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Introduction

System Overview

Thermo Fisher Scientific

Omni FTIR Multi Gas CEMS Instruction Manual

1-3

The Omni FTIR Multi Gas CEMS is a complete continuous emissions
monitoring system (CEMS) designed to extract a sample from a source and
deliver a hot/wet sample to the measurement instruments to determine
concentrations of various gases. This system utilizes a Fourier Transform
Infrared (FTIR) spectrometer to measure most gases.

Figure 1–2

shows the

major system components of a complete system.

Note

This manual is for use with the Omni FTIR Multi Gas CEMS

integrated by Thermo Fisher Scientific. Systems integrated by others will
vary from the information provided in this document.

▲

Figure 1–2.

Omni FTIR Multi Gas CEMS System Overview

System

Overview

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Summary of Contents for Omni FTIR Multi Gas CEMS

Page 1: ...Omni FTIR Multi Gas CEMS Instruction Manual Part Number 108004 00 11Apr2013...

Page 2: ...rms 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 For...

Page 3: ...ic has contracted with one or more recycling disposal companies in each EU Member State and this product should be disposed of or recycled through them Further information on Thermo Fisher Scientific...

Page 4: ...Thermo Fisher Scientific WEEE Compliance...

Page 5: ...ation process and procedures for calibrating the instrument Chapter 5 Preventive Maintenance and Servicing provides maintenance procedures to ensure reliable and consistent instrument operation and st...

Page 6: ...l Safety and Equipment Damage Alert Descriptions Alert Description DANGER A hazard is present that will result in death or serious personal injury if the warning is ignored WARNING A hazard is present...

Page 7: ...m each side of the analyzer not from the front and back Damage to the unit may occur Ethernet and serial Modbus can not be implemented at the same time Sample gas should not be introduced to the cell...

Page 8: ...tures could rise too quickly and damage those components Equipment Damage Some internal components can be damaged by small amounts of static electricity A properly grounded antistatic wrist strap must...

Page 9: ...aqi 1 866 282 0430 Toll Free 1 508 520 0430 International We continue to support our customers with advanced online resources Our Air Quality Instruments Online Library allows our customers access to...

Page 10: ...About This Manual Where to Get Help vi Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific...

Page 11: ...wer Requirements 1 8 Pneumatics 1 9 Cabinet 1 9 Other Manuals 1 10 System Installation Start Up and Shut Down 2 1 Lifting 2 1 Unpacking and Inspection 2 1 Site Requirements 2 2 Ambient Temperature Ins...

Page 12: ...10 Turn Power ON 2 10 Adjust Confirm Flow and Heat Settings 2 11 Air flow 2 11 Heat 2 12 IMACC 2 12 Autostart 2 12 Maintenance Switch 2 13 System Shut Down 2 14 Operation 3 1 Normal Operation 3 1 Sof...

Page 13: ...y Precautions 5 6 Cleaning the System 5 6 Maintenance for the Sample Probe 5 7 Replacing the Filter Element and Graphite Seals 5 7 Replacing the Pre filter 5 10 Maintenance and Servicing of the FTIR A...

Page 14: ...onents 5 76 Removing the Sample System Heater Assembly and Cover 5 76 Replacing the Thermostat 5 78 Replacing the Eductor Pump 5 79 Removing the Heated Block Assembly 5 82 Replacing the Check Valve 5...

Page 15: ...erface 7 12 Computer Interface 7 12 Humidity Control 7 12 Air Purifier 7 12 Industrial PC 7 13 I O Boards 7 14 Console 7 14 Datalogger 7 14 Electrical Panel Assembly 7 14 AC Power Input 7 15 Warranty...

Page 16: ...tate Relays SSR C 6 SSR Rail C 6 Calogix Setup D 1 Hardware Description D 1 Finding the Correct COM Port D 2 Setting the Virtual COM Port D 4 Programming the Controllers and Setting Parameters D 6 Cre...

Page 17: ...Figure 5 6 Removing the Right Side Panel 5 17 Figure 5 7 Removing the Source Assembly 5 17 Figure 5 8 Source Element is Inside Can Cut Out 5 18 Figure 5 9 Locating the Laser Assembly 5 20 Figure 5 10...

Page 18: ...meter of Omni FTIR CEMS 5 50 Figure 5 42 Cutting Insulation Paper at the Seam 5 52 Figure 5 43 Insulation Removal 5 53 Figure 5 44 Hose Clamp Removal 5 53 Figure 5 45 Heated Line Replacement 5 55 Figu...

Page 19: ...atic 7 8 Figure 7 7 Spectrometer Compartment 7 9 Figure 7 8 Major System Components 7 11 Figure 7 9 FTIR Purge Gas Generator 7 13 Figure 7 10 FTIR PC 7 13 Figure 7 11 Electrical Panel 7 15 Figure 7 12...

Page 20: ...Figures xvi Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific...

Page 21: ...Pneumatics 1 9 Table 1 6 Free Standing Cabinet 1 9 Table 3 1 Analog Current Channel Assignments 3 15 Table 4 1 Calibration Factors 4 20 Table 5 1 Replacement Parts List 5 3 Table B 1 Modbus Read Regis...

Page 22: ...Tables xviii Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific...

Page 23: ...nt provides high resolution line shapes superior long and short term stability and high speed high resolution data collection This combination of speed and performance provides a system capable of col...

Page 24: ...uction Manual Thermo Fisher Scientific For details see the following topics System Overview on page 1 3 Typical System Flow on page 1 6 System Power Distribution on page 1 6 Specifications on page 1 6...

Page 25: ...ement instruments to determine concentrations of various gases This system utilizes a Fourier Transform Infrared FTIR spectrometer to measure most gases Figure 1 2 shows the major system components of...

Page 26: ...ne and a 3 8 inch blowback line The sample line length may be from 33 feet 10 meters to 100 feet 30 5 meters The system includes a temperature control module which is used to control the temperatures...

Page 27: ...thers information from the FTIR and temperature controller and reports readings over analog and digital I O lines Ethernet and Serial Thermo Fisher Scientific OMNIC and Result software is used to cont...

