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Troubleshooting

System Troubleshooting Guides

Thermo Fisher Scientific

Mercury System Manual

4-13

Malfunction

Possible Cause

Action

Troubleshoot/replace if
necessary

Local PC will not connect
via

i

Port

Incorrect Ethernet cables
used

When attempting to
communicate directly between
the PC and instrument, a
crossover cable is required. If
using an Ethernet hub/switch
port (other than the UPLINK port),
straight cables are required.

Ethernet hub malfunction

Verify hub performance, replace
if necessary.

i

Port configured improperly

Open

i

Port, under File >

Preferences, ensure proper
selections are made.

Under Instrument > TCP Connect,
IP Addresses, ensure instrument
IP addresses are listed correctly
with a space between them.

Local PC configured
improperly

Under Network Connections,
ensure the Internet Protocol
(TCP/IP) Properties are set to
reflect an IP address similar to
those of the instrument(s). Also
ensure the Subnet mask is
255.255.255.000.

82

i

diagnostic readings

read zero (temp/pres)

RS-485 link down between
80

i

and 82

i

Verify 15-pin RS-485 cable is
connected between 80

i

and 82

i

.

Verify DIP switch on 82

i

Interface

Board is set to “00” (both
switches in DOWN position).

Verify RS-485 cable performance,
replace if necessary.

If a board has a voltage problem, the instrument generates an alarm for that
board. Use the Voltages menu to access the particular board and to display
the current diagnostic voltage readings.

●

In the Main Menu, select Diagnostics >

Voltages

, and select the board.

Troubleshooting Interface

Board Voltages

«
...
57
58
59
60
61
...
»

Summary of Contents for Mercury Freedom 80i

Page 1: ...Mercury System Manual Part Number 105933 00 28Jan2008 ...

Page 2: ...ons terms and pricing are subject to change Not all products are available in all countries Please consult your local sales representative for details Thermo Fisher Scientific Air Quality Instruments 27 Forge Parkway Franklin MA 02038 1 508 520 0430 www thermo com aqi ...

Page 3: ...ibration procedure the auto system calibration procedure and the calibration check procedure Chapter 4 Troubleshooting presents guidelines for diagnosing instrument failures isolating faults and includes recommended actions for restoring proper operation Chapter 5 Preventive Maintenance describes the periodic maintenance procedures that should be performed on the system instruments and components ...

Page 4: ...is operated in a manner not specified by the manufacturer the protection provided by the equipment may be impaired The service procedures in this manual are restricted to qualified service personnel only This product is supplied with a three wire grounding cord Under no circumstances should this grounding system be defeated Equipment Damage Do not attempt to lift the instrument by the cover or oth...

Page 5: ...romatic solvent to clean the LCD module use a soft cloth moistened with a naphtha cleaning solvent Do not place the LCD module near organic solvents or corrosive gases Do not shake or jolt the LCD module Service is available from exclusive distributors worldwide Contact one of the phone numbers below for product support and technical information or visit us on the web at www thermo com aqi 1 866 2...

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Page 7: ...izer Enclosure 1 12 Hydrator 1 13 Nitrogen Generator 1 14 Zero Air Supply 1 14 Scrubber Assembly 1 15 Stack Mounting Flange 1 15 Umbilical Cable 1 16 Mercury System Instruction Manuals 1 16 System Installation Set Up and Shut Down 2 1 Lifting 2 1 Hg CEMS Requirements 2 1 Plumbing and Electrical Hookup 2 2 Set Temperature Defaults 2 2 Mercury CEMS Power Up Sequence 2 2 Start Up 2 3 System Checkout ...

Page 8: ...oubleshooting 4 7 Establishing Communication Between Instruments in the Mercury System 4 11 Cabling Instruments in the Mercury System 4 11 Direct Connection 4 11 Hub Router Connection 4 12 Hub Router Connection with UPLINK 4 12 Firmware and Communications Troubleshooting 4 12 Troubleshooting Interface Board Voltages 4 13 Probe Troubleshooting with 82i LEDs 4 15 Troubleshooting 82i Interface Board ...

Page 9: ...Connections 6 4 Pneumatic Connections 6 5 80i Input Output Configuration 6 5 Functional Check 6 6 Zero Air Supply 6 7 Nitrogen Generator 6 7 Specifications 6 7 Sources of Compressed Air 6 10 Generator Performance 6 10 Recommended Configuration 6 10 Retrofitting Older Systems 6 10 Warranty A 1 System Reference Drawings B 1 Flowcharts of Menu Driven Firmware 262HC 1 105HIndex I 263H1 99HAppendix A 1...

