 112: ... 68 the background spectrum is displayed for evaluation In this mode it is also possible to Save New Factory Background Scan which would replace the prior reference background NOTE Do not save a new factory background unless you are requested to do so by your HA service technician or application chemist There should be a valid purpose for updating this reference ...

Page 113: ...ll not activate If the computer fails then the WDT will timeout and activate its relay The test function forces a WDT timeout Perform an entire line leak test Any authorized user can perform this test provided your ACM 150 is configured for automatic line leak tests Typically this test is initiated because one or more line failed its automatic test If services were performed to resolve the failure...

Page 114: ...l may be chosen For triggering the Kinked Tube Test manually the user needs to login at the console and press the button Perform an Entire Kinked Tube Test as shown below Figure 69 Hardware servicing Software Servicing Database Statistics The screen Software Servicing may be used to analyze and control the database on the ACM 150 monitor and is designed for our Field Service Engineers Figure 70 So...

Page 115: ...s file to a USB stick or to your Desktop PC if you are operating remotely Every time the statistics are generated the complete data is appended to the end of the existing file Therefore there is no risk of loosing old statistical data by clicking this button repeatedly Opened with Microsoft Excel the file will look like this Figure 72 Excel screen ...

Page 116: ...ual tests Each test requires login access CAUTION Placing the ACM150 in Manual Mode or Front Panel Mode will place all flow control in the hands of the operator If the vacuum pump is operating to provide vacuum the Operator must ensure that either sufficient flow reaches the pump to prevent overheating or that the pump is turned off to prevent damage Mode control Mode Control places the ACM 150 mo...

Page 117: ...t this mode The Operating Mode also changes in the greyed out status bar from Automatic Mode to Manual Mode NOTE While in the Manual Mode normal point scanning is halted When you finish the manual testing switch back to the Automatic Mode to resume point scanning Figure 73 Manual control mode ...

Page 118: ...ey are selected and activated to open Flow can pass through these open valves Select the blue square again to close the valve Figure 74 Manual Control option Venturi Supply with Line Leak In the Manual Mode you also have control over the venturi pump and the secondary pump The venturi pump requires an air supply which is off in the default mode Select S9 to open the air supply Alternately you can ...

Page 119: ...w This mode is a convenient way to test any specific sample valve or all valves in sequence Figure 76 Sample valves manual control Relays All of the output relays may be controlled manually The ACM 150 monitor has 40 programmable relays The figure below shows only the first row of the menu programmable relays 1 10 No relays are activated when you enter this mode Select the relay you want to activa...

Page 120: ...n frequently exposed to hazardous material Examples of service items that may be contaminated are cleaning materials gas cells filters valves pump parts tubing and ZnSe windows Service people should insure that the ACM is safe before attempting repairs The minimum recommended personal protection includes gloves and safety glasses It is the user responsibility to dispose of contaminated waste safel...

Page 121: ...m on those lines should increase when they are sampled and create a Service Status message Follow the test procedure Cycle valve tests and replace the filter if the test indicates a flow restriction NOTE Avoid unnecessary downtime Do not wait until a Service Status message is generated before replacing filters Replace filters on an established schedule You can modify the schedule based on actual e...

Page 122: ...ions are provided in Backup vacuum pump Servicing the valves Self Monitoring and Manual Testing If any solenoid valve fails to switch or open it will cause a change in absolute pressure or in the infrared spectrum that is sufficient to generate a Service Status message in most cases During scheduled PM services or following any Service Status messages that might indicate a sampling problem use the...

Page 123: ...s off of mirrors and ultimately focuses onto a 2 mm diameter detector To get the best performance from the ACM 150 monitor the path through these optics must be clean and clear and the optics must be in alignment Use this procedure to evaluate the condition of the optical path by examining the ZPD Value the Signal to Noise Ratio and Spectral Balance After completing these three evaluations proceed...

Page 124: ...have other problems e g related Service Status messages proceed to Servicing the gas cell unless the problem is a ZPD value that is too high Servicing the gas cell Service objective The objective when servicing the gas cell is to correct any conditions which significantly reduce the infrared signal passing trough it The 5 meter long path gas cell also requires clean and clear windows but it has th...

Page 125: ...rror finish If you find dusty or tarnished mirrors then also inspect the external mirrors and window on the FTIR optics bench These mirrors can be cleaned Replacing the gas cell Try cleaning the gas cell to remove dust spots or chemical coating If cleaning does not correct the condition or if you see that the mirror coating is pitting tarnished or flaking off replace the gas cell Servicing the lin...