Page 28: ...heck spike and check span in this FTIR CEMS system Each of them can be controlled either by the system operation software or by the user via PLC A detailed description is given in Chapter 7 System Com...

Page 29: ...0 10 0 0 003 Table 1 2 FTIR Performance Specifications Parameter Specification Linearity 2 of minimum measuring range Zero drift during period of unattended operation 3 of minimum measuring range Span...

Page 30: ...d concentration Digital Signals FTIR data valid Temperature alarm for sample probe heated lines sample conditioning assembly and FTIR cell Status measurement maintenance Gas mode inputs and outputs ch...

Page 31: ...densate 1 2 inch Instrument Air Total Consumption 75 l min 3 scfm Ejector Pump 12 0 l min Purge Air FTIR 1 0 l min Zero Air calibration FTIR 6 0 l min Flowback 6 0 l min Blowback 50 l min Table 1 6 Fr...

Page 32: ...wing manuals are currently available for the Omni FTIR Multi Gas CEMS system Antaris IGS User s Guide Result Software User s Guide M C Operating Instructions Gas Sample Probe Series SP Version SP2000...

Page 33: ...Connections on page 2 8 System Startup on page 2 10 System Shut Down on page 2 14 When lifting the analyzer use a procedure appropriate to lifting a large heavy object such as bending at the knees whi...

Page 34: ...nal elements or extreme process environments Ensure that the shelter enclosed space where Omni FTIR Mulit Gas CEMS operates has adequate air circulation Without adequate air circulation ambient air te...

Page 35: ...int is a single piece of foam wedged into the slot Be careful to not allow foam fragments to fall into the interferometer assembly Retain the shipping restraint for future use Replace the side panel L...

Page 36: ...op engaged Remove backing from loop side only and attach to bottom of FTIR power supply in 2 places widely spaced Remove screws and cover from FTIR shelf and set aside for reassembly later Pull FTIR s...

Page 37: ...to the Rack Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual 2 5 The following connections need to be made to the FTIR unit Purge Power Computer Pressure Cell heater and Sample lin...

Page 38: ...e corresponding quick release fitting on the lower edge of the FTIR chassis Figure 2 4 Figure 2 4 Connecting to the FTIR Unit The FTIR power supply is located inside the rear of the FTIR shelf Connect...

Page 39: ...ell s insulated jacket Polarity is not important Connect the RTD connector to the RTD probe mounted in the 1 8 inch Swagelok connector on the optical cell Connect the input and output of the FTIR abso...

Page 40: ...mperature control box Connect the sample line fitting to the port marked Heated Sample Line on the heated valve pump assembly Figure 2 5 Rear Panel Terminal Blocks Connect the sample line wiring to th...

Page 41: ...provided for the connection of separately controlled calibration gases marked Spike and Span Calibration gases connected to these ports are introduced into the system at the calibration port of the M...

Page 42: ...essure is applied to the system ensure that the system is in fail safe mode Disconnect the alarm connection from terminals 1 and 2 on rear terminal block X3 Figure 2 5 This will place the system in fa...

Page 43: ...set pressure according to test sheet for 4 lpm Normal range 1 0 3 0 bar 12 44 psi Purge air flow 1 0 l min Zero Air flow 6 0 l min Flowback Air flow 3 0 l min Probe Zero flow 6 0 l min Probe Span flo...

Page 44: ...180 C Heated line Outlet Temp 180 C The IMACC FSS software is preconfigured and starts automatically on computer power up Refer to Chapter 3 Operation for details on software operation For automatic...

Page 45: ...stem Startup Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual 2 13 Drag the shortcuts into the Startup folder Close the folder Turn the switch to the Measurement position to comple...

Page 46: ...ill switch the system to fail safe mode Wait 5 minutes to flush the complete system Close all Programs running on the PC Use the Startup menu of Windows to switch off the power on the PC Turn all othe...

Page 47: ...Grafix on page 3 13 CDM USB Driver on page 3 13 Data Server Software on page 3 13 In normal operation all software components of the Omni FTIR Multigas CEMS will be loaded in the Windows Startup menu...

Page 48: ...ware standpoint and expandable from a software standpoint Figure 3 1 Figure 3 1 Component Relational Diagram The Imacc FTIR Monitor is a user interface that displays the operational information and an...

Page 49: ...d with the layout View Script may be used while the monitor is running to observe the operation of the script Function blocks in the script will be highlighted as they are carried out Function blocks...

Page 50: ...text This control only works with a running FTIR It displays the most recent concentration values produced from analyzing the acquired spectrum Right clicking brings up the settings menu Settings Opti...

Page 51: ...ual 3 5 ProcessStatus is used to display various process parameters such as board temperature FTIR status percentage complete numbers of scans completed and pressure Settings Select Parameters Check t...

Page 52: ...lay settings The ConcentrationPlot is used to display concentration values over time on a strip chart Right clicking at the grey area of the plot displays a popup menu Choose settings from three tabs...

Page 53: ...roper timespan Timespan The time period over which data is displayed on the bottom graph in the concentration plot control Data outside of the range from the current time minus the timespan is automat...

Page 54: ...re where the displayed concentration values come from Server Directly from the ImaccServer The data are newly acquired from spectrum processing The computer must be connected to a running FTIR Directo...

Page 55: ...s to have a clean reference of the system s optical throughput so it can be compared to absorption caused by the sample gas C CONS Concentration data files are saved in the directory C CONS with the s...

Page 56: ...and can be launched by double clicking the ImaccServer icon The server is also launched automatically by various scripting components The ImaccServer icon appears in the system notify tray See diagra...

Page 57: ...Assembly as shown in the illustration OMNIC is the software that directly controls the FTIR spectrometer under the control of Imacc Monitor It can be manually launched from the Start menu in Windows...

Page 58: ...tem information and the bench align control can be accessed under the Collect menu Selecting Collect Experiment Setup displays a popup menu with the following tabs Collect Bench Quality Advanced Diagn...

Page 59: ...enable a virtual COM port for communication with the CALogix controllers The following data server software ImaccCurrentLoop ImaccModbus and ImaccModbusTCP can be loaded as needed to provide data outp...