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Page 11: ...ure 6 3 Hydrator Electrical Pinout Diagram 6 4 Figure B 1 83i System Plumbing Diagram 103013 00 B 2 Figure B 2 83i with Oxidizer System Plumbing Diagram 103013 01 B 3 Figure B 3 83i Electrical and Plumbing Installation 103535 00 B 4 Figure B 4 Wiring Interconnection with 83i GC B 5 Figure B 5 83i with Oxidizer Electrical and Plumbing Installation 103535 01 B 6 Figure B 6 Tubing Interconnection wit...

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Page 13: ...le 3 2 Zero Span Check Set Up 3 4 Table 4 1 Troubleshooting Most Common Service Calls 4 2 Table 4 2 Troubleshooting Power Up Failures 4 3 Table 4 3 Troubleshooting Alarm Messages 4 4 Table 4 4 Troubleshooting System Zero and Calibration 4 7 Table 4 5 Troubleshooting Firmware and Communications 4 12 Table 4 6 Probe Troubleshooting 82i Measurement Interface Board LEDs 4 15 Table 4 7 Communication an...

Page 14: ......

Page 15: ...emitting fluorescing UV light at the same wavelength Specifically 254 254 nm h Hg Hg nm h Hg ν ν The sample from the Hg probe Model 83i is introduced to the rear panel of the instrument as either Total Hg or Elemental Hg from the appropriate probe umbilical connection see Figure 1 1 When the Model 80i is sampling Total Hg the total sample is routed into the fluorescence chamber via Solenoids S1 NO...

Page 16: ...bed to the zero air and cal gas bulkheads on the rear panel of the Model 80i The zero or span gas is routed through an internal critical orifice through either the NO or NC port of Solenoid S4 through the NC port of Solenoid S3 and into the fluorescence chamber During this time both Total and Elemental Hg samples bypass the chamber and are sent to the external pump exhaust The Model 80i outputs th...

Page 17: ... a valve that is energized or in the Normally Closed NC state A valve status shown as OFF describes a valve that is de energized or in the Normally Open NO state Table 1 1 Model 81i Valve Mode Status Solenoid ID Standby Instrument Zero Instrument Cal Orifice Zero Orifice Cal System Zero System Cal Valve 1 ON ON ON ON ON ON ON Valve 2 OFF OFF ON OFF ON OFF ON Valve 3 OFF OFF ON OFF ON OFF ON Valve ...

Page 18: ...to the spike port for filter flooding by switching the appropriate probe valve orifice or spike The check valve is used to keep the orifice located in the probe from being over pressurized during an orifice zero or calibration Excess flow atmospheric dump during a probe calibration is routed through an internal Hg scrubber prior to being sent to exhaust Also during any zero air mode instrument ori...

Page 19: ...ssociated with the individual regulators are also contained within the Model 82i as well as an electronic vacuum transducer monitoring the dilution module vacuum in the Model 83i Figure 1 3 Model 82i Probe Controller Flow Diagram The Model 82i communicates with the Model 80i via a RS 485 link The Model 80i acts as the master component in the Mercury Freedom System with both the Models 81i and 82i ...

Page 20: ...ly to monitor gaseous Hg emissions from coal fired power plants The system is housed in a stainless steel enclosure and is designed to meet NEMA 4X specifications To prevent sample condensation all key elements filter diluting probe and sample eductor have been mounted between heated aluminum blocks that can be maintained at temperatures as high as 250 C The enclosure also houses an accumulator ta...

Page 21: ... for reducing oxidized Hg to elemental for subsequent analysis by the Model 80i The Model 82i provides both 220 and 110 AC voltage to the Model 83i 220 VAC powers the probe s stinger heater and filter eductor heater 110 VAC powers the Total Hg converter as well as four 4 probe solenoid valves for cal zero gas stinger blowback filter blowback and Hg spike The Model 82i also receives two 2 4 20 ma s...

Page 22: ...Introduction Model 83i 1 8 Mercury System Manual Thermo Fisher Scientific Figure 1 4 Model 83i Probe Flow Diagram ...

Page 23: ...Introduction Model 83i Thermo Fisher Scientific Mercury System Manual 1 9 Figure 1 5 Model 83i Probe Flow Diagram with Oxidizer ...

Page 24: ...prevent sample condensation and mercury adsorption prior to entering the filter block assembly The standard heated probe barrel assembly consists of a six foot long by 1 2 inch OD Hastelloy C sample stinger tube that is encased by a one inch OD schedule 40 316SS welded pipe flange assembly A five foot long 240 VAC 600 W coiled cable heater envelops the 1 2 inch OD sample stinger tube within the an...