Page 126: ...l of the time S6 is stuck open or leaking S2 is failing to open or the Boost Pump has failed Draws Vacuum but Vacuum Remains Specific Sample Point If the pressure fails to rise during the Surge or Fill cycles for any specific sample point the valve for that point is failing to open Slowly Returns to 0 During Fill Cycle Specific Sample Point This indicates a flow restriction Most likely the in line...

Page 127: ...mal when switched on Remote users can perform this test in the Manual Control Mode see Figure 73 Identify any valve that fails to cycle properly and service it Flow Test With all of the sample valves off disconnect the inlet tube fittings and attach a flowmeter to each inlet port a flowmeter test assembly is available from HA service Measure the flow rate from point to point and compare the flows ...

Page 128: ... can not correct the leak Tubing Leak Verify this by removing the fitting from the check valve inlet and capping it off Then run the leak test and observe If the tube fails to hold pressure look for a cut or a hole Replace damaged tubing and make changes to prevent a repeat of the same problem Setup Problem check the setup Line leak test setup procedure and correct any problems Evaluating Resolvin...

Page 129: ...em Background Spectrum 1 Compare your Background spectrum to the spectrum shown in Figure 78 Note the intensity of region A 2000 cm 1 and region B 4000 cm 1 2 The intensity at region B should be at least 20 of the intensity at region A If it is 20 or higher the spectrum is balanced If less than 20 the spectrum is imbalanced and It has an inadequate S N in region B This is resolved by cleaning or r...

Page 130: ...5 The ratio of energies at 5000cm 1 and 2500cm 1 are being evaluated as additional evaluation points for the Spectral Balance operation in the future There is less absorbance due to water in the air at 5000cm 1 and 2500cm 1 and Honeywell expects a throughput of at least 20 However at this time have no expected throughput data for the Spectral Balance for the 5000 2500 ratio at this time ...

Page 131: ...ld are all tight avoid using force to over tighten the screws Cycle valves Remove the Cycle Valves as a subassembly First disconnect the tube fittings connecting these valves to external components Next unscrew the electrical connectors These tube fitting connections and electrical connectors are identified in Figure 9 As you disconnect each tube and connector verify that it is properly labeled If...

Page 132: ...th a small hammer to break it loose 7 Scrape off the Gasket between the Muffler Box and the End Plate 8 Remove the 6 bolts that hold the End Plate to the Body 9 Remove the End Plate and the 4 Vanes 10 Use steel wool to clean dirt and dust made by the old Vanes off of surfaces 11 Install the 4 new Vanes from the kit so that the beveled end slides into the slots in the same orientation as the old va...

Page 133: ...2 Vane 1 3 Shroud 1 4 End plate 1 5 Gasket 1 6 Muffler box 1 7 O Ring 2 8 Felt Do not use 2 9 End cap 2 10 End cap arm 2 11 Nipple 2 12 Plate bolt 1 Service Kit denotes parts included in Service Kit 1 Line leak test setup procedure These are the procedures recommended to set up the Line Leak Test so that it works correctly ...

Page 134: ...alve all the way by turning clockwise The pressure gauge between the needle valve and S10 should drop to 0 Now open the needle valve about 1 8 turn or until the pressure reads about 2 or 3 psig Once set up the needle valve should not require adjustment Pass Fail You should observe that the test fails on the open lines tubes disconnected and passes on all of the connected lines It fails because it ...

Page 135: ...fail 82 Watchdog timer computer problem 83 Manual mode 84 General malfunction 85 General Alarm 1 86 General Alarm 2 NOTE These relays should be wired to a central control system or alarm panel that is monitored by personnel so that conditions requiring service attention are known as soon as possible Utilizing daily inspections As a backup to monitoring the output relays a quick daily inspection of...

Page 136: ...g the FTIR optical path System stopped No action required Stopped at user request System started No action required Stopped at user request No active scans are defined Set up an Order of Scan Order of scan Cannot establish com munication with control boards Verify that the cables and power cords are connected to the con trol boards Interconnecting cables Cannot update relays Verify that the cables...

Page 137: ... ingredients Chemical characterization CAS No Description 7758 02 3 potassium bromide Identification number s EINECS Number 231 830 3 3 Hazards identification Classification of the substance or mixture Classification according to Directive 67 548 EEC or Directive 1999 45 EC Not applicable Information concerning particular hazards for human and environment Not applicable Label elements Labelling ac...

Page 138: ...ion Do not allow to enter sewers surface or ground water Measures for cleaning collecting Pick up mechanically Additional information No dangerous substances are released 7 Handling and storage Handling Information for safe handling No special measures required Information about protection against explosions and fires No special measures required Storage Requirements to be met by storerooms and re...