Page 60: ...buttons to browse for the disk location of each file type to be used The Refresh Interval specifies the time in milliseconds between refreshes of the board s output The software examines each of the p...

Page 61: ...r voltage or current modes The current channels are ICH16 through ICH31 To have a live zero the output range has to be set to 0 20 mA Table 3 1 Analog Current Channel Assignments Compound Channel Sulp...

Page 62: ...columns will cause pull down menus of the permissible entries to be displayed Click on the desired entry to select it When a new concentration file is created it will contain nothing but the header re...

Page 63: ...It is necessary that a data file already exists in order to be able to perform this step Click the down arrow in the compound field to select a parameter to be transmitted Click the down arrow in the...

Page 64: ...terval at which the Modbus COM port is scanned for instructions Response Delay Delay in sending the response used in case of timing problems The AutoStart checkbox needs to be selected to cause Modbus...

Page 65: ...4 3 External Audit Gas Procedure on page 4 3 Calibration Gases on page 4 4 Manual Background Spectrum Collection Procedure on page 4 5 Manual Background Spectrum Collection using Thermo Modbus Control...

Page 66: ...ary filter In this way deviations in zero drift and or precision of the measuring system can be detected recorded either by system computer or data logger Adjustments of the zero value by the operator...

Page 67: ...ht next to system zero rotameter on the pneumatic control panel shown in Figure 4 1 The system has an option for the operator to perform system dynamic spiking by triggering the system dynamic solenoi...

Page 68: ...d Relatively NH3 has a faster response time than HCl so a shorter duration for the NH3 daily calibration check can be chosen In this case the NH3 gas cylinder will last much longer than the HCl cylind...

Page 69: ...R Multi Gas CEMS Instruction Manual 4 5 When running IMACC Monitor press Stop Script and press OK go to tab OMNIC In OMNIC select Exp Set tab Collect and set the following No of scans 30 Resolution 0...

Page 70: ...nual Thermo Fisher Scientific Select tab Bench verify or set the following Max range limit 4500 Min range limit 400 Gain 1 0 Velocity 0 3165 Aperture 15 Press OK Then go to Col Smp Collect Sample Set...

Page 71: ...n Procedure Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual 4 7 Make sure the system is flushed with zero air wait 5 min then press OK again The system will now collect 30 scans w...

Page 72: ...Gas CEMS Instruction Manual Thermo Fisher Scientific Select tab Process and select Reprocess Verify or set the following Resolution 0 5 Apodization Happ Genzel Phase correction Mertz Zero filling None...

Page 73: ...ientific Omni FTIR Multi Gas CEMS Instruction Manual 4 9 Select tab File and select Save As Go to directory BKGS and press Set Filename to Title Go to tab My Documents If not opened yet then open it w...

Page 74: ...ves are energized Zero air flows into the gas cell while the sample valve is closed and the flow back valve is open Let the system run in this mode for at least 10 minutes so that the concentrations f...

Page 75: ...on config button of Spectrometer Control Click the Collect tab to display the method and background used for the calibration factors Verify or set the following Background C backgrounds bkg spa Metho...

Page 76: ...l Thermo Fisher Scientific Click tab Bench to display bench parameters Verify or set the following Bench Parameters Enabled Pathlength 5 209 Source IR Aperture 15 0 Velocity 0 2659 Gain 4 0 Resolution...

Page 77: ...data IEEE float Code CellTemp Register 0x0a20 COM Port 6 Parity None Baud 9600 Stopbits 1 Databits 8 Flow Control None Press OK to close ModbusMultiSensor Settings box Click on the button of Pressure...

Page 78: ...le Collect button to verify that the system is operating properly Switch to calibration tab Click on the open tab to open Method C Methods omni Press map to check that all compounds are listed If not...

Page 79: ...lect the compound to be calibrated in this case N2O and set the value of the calibration gas in the Spike Value ppm box Set the following Scan Time MM SS 01 00 Averaging Count 3 Press GO Upon completi...

Page 80: ...ny changes to the loaded ftir_calibrate collect file press save The calibration procedure can be repeated to verify that the span factor has been corrected without saving changes again The reading sho...

Page 81: ...ibration System Calibration Procedure Using IMACC Collect Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual 4 17 When pressing Start Script the new zero air background will now be u...

Page 82: ...ct calibration factors for each gas Click All Programs on Windows and locate the IMACC FTIR software suite Move the cursor to Tools and open IMACCquantify Click the Open tab to locate the method in th...

Page 83: ...rming the system calibration connect the certified gas cylinder to the port labeled as Span Check on the right side panel of the system You can also directly connect the gas cylinder to the FTIR gas c...

Page 84: ...50 ppm SO2_dry 0 to 350 ppm 13 NO2_wet 0 to 60 ppm 1 NO_wet 10 500 ppm 1 CO_HI 57 to 766 ppm N2O 0 to 50 ppm SO2_Hi 0 to 350 ppm HCl_Lo 0 to 13 ppm HCl_Hi 15 to 100 ppm H2O_LO 5 to 40 2 HF_dry 0 to 1...

Page 85: ...Precautions on page 5 6 Cleaning the System on page 5 6 Maintenance for the Sample Probe on page 5 7 Maintenance and Servicing of the FTIR Analyzer Components on page 5 11 Replacing the Air Filters o...

Page 86: ...ti Gas CEMS Instruction Manual Thermo Fisher Scientific Replacing the National Instruments Boards on page 5 59 Temperature Control Box Components on page 5 62 Electrical Panel Components on page 5 71...

Page 87: ...hs Sample Probe Stinger PID Controller 113319 00 Sample Probe Pre Filter Element 25 micron Coated SS ext screw 113321 00 1 year Sample Probe Heated Stinger Assembly 1 0M 113335 00 Sample Probe Filter...

Page 88: ...s FTIR Desiccant packages and humidity label 113312 00 FTIR Desiccant package 106975 00 1 year FTIR Humidity Indicator 113313 00 2 years FTIR IGS HeNe Laser Assembly 106963 00 FTIR IGS Source Assembly...