Page 25: ...ppm Cl2 in N2 Balance and the elemental mercury is supplied by the Model 81i elemental Hg generator An oxidized mercury source is required in order to comply with 40 CFR Part 75 which states that a system integrity test needs to be performed once a week Figure 1 6 Oxidizer Flow Diagram Refer to Figure 1 7 to identify and locate the oxidizer components The oxidizer weldment acts as the reaction cha...

Page 26: ...izer temperature The insulation surrounding the heater block helps maintain a uniform and constant temperature The oxidizer enclosure is an aluminum box that contains the oxidizer components Figure 1 7 Oxidizer Components Heater Block Thermocouple Insulation Oxidizer Enclosure Thermocouple Heater Oxidizer Weldment Oxidizer Enclosure Heater Block Top Heater Block Bottom Insulation 2 x 2 2 7 x 4 2 x...

Page 27: ... improves system response and enables more complete Hg recovery See Figure 1 8 and Figure 1 9 Figure 1 8 Hydrator System Mount and Close up View Figure 1 9 Hydrator Components Hydrator DC Power Jack Cannister Cap Cannister Top Upper Cannister Hydrator Enclosure Lower Cannister Hydrator Connector Board Front Panel ...

Page 28: ...the Nitrogen Generator for constant performance with support to the Model 80i Refer to the Optional Equipment chapter for more information Figure 1 10 Zero Air Panel System with Nitrogen The Zero Air Supply has been designed to provide oil free and particulate free dry air from plant air Zero Air Supply components include an oil mist coalessor water coalessor with auto drain particulate filter acc...

Page 29: ...tional hydrocarbon and interference removal Activated Charcoal Hydrocarbons and O3 SO2 Hg 0 removal Figure 1 11 Scrubber Assembly The stack mounting flange Figure 1 12 Provides the mounting interface for the Model 83i probe enclosure to the stack Mounts to a standard 8 hole 150 four inch flange on the stack Note The special four inch adapted mounting flange for installing onto the port supports th...

Page 30: ...ystem Reference Drawings appendix The following instruction manuals are currently available for the Mercury instruments Model 80i Hg Analyzer Instruction Manual 103194 00 Model 81i Hg Calibrator Instruction Manual 103068 00 Model 82i Hg Probe Controller Instruction Manual 103519 00 Model 82X Fiber Optic Probe Controller Instruction Manual 105464 00 Model 83i Extraction Probe Instruction Manual 101...

Page 31: ...d the other by grasping the bottom in the rear Equipment Damage Do not attempt to lift the instrument by the cover or other external fittings 120 VAC 15 amps for 80i 81i pump and support 208 240 VAC 20 amps for 82i Probe 208 240 VAC 30 amps per 200 feet of heated umbilical 0 13 amp ft two zones maximum All power is needed at instrument end power for probe sent via umbilical in a standard system Sy...

Page 32: ...ble 2 1 Default Temperatures Parameter Default Temperature Setting Bench Temp 45 C Probe Temp 220 C Umbilical Temp 120 C Converter Temp 760 C Failsafe Valve Temp 200 C Oxidizer Temp 400 C Use the following procedure to power up the Mercury CEMS Note If the 81i is in Service Mode it will ignore 80i commands 1 Apply Power to the CEMS turn power switches ON in the following order Model 82i Model 81i ...

Page 33: ...e is indicated on the 80i Use the following procedure to power up the Mercury CEMS 1 Place the System in System Zero Mode to flush the system 2 Turn OFF flow related components Power OFF the sample pump Component Power Eductor Power Service Probe Set Temp Failsafe Set To 250 C 3 Heat components to temperatures Component Power Umbilical 1 Power Component Power Umbilical 2 Power Component Power Conv...

Page 34: ... Main Menu select Instrument Controls Component Power Converter Power and turn the converter ON 5 At the 80i Main Menu select Diagnostics Temperatures Probe Converter observe the converter temperature rise and control to 760 C Verify the temperature control is within 10 C of set point 6 At the 80i Main Menu select Instrument Controls Component Power Probe Power and turn probe power ON 7 At the 80i...

Page 35: ... verify vacuum pressure is 20 inches Hg at 55 psig for 83i 17 5 inches Hg at 35 psig for 83i GC 14 Model 83i only At the 80i Main Menu select Diagnostics Pressure Probe and note venturi pressure 15 At the 80i Main Menu select Instrument Controls Component Power and turn Eductor Valve Power ON 16 At the 80i Menu Diagnostics Pressure Probe note venturi pressure It should be at least 1 5 inches H2O g...

Page 36: ... 150k Hz Cooler Temperature 10 15 C Bench Temperature 45 50 C Probe Temperature 190 220 C Valve Failsafe Temperature 190 C Umbilical Temperature 120 C Converter Temperature 760 C Blowback Pressure 40 65 psig Eductor Pressure 5 20 psig Dilution Pressure 30 65 psig Oxidizer Temperature 400 C Table 2 3 Set up Blowback Schedule Parameter Range Default Period 0 24 Hours 12 Hours Filter Duration 0 60 Se...