Page 139: ...material The exact break trough time has to be found out by the manufacturer of the protective gloves and has to be observed Eye protection Not required 9 Physical and chemical properties General Information Appearance Form Crystalline powder Color Colorless Odor Odorless Change in condition Melting point Melting range Undetermined Boiling point Boiling range Undetermined Flash point Not applicabl...

Page 140: ...h household waste Uncleaned packagings Recommendation Disposal must be made according to official regulations Recommended cleansing agent Water if necessary with cleansing agents 14 Transport information Land transport ADR RID cross border ADR RID class Maritime transport IMDG Marine pollutant No Transport Additional information Not dangerous according to theabove specifications 15 Regulatory info...

Page 141: ...afety assessment A Chemical Safety Assessment has not been carried out 16 Other information Disclaimer The information provided in this Material Safety Data Sheet is based on our present knowledge and believed to be correct at the date of publication However no representation is made concerning its accuracy and completeness It is intended as guidance only and is not to be considered a warranty or ...

Page 142: ...331 Toxic if inhaled GHS08 health hazard STOT RE 2 H373 May cause damage to organs through prolonged or repeated exposure GHS09 environment Aquatic Acute 1 H400 Very toxic to aquatic life Aquatic Chronic 1 H410 Very toxic to aquatic life with long lasting effects Classification according to Directive 67 548 EEC or Directive 1999 45 EC T Toxic R23 25 Toxic by inhalation and if swallowed N Dangerous...

Page 143: ... treatment see on this label P311 Call a POISON CENTER or doctor physician P304 P340 IF INHALED Remove victim to fresh air and keep at rest in a position comfortable for breathing P314 Get medical advice attention if you feel unwell P330 Rinse mouth P391 Collect spillage P405 Store locked up P403 P233 Store in a well ventilated place Keep container tightly closed P501 Dispose of contents container...

Page 144: ...f any immediate medical attention and special treatment needed No further relevant information available 5 Extinguishing media Suitable extinguishing agents CO2 powder or water spray Fight larger fires with water spray or alcohol resistant foam Special hazards arising from the substance or mixture No further relevant information available Protective equipment No special measures required 6 Acciden...

Page 145: ...feed Immediately remove all soiled and contaminated clothing Wash hands before breaks and at the end of work Store protective clothing separately Respiratory protection In case of brief exposure or low pollution use respiratory filter device In case of intensive or longer exposure use self contained respiratory protective device Protection of hands Protective gloves The glove material has to be im...

Page 146: ...elative density Not determined Vapour density Not applicable Evaporation rate Not applicable Solubility in Miscibility with water Not miscible or difficult to mix Segregation coefficient n octanol water Not determined Viscosity Dynamic Not applicable Kinematic Not applicable Organic solvents 0 0 Solids content 100 0 Other information No further relevant information available 10 Stability and react...

Page 147: ...ystem Danger to drinking water if even small quantities leak into the ground Also poisonous for fish and plankton in water bodies Very toxic for aquatic organisms Results of PBT and vPvB assessment PBT Not applicable vPvB Not applicable Other adverse effects No further relevant information available 12 Disposal considerations Recommendation Must not be disposed together with household garbage Do n...

Page 148: ... Model Regulation UN2811 TOXIC SOLID ORGANIC N O S ENVIRONMENTALLY HAZARDOUS 6 1 I 14 Safety health and environmental regulations legislation specific for the substance or mixture Labelling according to Regulation EC No 1272 2008 The substance is classified and labelled according to the CLP regulation Hazard pictograms GHS06 GHS08 GHS09 Signal word Danger Hazard determining components of labelling...

Page 149: ...01 Dispose of contents container in accordance with local regional national international regulations Chemical safety assessment A Chemical Safety Assessment has not been carried out 15 Other information Disclaimer The information provided in this Material Safety Data Sheet is based on our present knowledge and believed to be correct at the date of publication However no representation is made con...

Page 150: ...le point These spectra cover the fingerprint or mid infrared wavelength region Nearly all chemicals have an IR absorbance spectrum which is always the same and unique for each chemical The FTIR spectra have a high resolution which enables the distinct identification of one chemical from the another The ACM 150 monitor only monitors for chemicals in their gas vapor phase HA Honeywell Analytics LAN ...

Page 151: ...n values for gases in parts per million PPM and parts per hundred thousand PPHT water vapor only A pure gas would have a value of 100 concentration by volume One part in one million 1 PPM is 0 0001 or 100 divided by 1 million 1 PPHT 10 PPM These are the relationships between PPB PPM and PPM 0 01 0 000001 0 1 0 00001 1 0 0001 10 0 001 1 000 0 1 1 million 100 0 TLV Threshold limit value TWA Time wei...

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