Page 89: ...onductor 2M 110039 00 Cable NI Digital I O 100 Conductor 2M 112496 00 Pneumatic Panel Part Number Replacement Period Pneumatic Panel Assembly 2 Gauge 112689 02 Assembly Replacement Pressure Reducer 11...

Page 90: ...tem During normal operation the system may become dirty over time depending on the environment in which it is installed The system may be cleaned keeping in mind the following warning and important no...

Page 91: ...on of aggressive components of the process gas This can best be accomplished by performing a probe zero Important Note For any sample probe service procedures that are not covered in this manual pleas...

Page 92: ...set it aside 4 Turn the T handle approximately 1 turn counterclockwise Loosen the small bar handle behind it enough to flip the retaining clamp out of the way Grasp the T handle and firmly pull the f...

Page 93: ...See Figure 5 2 for the correct order of installation Thread on the knurled filter lock screw and tighten until snug 9 Before re installing the filter housing lid assembly the filter housing itself ca...

Page 94: ...s 2 Shut down the probe by turning off the Probe circuit breaker on the breaker box 3 Using the 15 16 inch wrench loosen and remove the 4 flange nuts and washers that secure the probe assembly to the...

Page 95: ...ically to keep the analyzer running efficiently Service procedures are performed to replace a failing component in the analyzer WARNING Perform only those procedures on the analyzer described in this...

Page 96: ...is pink the desiccant and the humidity indicator need to be replaced Figure 5 3 For more information see Replacing the Humidity Indicator Figure 5 3 Locating the humidity Indicator 3 Shut down the FTI...

Page 97: ...alyzer to avoid damaging them 7 Power up the FTIR analyzer by turning on the FTIR circuit breaker on the breaker box 8 Slide the FTIR drawer back into the rack then use the Phillips screwdriver to re...

Page 98: ...stall the FTIR cover panel and its mounting screws to complete the procedure The cooling fan on the FTIR analyzer ensures that the electronics are not damaged by high temperatures The filter prevents...

Page 99: ...complete the procedure The information that follows describes several hardware replacement procedures for internal components of the FTIR analyzer These procedures include replacing the source and the...

Page 100: ...he ceramic base Equipment Damage Some internal components can be damaged by small amounts of static electricity A properly grounded antistatic wrist strap must be worn while handling any internal comp...

Page 101: ...move the right side panel by removing the 6 mounting screws Slide the panel toward the front of the analyzer to clear the rear support bracket Be careful to support the panel as it drops free of the a...

Page 102: ...otate the clamp bar 90 degrees clockwise and then tighten the thumbscrew until snug to secure the source to the analyzer base plate 9 Connect the source power supply cable to the power distribution ca...

Page 103: ...em operator can replace the laser however it is recommended that only our certified service engineers or on site maintenance personnel who have been trained by us replace the laser Whenever the analyz...

Page 104: ...the 3 32 inch hex wrench remove the analyzer rear panel by removing the 4 mounting screws Be careful to support the panel as it drops free of the analyzer when all of the screws are removed Be careful...

Page 105: ...gure 5 11 Figure 5 11 Removing the Laser Assembly 8 Install the new laser assembly by positioning it with the power cable on the right Lower it onto the mounting brackets so that the alignment pin on...

Page 106: ...14 Power up the FTIR analyzer and heaters by turning on the FTIR circuit breaker and the Temperature Control circuit breaker on the breaker box 15 If the new laser is working properly the laser indic...

Page 107: ...alyzer 2 Shut down the FTIR analyzer by turning off the FTIR circuit breaker on the breaker box Be careful not to touch the gas cell which is extremely hot 3 Using the 3 32 inch hex wrench remove the...

Page 108: ...t blade screwdriver remove the detector access plate The switch is located two thirds of the way up on the right hand side of the PC board Figure 5 13 The settings are as follows SW2 Switch 1 OFF Swit...

Page 109: ...Vmax in IMACC monitor refer to Chapter 3 Operation Vmax should be greater than 4 volts Use the following procedure to replace the beamsplitter in the FTIR analyzer The beamsplitter is located undernea...

Page 110: ...R circuit breaker and the Temperature Control circuit breaker on the breaker box Allow it to cool for 1 hour This will put the system in fail safe mode so that it will not be sampling stack gas 2 Usin...

Page 111: ...ngs at the rear of the unit Note or mark their position to facilitate re connection 7 Using the Phillips screwdriver remove the 20 screws that mount the cover on the coupling optics and then remove th...

Page 112: ...dle and lift it out of the analyzer Figure 5 17 Figure 5 17 Removing the Beamsplitter 11 Grasp the new beamsplitter by the handle with the label facing you Again use the flat blade screwdriver to pry...

Page 113: ...air and looking at the maximum peak voltage Vmax in IMACC monitor refer to Chapter 3 Operation Vmax should be greater than 4 volts Use the following procedure to replace the filters in the filter brac...

Page 114: ...ilter Cap 3 Grasp the filter element then turn it to the left until it unscrews from the threaded rod Figure 5 20 Properly dispose of the spent filter element Figure 5 20 Unscrewing Filter Element 4 T...

Page 115: ...ir is off There is a desiccant pack inside the FTIR but if it will be off the purge air for more than a few hours an alternative source of purge air should be connected Use the following procedure to...

Page 116: ...ch on the purge gas generator and disconnect the power cable Figure 5 22 3 Using the 9 16 inch wrench loosen the nut and remove the inlet tubing to the purge gas generator Figure 5 22 4 Using the 9 16...

Page 117: ...is a desiccant pack inside the FTIR but if it will be off the purge air for more than a few hours an alternative source of purge air should be connected Use the following procedure to remove the side...

Page 118: ...rewdriver Small Phillips screwdriver CAUTION High surface temperatures present Allow sufficient time to cool 1 Shut down the FTIR and heaters by turning off the FTIR circuit breaker and the Temperatur...

Page 119: ...g the FTIR Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual 5 35 Figure 5 25 Remove Screws and Two Lowest Panels 4 Slide the FTIR drawer out of the system to access the rear of the...