Page 37: ...0 µg Span AutoCal Probe Max Offset 0 600 µg 4 0 µg Probe Dilution Factor 1 100 30 Hg 0 Concentration 0 600 µg 600 µg Hg 2 Concentration 0 600 µg 600 µg Hg t Concentration 0 600 µg 600 µg Mother Board Status OK Interface Board Status OK Table 2 5 Probe Alarms Settings Parameter Range Typical Value Umbilical Temperature 100 200 C 120 C Probe Temperature 190 250 C 220 C Converter Temperature 700 900 ...

Page 38: ... based on 10 µg m3 at 9 LPM Eductor pressure is set to 5 psig for wet stack and 15 psig during dry stack application If the orifice pressure is greater than 1 0 psig during a filter zero or span it is possible that the probe inlet is clogged because the outlet isolation valve is closed and if the inlet stinger is clogged the cal gas pressurizes the fastloop and pressurizes the orifice Normal Opera...

Page 39: ...FF OFF OFF ON ON OFF OFF OFF 83i Probe Cal Zero Valve OFF OFF OFF ON ON OFF OFF OFF OFF OFF Eductor Press psig 5 15 5 15 5 15 5 15 5 15 0 1 0 1 0 1 5 15 5 15 81i Press mmHg 760 760 800 760 900 760 850 1150 850 1150 760 760 Typ Orifice Press psig 0 1 0 1 0 1 2 2 0 1 0 1 1 5 Typ Venturi Press inH 2 O 0 4 0 4 0 4 0 4 0 4 15 10 0 4 0 4 Fastloop Actuator Open Open Open Open Open Closed Closed Closed Op...

Page 40: ... stack gas and moisture will condense inside the probe and cause contamination Use the following procedure to shut down the system 1 Turn the system air supply OFF 2 At the 80i Main Menu select Mode FILTER ZERO Normal Operational Parameters with 83i GC MODE Typical Orifice Pressure psig 81i Pressure mmHg Eductor Pressure psig 83i GC Cal Zero Valve 83i Probe Spike Valve 83i Probe Stinger Blowback 8...

Page 41: ...g from the UPS connector and disconnect the 208 220 VAC from the rear connectors 5 Turn the sample pump OFF 6 Inside the 82i turn the two hot line power breakers OFF The firmware can be updated by the user in the field via the serial port or over the Ethernet This includes both the main processor firmware and the firmware in all low level processors Refer to the iPort manual for the firmware updat...

Page 42: ......

Page 43: ...t Zero 5 Allow approximately four minutes for the instrument to stabilize 6 From the Main Menu select Calibration Calibrate Hg 0 Background and press 7 From the Main Menu select Instrument Controls Gas Mode Instrument Span Mode 8 From the Main Menu select Calibration Auto Zero Span Check Inst Hg Span Conc select any target value between Span 1 and 6 then press 9 Allow approximately four minutes fo...

Page 44: ...lize 18 From the Main Menu select Calibration Cal Hg 0 Background and press 19 From the Main Menu select Calibration Cal Hg t Background and press 20 From the Main Menu select Calibration Auto Zero Span Check Sys Hg Span Conc and choose the target concentration Span 1 through 6 Note The Sys Hg Span Conc screen is available only while in Hg 0 or Hg t Manual mode 21 From the Main Menu select Instrum...

Page 45: ... Verify Service mode is OFF 3 From the Main Menu select Calibration Auto Zero Span Check 4 Set the parameters shown in Table 3 1 Individual user requirements may vary from the values shown in Table 3 1 Table 3 1 Example of Parameter Settings Parameter Setting next time As Required period hour 24 hours inst zero durat min 10 inst span durat min 10 inst zero cal reset ON inst span cal reset ON inst ...

Page 46: ...strument Zero Duration Min Duration of Analyzer Zero typically 5 to 6 minutes Instrument Span Duration Min Duration of Analyzer Span typically 5 to 6 minutes Instrument Zero Cal Reset Automatically update the Analyzer Background factor at the end of Zero Duration step Instrument Span Cal Reset Automatically update the Analyzer Coefficient at the end of Span Duration step Instrument Hg Span Conc Ta...

Page 47: ...g Guides beginning on page 4 1 Service Locations on page 4 19 Read the safety precautions at the front of this manual before performing any actions described in this chapter The troubleshooting guides presented in this chapter are designed to help identify and isolate system level problems These guides provide general troubleshooting information indicate the checks that you should perform if you e...

Page 48: ...able 4 1 Troubleshooting Most Common Service Calls Malfunction Possible Cause Action 80i or 81i screen disappears on laptop iPort failure Close any open windows and restart iPort Filter System span will not reach 81i value Hydrator empty or liquid gas leak Ensure top reservoir is filled and the fill logic is correct Eductor pressure near 0 in sample mode 82i Pressure regulator failed Tap regulator...

Page 49: ... during Hg T analysis Melted Teflon at convertor tube when probe enclosed Install stainless fittings with Teflon ferrules at each end of convertor Convertor temp too low Relay in 82i failed or heater burned out Replace relay or heater Convertor temp too high Relay in 82i failed and heater has not burned out yet Replace relay High chamber pressure noisy vacuum pump Vacuum pump failed or is about to...

Page 50: ...n through RS 232 or Ethernet Reboot instrument Contact Thermo Fisher Scientific Service Department Table 4 3 describes the alarm messages for the 80i and the 81i The 81i alarms are indicated with Alarm 81i in the Alarm Message description When a reference to a manual is included in the Action description go to the associated manual such as the 80i or 81i not this Mercury System Manual Table 4 3 Tr...

Page 51: ...s failing Replace lamp Alarm Internal Temp Instrument overheating Replace fan if not operating properly Clean or replace foam filter Ambient temperature resistor open or shorted Check ambient temperature resistor Bad interface board Check interface board 83i ONLY Alarm Orifice Pressure Low pressure system leak Perform a leak test High pressure blocked orifice Check orifice Alarm Pressure High pres...

Page 52: ...mponent power is ON Temperature is not set to 120 C Check that temperature is set to 120 C No AC voltage to probe Check that AC voltage is applied to probe Faulty communication between 80i 81i 82i Check communication between 80i 81i 82i Cabling problem to instruments Check cabling in back of instruments Measure ohms of heater Alarm Vacuum Pressure Low pressure leak Perform a leak test Ensure dilut...

Page 53: ...rs or requires maintenance Test against an ultra zero cylinder from a reputable scientific gas supplier or check effect of a new chromatography grade activated charcoal scrubber installed at the instrument inlet Zero air flow rate is inadequate Verify that the zero air system is providing adequate flow Instrument is not drawing in zero or span gas Check sample flow and pressure readings Diagnostic...

Page 54: ...ered to the correct spot Flow rate of the diluted span mix is inadequate Verify that the zero air system is providing adequate flow Critical orifice blocked Check clean orifice Instrument is not drawing in span gas Check sample flow and pressure readings Diagnostics menu Use an independent flow meter to check flows at the span inlet and exhaust bulkheads they should match Perform a leak test Hg is...

Page 55: ...water Check to see if bottom reservoir has water Locate gas leak and repair External pump failure Replace the external pump Averaging time is not set correctly Check the Averaging Time Main Menu If too high the unit will be slow to stabilize If too low the signal may appear noisy Set Averaging Time to one minute Hot line temperature failure Ensure hot line has power Reduced response or no response...

Page 56: ...d Calibration Input Frequency Display ignore warning and press Enter leave Test off Change Gain to 100 Frequency should be approx 400 kHz Unplug PMT signal cable Frequency should drop to approx 6 kHz PMT failure Check that the PMT voltage is approx 750V Service menu or Diagnostics menu Lamp assembly failure Check that the lamp intensity is approx 80 kHz Diagnostics menu Poor linearity Nitrogen Gen...

Page 57: ...ddress differs from but is close to the 81i IP address such as 192 168 1 200 3 Under Main Menu select Instrument Controls Service Mode and turn Service mode ON The Service mode must be ON in order to change Cal Enable 4 Return to Main Menu select Diagnostics System Configuration and set the 81i Cal Enable to YES 5 Return to System Configuration enter the 81i TCP IP address as displayed on the 81i ...

Page 58: ... 80i was powered up before 81i 82i were powered up Shut down the three instruments Power up 81i and 82i wait 60 seconds then power up the 80i Units are not connected via secure cables Check cable connections 80i does not communicate with 81i 81i is in Service mode Verify 81i is not in Service mode set to OFF if necessary 81i will not respond to Gas mode commands from the 80i 80i configured imprope...

Page 59: ... addresses are listed correctly with a space between them Local PC configured improperly Under Network Connections ensure the Internet Protocol TCP IP Properties are set to reflect an IP address similar to those of the instrument s Also ensure the Subnet mask is 255 255 255 000 82i diagnostic readings read zero temp pres RS 485 link down between 80i and 82i Verify 15 pin RS 485 cable is connected ...