Page 120: ...ground wire from the rear plate of the cell assembly Disconnect the 2 blue connectors for the heaters at the rear of the unit by carefully pulling them apart Figure 5 27 10 Disconnect the temperature...

Page 121: ...g Connections 13 Using the 7 16 inch wrench disconnect the 2 nuts and washers from each of the 4 rubber mounts that hold the FTIR to its base Figure 5 28 Figure 5 28 Rubber Mount Nut Removal 14 Using...

Page 122: ...If shipping the FTIR place the unit in the original plastic bag with a few dessicant bags and seal it Refer to the tag on the left side of the FTIR that says to change desiccant when pink Use the foll...

Page 123: ...present Allow sufficient time to cool 1 Shut down the FTIR heaters by turning off the Temperature Control circuit breaker on the breaker box and allow it to cool for 1 hour This will also put the sys...

Page 124: ...gh the supplied fitting nut and ferrules Position the ferrules the same as they are on the old sensor 8 Insert the sensor into the fitting and thread the nut on loosely Push the sensor in as far as it...

Page 125: ...FTIR heaters by turning off the Temperature Control circuit breaker on the breaker box and allow it to cool for 1 hour This will put the system in fail safe mode so that it will not be sampling stack...

Page 126: ...ely the same orientation as it was before 7 Re install the cable assembly by pressing it onto the 4 tabs on the sensor Note that 1 tab is wider than the other 3 so that it can only be installed one wa...

Page 127: ...IR cover panel in the front of the system and the blank panel above it 4 Slide the FTIR drawer out of the system to access the rear of the unit 5 Note or mark the position of wiring and fittings to fa...

Page 128: ...r Do not reconnect the pressure sensor temperature sensor heated lines ground wire or heater connector until the gas cell alignment procedure is complete Do not turn on the Temperature Control circuit...

Page 129: ...improper alignment which will affect the performance of the system 1 Be sure that the FTIR heaters are still off from the Replacing the Gas Cell procedure that is the Temperature Control circuit break...

Page 130: ...ment using a source and beamsplitter replace the source and beamsplitter with a white light source and quartz beamsplitter in the FTIR optical bench For field service a visible laser module set depict...

Page 131: ...ger screws Figure 5 37 Beam Image on the First Objective Mirror in the Multi pass Gas Cell 7 Adjust the 45 degree mirror 3 to get the first beam image centered on the first objective mirror Figure 5 3...

Page 132: ...tive mirror use the 9 64 inch hax wrench to turn the adjustment screws Input Adjust horizontal and Input Adjust vertical located behind the gas cell back plate fitting plate Note that the plate was re...

Page 133: ...int be adjusted for minimum pass Turn the pass adjustment screw horizontal adjustment of the second objective mirror clockwise to increase the number of passes Observe the two rows of images that appe...

Page 134: ...gas cell with the input window on the left and the output window on the right 12 Once the desired image pattern shown in Figure 5 40 is obtained and the exit image is clearly positioned on the output...

Page 135: ...pter for more information Turn the Temperature Control circuit breaker on and allow the system to come up to temperature CAUTION High surface temperatures present Allow sufficient time to cool 14 For...

Page 136: ...by turning off the Temperature Control circuit breaker on the breaker box and allow it to cool for 1 hour This will put the system in fail safe mode so that it will not be sampling stack gas 2 Remove...

Page 137: ...hen remove the heater Figure 5 44 Note the orientation of the heater and the wires Figure 5 44 Hose Clamp Removal 6 Place the new heater onto the gas cell in the same orientation as the removed heater...

Page 138: ...k gas 2 Remove the rack left side panel per procedure Removing the Left Side Panel for better accessibility optional step 3 Using the Phillips screwdriver remove the FTIR cover panel in the front of t...

Page 139: ...system heater assembly located at the back of the system rack The 5 8 inch wrench may be used to keep the bulkhead mounting nuts secure against the heater box Figure 5 45 Again note their position to...

Page 140: ...f the PC console to the Release position Slide the PC and console out to gain access to PC cables 4 Disconnect the 9 cables from the rear of the PC Figure 5 46 Note or mark the location of each to fac...

Page 141: ...locks in place still outside of the rack Figure 5 46 11 Re attach the cable routing arm to the bracket on the rear of the PC by lining up the holes and inserting the pin that was removed earlier 12 R...

Page 142: ...PC console out of the rack from the front Once it is part of the way out it is helpful to press the side tabs and compress the console as it would be when inside the system 6 Before installing the new...

Page 143: ...stall the blank panel that was previously removed above the PC console 12 Slide the Release lever on the front of the PC console back to the Lock position Turn on the PC Console circuit breaker on the...

Page 144: ...e PC from the FTIR rack by following the procedure Replacing the PC but do not remove the slide rails from the sides of the PC 3 Using the Phillips screwdriver remove the 5 screws holding the computer...

Page 145: ...n the PC and rotate it up to access the NI boards being careful not to pull out any cables Figure 5 51 Figure 5 51 Positioning the Card Cage 6 Using the Phillips screwdriver remove the mounting screw...

Page 146: ...the PC cover and install the 5 mounting screws using the Phillips screwdriver 10 Re install the PC back into the rack by following the procedure Replacing the PC 11 Turn on the PC Console circuit brea...

Page 147: ...ccessibility 3 Using the Phillips screwdriver remove the 4 front screws that secure the temperature control box to the rack Slide the temperature control box out the front of the rack so that it is fu...

Page 148: ...damaged by small amounts of static electricity A properly grounded antistatic wrist strap must be worn while handling any internal component If an antistatic wrist strap is not available be sure to to...

Page 149: ...Temperature Control circuit breaker on the breaker box to complete the procedure Use the following procedure to replace any of the internal fuses in the temperature control box Equipment Required Phi...

Page 150: ...th the 2 mating holes in the connector and push the fuse in all the way until flush Note that there is no polarity on the fuses 4 Re install the temperature control box cover per the above procedure R...

Page 151: ...e connection Disconnect all of those cables from the board Figure 5 55 3 Using the Phillips screwdriver remove the 2 mounting screws located on the center of the long edges of the board 4 Note the ori...