Page 60: ...ading displayed on the Interface Board Voltages screen is different than the normal value check the actual voltage reading on the interface board with a voltmeter You can also use a voltmeter to check interface board voltages when the voltage readings are normal but you suspect there is a board problem Note If the interface board voltages all read 0 0 V check that the 24 V LED is ON Figure 4 1 If ...

Page 61: ... In most cases the problem will involve wiring and or plumbing Table 4 6 Probe Troubleshooting 82i Measurement Interface Board LEDs LED No Description Action 4 Blowback stinger 83i 5 Blowback filter 83i Check air supply and pressures via diagnostics Check air at the probe 6 Cal zero 83i 7 Hg spike 83i Verify that the 81i is outputting cal gas diagnostics flows Check at probe also 8 Eductor 82i Che...

Page 62: ...n Possible Cause Action Low total mercury reading during oxidizer test Hydrator is leaking Leak test the hydrator to ensure there are no gas leaks Use a hand vacuum pump and gauge assembly or pressurize to 10 psig and use Snoop leak test solution Hydrator is dry Bottom cylinder is empty because the I O is not properly configured The top cylinder is out of water Cold spots in the probe low Hg t rea...

Page 63: ...r s w versions 01 00 21 231 or later this delay can be adjusted Ensure that the 82i is communicating with the 80i and opening the valves when required On the 82i interface board the left most LED indicates that power is being sent to the Hg valve The 2nd left most LED indicates that power is being sent to the Cl2 valve Leak in the Hg or Cl2 valve to the oxidizer in probe Ensure that the tubing and...

Page 64: ... Miscellaneous Malfunction Possible Cause Action Excessive noise or spikes on analog outputs Defective or low sensitivity PMT With previous coefficients and PMT voltage known introduce a known concentration of span gas Defective input board or BNC connection Identify the defective component and replace Noise pick up by recorder or data logger Check analog cable shielding and grounding Try to local...

Page 65: ... Analog Output Testing in the Servicing chapter Analog output goes above full scale value or below zero By default a 5 over and underrange on the analog outputs is provided If this is not desirable due to system restrictions it may be turned off in the Instrument Controls I O Configuration Analog Output Config screens Recorder is drawing down output Verify that the recorder or data logger input im...

Page 66: ......

Page 67: ...spect the system components frequently until an appropriate maintenance schedule is determined IMPORTANT NOTE The 81i has been calibrated at the factory against a NIST traceable vendor prime Any adjustments made will void NIST traceability This chapter includes the following maintenance information and replacement procedures System Preventive Maintenance on page 5 2 Heated Umbilical on page 5 2 Se...

Page 68: ...obe control unit to the stack probe and mercury converter The umbilical contains heated PFA transport tubing signal and power cables The heated umbilical contains eight lines three heated PFA lines and five unheated lines The three heated PFA lines consist of Two lines for the total and elemental mercury inch diameter 0 040 inch wall thickness One line for the 81i 3 8 inch diameter 0 062 inch wall...

Page 69: ...ines Refer to Table 5 1 for the recommended cleaning schedule Cleaning Materials Required 5 solution of nitric acid mixed with DI water Distilled water 1 Turn the power OFF to the umbilical or set it to 50 C 2 Disconnect the Total and Elemental lines from the 80i 3 Disconnect the Total and Elemental lines up at the 83i 4 Place a collection container at the CEMS rack and insert either the Total or ...

Page 70: ... site specific Inspect the umbilical periodically until you establish a cleaning schedule appropriate for your site For additional assistance Thermo Fisher Scientific has service available from exclusive distributors worldwide Contact one of the phone numbers below for product support and technical information or visit us on the web at www thermo com aqi 1 866 282 0430 Toll Free 1 508 520 0430 Int...

Page 71: ...r react on any cool surface below 190 C The chlorine is supplied by a small cylinder 900 ppm Cl2 in N2 Balance and the elemental mercury is supplied by the Model 81i elemental Hg generator An oxidized mercury source is required in order to comply with 40 CFR Part 75 which states that a system integrity test needs to be performed once a week The Hydrator humidifies calibration gas improves system r...

Page 72: ...system use the through holes on the Hydrator mounting tabs to mark the mounting hole location and taking care not to over penetrate drill mounting holes using the appropriate drill bit setup Use appropriate stainless steel hardware such as 1 4 20 to mount the assembly to the rack Figure 6 1 Hydrator Mounted Outside Rack 3 Connect the modular eight pin connector to the Hydrator bulkhead connector l...

Page 73: ...tor bulkhead connector located at the top left of the unit when viewed from the front Run this cable to the rear of the 80i utilizing the available Panduit tray and leave an adequate service loop at the rear of the 80i to facilitate sliding the instrument out of the rack Use the following procedure to retrofit the Hydrator on a fielded Mercury System 1 Determine Hydrator location When selecting a ...

Page 74: ... setup Use appropriate stainless steel hardware to mount the Hydrator 1 Attach the two 37 pin terminal boards supplied with the kit to the corresponding 37 pin connectors on the rear of the 80i and secure with the supplied hardware 2 Terminate additional harness wires to the jacket of the cable with a small tie strap Note Pinout diagram shows only 24 active termination points Figure 6 3 Hydrator E...

Page 75: ...bilical Line 3 was prior to relocation during Step 1 3 Open the 81i and flip the check valve 180 degrees so that the arrow is facing the back of the instrument 4 Check tightness of the fittings internal and external to the Hydrator and apply air to system by opening the air handling inlet valve 1 At the 80i Main Menu select Instrument Controls I O Configuration Output Relay Settings and press 2 Wi...

Page 76: ...ses with the water level and closes at the top of its travel This action will open the circuit and the solenoid valve will de energize stopping water flow 4 Remove the upper chamber cap and top off to full Replace cap 5 At the 80i Main Menu select Instrument Controls Gas Mode System Span The 81i gas mode will change and Hg calibration gas will begin to flow across the surface of the water in the l...

Page 77: ...with nitrogen By using a three way valve the Nitrogen Generator can also be operated in Bypass mode which diverts airflow around the N2 generator to provide instrument grade air to the Mercury System This may be beneficial for testing applications and when routine maintenance on N2 components is required If this feature is not within the scope of the application simply vent to atmosphere Refer to ...

Page 78: ...from pressurized air The composition of the product is determined by measuring the residual oxygen content The nitrogen content is calculated by subtracting the residual oxygen content from 100 air Air is composed of nitrogen 78 1 oxygen 20 9 Argon 0 9 CO2 0 03 and some traces of inert gases Therefore it should be kept in mind that the value that is normally called the nitrogen content is actually...

Page 79: ...Optional Equipment Nitrogen Generator Thermo Fisher Scientific Mercury System Manual 6 9 ...

Page 80: ...psig The Nitrogen Generator system must be supplied with 85 100 psig compressed dry air CDA at the inlet regulator The Thermo Scientific Air Handling System feeding the Nitrogen Generator will have a potential pressure drop of 10 psig meaning the Nitrogen Generator air input could drop as low as 75 psi This pressure would result in a nitrogen output purity of approximately 97 Although verified at ...

Page 81: ...n Material Authorization RMA which may include biohazard decontamination procedures and other product specific handling instructions and c then if applicable Buyer may return the defective Products to Seller with all costs prepaid by Buyer Replacement parts may be new or refurbished at the election of Seller All replaced parts shall become the property of Seller Shipment to Buyer of repaired or re...

Page 82: ...therefor at Seller s then prevailing time and materials rates ANY INSTALLATION MAINTENANCE REPAIR SERVICE RELOCATION OR ALTERATION TO OR OF OR OTHER TAMPERING WITH THE PRODUCTS PERFORMED BY ANY PERSON OR ENTITY OTHER THAN SELLER WITHOUT SELLER S PRIOR WRITTEN APPROVAL OR ANY USE OF REPLACEMENT PARTS NOT SUPPLIED BY SELLER SHALL IMMEDIATELY VOID AND CANCEL ALL WARRANTIES WITH RESPECT TO THE AFFECTE...

Page 83: ... 83i with Oxidizer Electrical and Plumbing Installation 103535 01 on page B 6 Figure B 6 Tubing Interconnection with 83i GC on page B 7 Figure B 7 83i GC Plumbing System Diagram 104358 00 on page B 8 Figure B 8 83i GC with Oxidizer Plumbing System Diagram 104358 01 on page B 9 Figure B 9 Interconnection Schematic on page B 10 Figure B 10 83i Terminal Block Wiring Diagram 104588 00 on page B 11 Fig...

Page 84: ...System Reference Drawings B 2 Mercury System Manual Thermo Fisher Scientific Figure B 1 83i System Plumbing Diagram 103013 00 ...

Page 85: ...System Reference Drawings Thermo Fisher Scientific Mercury System Manual B 3 Figure B 2 83i with Oxidizer System Plumbing Diagram 103013 01 ...

Page 86: ...System Reference Drawings B 4 Mercury System Manual Thermo Fisher Scientific Figure B 3 83i Electrical and Plumbing Installation 103535 00 ...

Page 87: ...System Reference Drawings Thermo Fisher Scientific Mercury System Manual B 5 Figure B 4 Wiring Interconnection with 83i GC VIEW A TOP VIEW OF 83iGC TERMINAL BLOCK WIRE REFERENCE CHART ...