Page 152: ...alling the Cover 2 Using your fingers pop the end covers of the relay up to access the screws 3 Using the flat blade screwdriver loosen the 2 screws on the relay side that does not have the varistors...

Page 153: ...procedure Removing and Installing the Cover Use the following procedure to replace any of the 4 temperature control modules inside of the FTIR temperature control box Note that not all of the modules...

Page 154: ...al block connectors in the front and rear of the new module in the appropriate position until they snap into place 7 Place the control module and base unit assembly onto the threaded studs in the corr...

Page 155: ...l the two connectors off of the front of the temperature control base unit noting their location to facilitate reconnection 6 Slide the din rail out of the bottom of the base unit to remove it 7 Slide...

Page 156: ...ervicing Electrical Panel Components 5 72 Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific Figure 5 56 Electrical Panel Component Location Front Side Figure 5 57 Electrical Panel C...

Page 157: ...the switch Ports 1 3 and then move the green ground wire out of the cable routing strip 2 Using the Phillips screwdriver loosen but do not remove the two mounting screws securing the Ethernet switch...

Page 158: ...crews Slide the panel slightly to the left to free it 4 Carefully turn the electrical panel around to access the rear components being careful not to pull any of the wires out or damage any of the com...

Page 159: ...ack near the electrical panel 3 Using the Phillips screwdriver detach the electrical panel by loosening the right 2 mounting screws and removing the left 2 mounting screws Slide the panel slightly to...

Page 160: ...2 inch and 5 8 inch Wire cutters Tie wraps zip ties CAUTION High surface temperatures present Allow sufficient time to cool 1 Shut off the Temperature Control circuit breaker on the breaker box and a...

Page 161: ...8 inch wrench may be used to keep the bulkhead nuts against the sample system heater assembly from turning for FTIR In and FTIR Out Note the location of each line to facilitate reconnection To fully d...

Page 162: ...0 Pull the pieces of insulation off to gain access to the internal hardware Note the placement of the insulation and wiring to facilitate re assembly 11 To re install the cover carefully place the ins...

Page 163: ...all the new thermostat by mounting it to the plate with the mounting screws using the Phillips screwdriver 5 Re install the sample system heater assembly cover by referring to procedure Removing the S...

Page 164: ...pump cover by removing the 5 mounting screws that secure it to the heater block Figure 5 59 Figure 5 59 Sample System Heater Assembly Component Replacement and Heated Block Removal 4 Using the 9 64 i...

Page 165: ...ctor Exhaust On the right side of the system disconnect the inlet air line of the purge gas generator from the tee fitting and connect the 6 foot piece of PTFE or PFA tubing to the tee to create a lon...

Page 166: ...t and right side pieces of insulation that are tucked against the inner walls of the box Note how they are installed for re installation later 3 Using the 5 8 inch wrench loosen the nuts that secure t...

Page 167: ...Required Phillips screwdriver Wrench 5 8 inch 2 9 16 inch and 1 2 inch Hex wrench 3 16 inch and 9 64 inch Wire Cutters Tie Wraps zip ties 1 4 inch Swagelok union fittings Plugs for 1 4 inch Swagelok t...

Page 168: ...h loosen the brass nut that attaches the copper tubing to the inlet of the check valve and disconnect that tubing 6 Using the 9 16 inch wrench and the 5 8 inch wrench loosen the stainless steel nut an...

Page 169: ...inch Swagelok union fitting and install that onto the Sample In line Turn the air regulator up to 25 PSI Using the liquid leak detector wet the connection between the check valve and the copper tubin...

Page 170: ...FA tubing with 1 4 inch nuts and ferrules attached Sample solenoid valve CAUTION High surface temperatures present Allow sufficient time to cool 1 Remove the sample system heater assembly and its cove...

Page 171: ...the adjacent side of the heated block from the check valve and disconnect that tubing Figure 5 60 7 Turn the heated block assembly back around to access the front of the assembly 8 Using the 9 64 inc...

Page 172: ...every connection on the check valve side of the solenoid valve to see if there are any leaks which will produce air bubbles If any are present tighten the fitting until the leaking stops Turn the air...

Page 173: ...e In line 20 To leak test the other side of the union fitting that connects to the copper tubing disconnect the air line with the 1 4 inch Swagelok union fitting from the Flowback line using the wrenc...

Page 174: ...edure to replace the pressure reducers on the pneumatic panel The procedure is the same for either pressure reducer Equipment Required Wrench 9 16 inch Adjustable wrench with a 1 1 8 inch minimum open...

Page 175: ...the panel 6 Remove the nuts and ferrules from the 3 fittings on the new pressure reducer and discard them 7 Insert the new pressure reducer into the panel from the rear and thread on the panel nut Po...

Page 176: ...ning it in the same orientation as the other gauge At the rear of the panel slide the mounting bracket over the threaded studs and thread the wing nuts onto the studs Tighten the wing nuts with your f...

Page 177: ...solenoids are being replaced note the pressure on the house air regulator located on the right side of the system so that it can be reset later Pull up on the knob to unlock it and turn the pressure d...

Page 178: ...d one way 9 Install the new solenoid valve onto the valve plate using the 4 screws removed previously and tighten until snug Make sure that the solenoid valve is in the same orientation as the other v...

Page 179: ...igure 5 18 3 The components are accessed from the rear of the pneumatic panel Using the 9 16 inch wrench loosen the nut and remove the tubing from the top and bottom fittings on the flow meter Note th...

Page 180: ...aced the corresponding solenoid valve must be activated to be able set the flow rate If a DCS is used to control the FTIR system it can be used to activate the solenoid valve Once activated turn the k...

Page 181: ...97 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 o...

Page 182: ......

Page 183: ...Thermo Fisher Scientific can also be consulted in the event of problems See Service Locations at the end of this chapter for contact information In any correspondence with the factory please note both...

Page 184: ...r 2 hour ramp up Internal Heated Lines if installed 180 Deg C LED indicators on FTIR Power should be on continuously if not check circuit breaker and power supply Laser should be on continuously if no...

Page 185: ...st Temperature screen readout in Status on IMACC monitor software main screen see Temperature Errors Improper cell pressure reading Check Last Pressure screen readout in Status on Imacc monitor softwa...