Page 88: ...System Reference Drawings B 6 Mercury System Manual Thermo Fisher Scientific Figure B 5 83i with Oxidizer Electrical and Plumbing Installation 103535 01 ...

Page 89: ...System Reference Drawings Thermo Fisher Scientific Mercury System Manual B 7 Figure B 6 Tubing Interconnection with 83i GC ...

Page 90: ...System Reference Drawings B 8 Mercury System Manual Thermo Fisher Scientific Figure B 7 83i GC Plumbing System Diagram 104358 00 ...

Page 91: ...System Reference Drawings Thermo Fisher Scientific Mercury System Manual B 9 Figure B 8 83i GC with Oxidizer Plumbing System Diagram 104358 01 ...

Page 92: ...System Reference Drawings B 10 Mercury System Manual Thermo Fisher Scientific Figure B 9 Interconnection Schematic ...

Page 93: ...System Reference Drawings Thermo Fisher Scientific Mercury System Manual B 11 Figure B 10 83i Terminal Block Wiring Diagram 104588 00 ...

Page 94: ...System Reference Drawings B 12 Mercury System Manual Thermo Fisher Scientific Figure B 11 83i GC with Oxidizer Terminal Block Wiring Diagram 104734 00 ...

Page 95: ...System Reference Drawings Thermo Fisher Scientific Mercury System Manual B 13 Figure B 12 Umbilical Wiring Detail ...

Page 96: ...System Reference Drawings B 14 Mercury System Manual Thermo Fisher Scientific Figure B 13 Model 83i with Oxidizer Terminal Block Wiring Diagram 105507 00 ...

Page 97: ...stem Manual C 1 Appendix C Flowcharts of Menu Driven Firmware This section presents detailed flowcharts for the 80i and the 81i menu driven firmware and are provided here for convenience in navigating the Mercury System menus and screens ...

Page 98: ...an Set Defaults Flow Calibration Zero Span Set Defaults Input Board Cal Manual Input Adjust Automatic Input Adjust Input Frequency Disp Temp Cal Analog Out Cal Voltage Channel 1 6 Current Channel 1 6 Analog Output Cal Zero Analog Output Cal Full Scale Analog Input Cal Input Channel 1 8 Analog Input Cal Zero Analog Input Full Scale Display Pixel Test Restore User Defaults Lamp Normalization Passwor...

Page 99: ...onc Motherboard Status Interface Status I O Exp Status Service Cooler Set Temp Flow Control Selection Dilution Hg Calibration Pres Temp Zero Flow Calibration Dilution Air Flow Cal Hg Flow Calibration Hg Air Flow Cal Pressure Calibration Pressure Sensor Cal Zero Span Set Defaults Ambient Temp Cal Cooler Temp Cal Analog Out Cal Analog Input Cal Display Pixel Test Restore User Defaults NIST Traceabil...

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Page 101: ... 4 Checkout system 2 4 Critical orifice pressure transducer 1 5 D Dilution gas pressure 1 5 E Equipment damage alerts ii F Firmware Model 80i flowchart C 2 Model 81i flowchart C 3 updating 2 11 Flange stack mounting overview 1 15 Flow diagram Model 80i 1 2 Model 81i 1 4 Model 82i 1 5 Model 83i 1 8 H Heated umbilical description 5 2 maintenance 5 3 Heater filter eductor 1 6 probe stinger 1 6 Help w...

Page 102: ...verview 1 6 system plumbing diagram Figure B 2 system plumbing diagram w oxidizer Figure B 3 terminal block wiring diagram Figure B 11 terminal block wiring diagram w oxidizer Figure B 14 Model 83i GC normal operational parameters 2 10 overview 1 10 plumbing system diagram Figure B 8 plumbing system diagram w oxidizer Figure B 9 system tubing interconnection Figure B 7 system wiring interconnectio...

Page 103: ...efault temperatures 2 2 initial parameter 2 6 initial service Table 2 6 parameter example Table 3 3 Shut down 2 10 Signals 4 20 mA 1 5 Solenoid probe 1 6 Stack mounting flange Figure 1 16 Start up 2 3 Sys Hg Span Concentration screen problem accessing 3 2 System checkout 2 4 list of reference drawings B 1 power up sequence 2 2 shut down prior to removal 2 10 T Temperatures default Table 2 2 Model ...

Page 104: ...3 UPLINK port connection cable 4 12 V Vacuum dilution module 1 5 Vacuum transducer 1 5 Valve solenoid status Table 1 3 Venting nitrogen generator 2 10 Venturi pressure transducer 1 5 W Warranty statement A 1 Z Zero air panel with nitrogen Figure 1 14 Zero air supply overview 1 14 Zero and calibration troubleshooting Table 4 7 Zero Span check set up Table 3 4 ...

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