Page 186: ...rt automatically Verify the following programs are in the setup Omni layout ImaccCurrentLoop ImaccModbus ImaccModbusTCP See System Startup in Chapter 2 Bad temperature readings Either in Status or in...

Page 187: ...ken temperature sensor see Chapter 7 System Component Description and check terminals 5 6 of heater cable High temperature Calogix controller error see Appendix D Calogix Setup Broken temperature sens...

Page 188: ...software main screen reads 750 000000 Check virtual com port number See Appendix D Calogix Setup Check USB connection between PC and temperature controller Stop and re start script in ImaccMonitor Ex...

Page 189: ...ted for one or more gases Check ImaccCurrentLoop server value and outputs mA readings If value doesn t look correct see Concentration Errors Otherwise if output mA doesn t look correct check the chann...

Page 190: ...eaker board to NI PCI 6709 board inside PC Maintenance digital output is not reporting the expected mode Check the key switch position The vertical position is maintenance mode and voltage should be c...

Page 191: ...ribes the function of the system components per the following Sample Probe on page 7 2 Temperature Controller on page 7 3 Heated Sample Line on page 7 3 Heated Pump Valve Assembly on page 7 4 Hydrator...

Page 192: ...to 200 C This ensures reliable operation external to the process preventing the temperature falling below the dew point The housing design offers little or no dead volume external to the process Also...

Page 193: ...pump valve assembly Heated sample lines In addition the FTIR cell pressure is measured with this controller A USB connection is included to report the system temperatures and pressure to the PC The h...

Page 194: ...en up the sample line to the probe which is known as the flowback mode The pre heaters ensure that the normally cold zero air won t cool down the sample line and FTIR cell in this mode When the sample...

Page 195: ...ugh the pre filter Depending on the particulate loading in the tested stack the blowback can be executed multiple times per day During the instrument background scan and flowback mode the sample contr...

Page 196: ...tem is configured for sample mode with the probe spike valve open for dynamic spiking operation The spike gas flows into the stinger via the cal zero port at a reduced rate typically not more than 10...

Page 197: ...e intensity of absorption is related to the concentration of the component After the data collection method is calibrated which establishes how concentration changes affect absorbance changes the abso...

Page 198: ...Detector Interferometer ADC Single beam spectrum Interferogram FT Figure 7 6 FTIR Flow Schematic The cosine waves produced by the source and modulated by the interferometer appear to the detector as...

Page 199: ...of the sample Figure 7 6 shows the infrared beam path and data processing steps The major system components provide the basic system functionality for the instrument The spectrometer compartment provi...

Page 200: ...water from the air so the FTIR instrument must be continuously purged to remove water The FTIR analyzer uses a helium neon He Ne laser equipped with a neutral density filter to help reduce power and...

Page 201: ...The standard gas cell is a general purpose low pressure gas cell designed to be used with a variety of sample gases and sampling environments This gas cell is suitable for use in both ambient and elev...

Page 202: ...path An optical interface to allow the infrared beam to pass between the analyzer and the gas cell sample beam path An electrical interface used by the software to control the gas cell temperature wit...

Page 203: ...troller optional FID and report this data The PC provides several methods for establishing data communication with a DCS PLC including Modbus protocol RS 232 Serial or Ethernet Analog output connectio...

Page 204: ...touchpad is also included in the system to facilitate user input at the system The display is a 9U 19 TFT high brightness industrial LCD monitor An optional data logger may be used to Capture user se...

Page 205: ...ect the PC to an external network All of the internal system connections to the valves and hydrator are made to the inside face of this panel An electrical box is mounted to the ceiling of the rack Fi...

Page 206: ......

Page 207: ...Return 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 Produc...

Page 208: ...all pay Seller 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 PERFORME...

Page 209: ...serve as a slave on a Modbus network It transmits data archived in the ASCII concentration data files to the Modbus master in response to an F03 Read Holding Register command ImaccModbus uses two Modb...

Page 210: ...delay 10 mS and response delay 0 mS are user programmable The Modbus TCP protocol is supported using the ImaccModbusTCP server The register definition is the same as for the serial interface TCP conne...

Page 211: ...ssion The error check is a two byte 16 bit CRC value This section describes the various function codes that are supported by the Omni FTIR Multi Gas CEMS Read Holding Input Registers reads the measure...

Page 212: ...ple of a request and response to read registers 9 12 Request Field Name Hex Function 0x03 Starting Address Hi 0x00 Starting Address Lo 0x08 No of Registers Hi 0x00 No of Registers Lo 0x04 Response Fie...

Page 213: ...on your Modbus master to ensure that it matches the register number on the instrument Note For additional information on how to read registers and interpret the data refer to the 0x03 Read Holding Reg...

Page 214: ...ODE SAVE BACKGROUND This mode is the combination of mode 3 and mode 4 After flowing the zero air into the gas cell for five minutes the FTIR starts to collect zero air spectrum and then saves the spec...

Page 215: ...us Protocol Modbus Parameters Supported Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual B 7 Table B 4 System Flag Bits Value Description 0x00000000 Data Valid 0x00000001 Data Inva...

Page 216: ......

Page 217: ...Multi Gas CEMS see the following topics Introduction on page C 1 Connecting a DCS PLC to the Omni FTIR Multi Gas CEMS on page C 2 Establishing Communications on page C 3 Typical communications functi...

Page 218: ...o Figure C 1 and the Installation chapter For Modbus over Ethernet use TCP port 502 by default user selectable The terminal block shown in Figure C 1 provides a convenient way to connect devices to th...

Page 219: ...dual outputs with the positive side on the right and the return side on the left The positive side terminal includes a disconnect feature so that externally connected components may be disconnected fr...

Page 220: ...igital inputs are on pins 2 6 The inputs are 5V TTL signals with a max range of 0 5 to 5 5 VDC a low threshold of 0 8 VDC and a high threshold of 2 0 VDC Pins 7 28 support digital output functionality...

Page 221: ...ode Input Check Spike 4 4 Gas Mode Input Check Zero 5 5 Gas Mode Input Bkg Flowback 6 6 Gas Mode Input Blowback 7 7 8 Gas Mode Output Check Span 8 9 10 Gas Mode Output Check Spike 9 11 12 Gas Mode Out...

Page 222: ...re mounted on a DIN rail on the interior of the electrical panel Figure C 4 Figure C 4 SSR Rail The SSR panel located in the interior of the system may be observed during maintenance or troubleshootin...

Page 223: ...D 4 Programming the Controllers and Setting Parameters on page D 6 The pressure and temperature controller hardware is located in a 2U chassis located in the rack It consists of four 2 channel contro...

Page 224: ...ith a virtual COM port The system computer assigns the virtual COM port to communicate with the controller It is necessary to determine the virtual COM port number assigned to the USB COM port control...

Page 225: ...Calogix Setup Finding the Correct COM Port Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual D 3 3 Select the Hardware tab in System Properties 4 Select Device Manager...

Page 226: ...s COM LPT Find USB Serial Port COMn where n is the number of the com port here it is 6 6 Close Control panel without making any changes Use the following procedure to set the virtual COM port 1 Open C...

Page 227: ...etup Setting the Virtual COM Port Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual D 5 3 Click Browse in the Select Devices popup menu 4 Select the correct number for the COM port...

Page 228: ...ues and parameters in the CALogix controllers These settings are pre configured into the system at the factory but may need to be set if a module is replaced CAUTION The following procedures must be f...

Page 229: ...here on the CALogix window Select Edit Programs from the pop up menu 2 Select the Module 1 tab Enter Segment 1 Segment type RAMP Ramp rate 90 Target Setpoint 185 Holdback band 0 EOP Status None Enter...

Page 230: ...Segment 2 Segment type SOAK Soak time Continuous EOP Status None 4 Select the Module 3 tab Enter Segment 1 Segment type RAMP Ramp rate 90 Target Setpoint 185 Holdback band 0 EOP Status None Enter Seg...

Page 231: ...the following procedure to input controller values 1 Right click anywhere on the CALogix window Select Properties from the pop up menu and then select each module in turn to enter values for it 2 Once...

Page 232: ...RTD 2 wire RTD 2 wire Custom Sensor Channel 2 Setpoint Upper Limit 200 200 200 1000 Channel 2 Setpoint Lower Limit 0 0 0 0 Channel 2 Span Offset 0 0 0 527 17 Channel 2 Zero Offset 0 0 0 69 Output sett...

Page 233: ...PID PID PID PARK Alarm Control Input Mode Channel 1 Channel 1 Channel 1 Channel 1 Operating Mode BAND BAND BAND None Mode OnOff OnOff OnOff PARK Subsidiary Mode None None None None Setpoint 10 10 10 0...

Page 234: ......

Page 235: ...ch all scheduled events are triggered by users via PLC All scripts are saved in the same directory of c scrips Script setting for CEMS_SampleMode Users can open the script CEMS_samplemode either using...

Page 236: ...ription assigns the corresponding National Instrument Board channels to control the solenoid valve operation Pattern takes hex number to trigger all related channels In this case this setting is to tr...

Page 237: ...g block to Measurement Channel Mapping There are six rows of register information including measurement data type code name register address and a check box for writing to con file Highlight the targe...

Page 238: ...optical bench or interferometer Double click the setting block named Collect EZ setup to set its setting subpanel to pop up as shown On the top there are six named function buttons The setting panel i...

Page 239: ...ated The gain value is selected using the pull down menu Another approach to boost the IR source intensity is to adjust the velocity of the interferometer moving mirror As indicated right menu panel t...

Page 240: ...offset value and click the OK button to save it The zero offset corrected output results will be saved as HCl_offset in the con file Schedule setting for auto zero background collection By default the...

Page 241: ...t time is added into the box with a format of HH MM SS which is editable to the expected schedule To perform additional auto background spectrum collection just click the add button and follow the sam...

Page 242: ...ve All the setting should be the same except for the scan time and the background spectrum file In this case the scan time is 3 minutes and 10 seconds Users are not recommended to make any adjustment...

Page 243: ...ration setting are included in the same green block Click the left top corner labeled ifTimeCondition equal to so the schedule setting block pops up As seen in the pull down manual there is a list of...

Page 244: ...he same procedure is repeated for two more times before switching back to the normal sample mode setting Script Setting for Modbus Version Script For the Modbus version script all commands are set or...

Page 245: ...tting blocks on the left and are named Calc_2 and Calc_4 System Alarm Setting This setting is included in the first container block inside the while statement loop The calc_8 setting is the definition...

Page 246: ...expression as indicated Script setting for system command and status This setting is included in the second container as shown There are three script setting blocks and one calculation block The firs...

Page 247: ...s Protocol Each mode involves a couple of valve operations Follow the similar procedure as described in the section of CEMS_samplemode to set the valve control setting For instance to configure the bl...

Page 248: ...ix parameters in the register They are sample line temperature short sample line inlet temperature educator pump temperature gas cell temperature gas cell pressure and short sample line outlet tempera...

Page 249: ...alogix setting Click the serial button on the top so its setting block pops up as shown This setting is the same for all six parameters Collect EZ setting for running FTIR interferometer The spectrum...

Page 250: ...block in the script setting At the end of the script loop all the measured data and parameters should be saved to the cons files in the hard drive As indicated this setting frame includes two setting...

Page 251: ...tion problems The web server technique allows the user to run Internet Explorer IE or a user generated software on a remote computer and retrieve real time concentration data The file appears in the I...

Page 252: ...file inetmgr exe and move the shortcut into the Startup folder referred to in Step 1 4 Close Explorer IIS will now autostart whenever Windows opens Configuration of IIS for Data Transfer FTIR Computer...

Page 253: ...4 Internet Explorer will return the concentration file 5 The extraction and use of the data returned by IE is the responsibility of the individual user However the use of IE for data transfer is not n...

Page 254: ...made password protected by the following series of steps 1 In the IIS management window right click on FTIR Data and click Properties 2 Click the Directory Security tab and the Edit button 3 Uncheck A...

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