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Gasmet Alnab CMM, Инструкция по установке и эксплуатации

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CMM USER'S MANUAL (E2.51)

10

1

GASMET CMM OVERVIEW

1.1  Basic structure

The Gasmet CMM is designed for continuous total mercury (atomic mercury Hg

0

 and oxidized Hg

2+

,

HgCl

2

)  monitoring  and  the  measurement  is  based  on  Cold  Vapor  Atomic  Fluorescence  (CVAF).

Integrated high temperature dry thermal converter converts all Hg compounds to atomic mercury.

The  Gasmet CMM is  designed for  on-line measurements. It measures hot, wet  and  corrosive  gas
streams. All sample wetted parts of the Gasmet CMM are heated up to 180 °C.

The Gasmet CMM consists of the Gasmet CVAF mercury analyzer, the Gasmet test gas generator for
atomic mercury and mercury chloride, and the Gasmet Hg dilution probe (

Error! Reference source n

ot found.

). All parts of the system are 19” rack mounted and are installed on pullout shelves. The

Gasmet CMM includes all power connections and temperature controllers for heated line and heated
sample  probe.  The  operation of  the  system  is  fully automatic and  controlled by  the  Gasmet MAUI
application software. Additionally, all functions of the Gasmet CMM can also be performed manually.

The built-in control panel PC and the Gasmet MAUI software control the CMM fully automatically. The
measuring data can be transferred from the CMM to control room with analog output 4-20 mA. The
alarms are transferred with relay contacts. The Gasmet CMM provides alarm functions such as System
alarm, Service request, Maintenance, Concentration alarm and Result valid.

The Gasmet CMM is air conditioned by a compressor-cooling unit.

Figure 1. A general view of the CMM

Содержание Alnab CMM

Страница 1: ...Continuous Mercury Monitoring System CMM CMM AutoQAL Instruction and Operating Manual v E 2 51 ...

Страница 2: ...ither replace or repair free of charge Ex Works Helsinki Incoterms 2010 any such defective product or part that is returned to its repair facility within one 1 year of the delivery date All parts or products removed under this warranty become the property of Gasmet Technologies Oy or its subsidiaries The replacement product or part takes on the warranty status of the removed product or part The wa...

Страница 3: ... 1 2 6 Instrument air preparation 12 1 2 7 Alarm outputs 12 1 2 8 Air conditioning 12 1 2 9 Dilution probe 12 1 2 10 Heated line 13 1 2 11 Electrical connections 13 1 2 12 Measuring data outputs 13 1 2 13 Enclosure 13 2 PREPARATION USE OF THE SYSTEM 14 2 1 Package 14 2 2 Contents of the Gasmet CMM delivery 14 2 3 Transportation and storing 14 2 4 Installation 15 2 4 1 Explosion protection 15 2 4 2...

Страница 4: ...4 3 Settings of the program 30 4 INSTRUCTIONS 32 4 1 Warnings 32 4 2 Operation 32 4 2 1 Operation chart 32 4 2 2 Software operation 34 4 2 3 HW status 35 4 2 4 Info view 36 4 2 5 Support 37 4 2 6 User Mode 37 4 2 7 About 37 4 2 8 Automatic adjustments and starting of a continuous measurement 38 4 2 9 Manual mode operation 38 4 3 Interrupted use 39 4 3 1 Switching off the system 39 4 3 2 Restarting...

Страница 5: ...rtridge filter changing 50 5 1 4 Replacing the absorption dryer 52 5 1 5 Exchange of liquids CMM AutoQAL 52 5 1 6 Zero and span adjustments 53 5 1 7 Linearity check 53 5 2 Service instructions for professional 53 5 2 1 Program initialization 53 5 2 2 Replacing the lamp 53 6 Technical terms and symbols 55 7 Gasmet Sales and Support Offices 56 ...

Страница 6: ...Correctly aligned connector nuts 24 Figure 15 Correctly aligned connector nuts 24 Figure 16 Incorrectly aligned connector nuts 24 Figure 17 Analyzer settings 26 Figure 18 Test gas generator settings example parameters only not for reference 27 Figure 19 Program settings example parameters only not for reference 30 Figure 20 The operation chart 33 Figure 21 View of the main program screen 34 Figure...

Страница 7: ...CMM USER S MANUAL E2 51 7 Figure 33 Absorption dryer material 52 ...

Страница 8: ...able in service mode 27 Table 7 Test gas generator settings Read only Read only in basic user mode but editable in service mode 29 Table 8 Program setting Read only in basic user mode but editable in service mode 31 Table 9 HW Status dialog parameters 35 Table 10 Manual mode operation 38 Table 11 Maintenance plan 40 Table 12 Alarms in the CMM 44 Table 13 Main Activity 45 Table 14 Sub Activity 45 T...

Страница 9: ...MM Please read this manual carefully prior to using the system Improper use of the system may damage the equipment This instructions manual is copyrighted 2012 2020 by Gasmet Technologies Oy All rights reserved No part of this manual may be reproduced in whole or in part in any form without the prior permission of Gasmet Technologies Oy ...

Страница 10: ... Error Reference source n ot found All parts of the system are 19 rack mounted and are installed on pullout shelves The Gasmet CMM includes all power connections and temperature controllers for heated line and heated sample probe The operation of the system is fully automatic and controlled by the Gasmet MAUI application software Additionally all functions of the Gasmet CMM can also be performed m...

Страница 11: ...ation software MAUI 1 2 2 Spectrometer with integrated thermal converter Operation principle Direct cold vapor atomic fluorescence CVAF in vacuum pressure Detector Photon detection unit with photon counting Source Low pressure mercury vapor lamp Operation wavelength 253 7 nm Sample conversion Integrated high temperature thermal converter 1 2 3 Test gas generator for Hg0 Operation principle Hg0 Vap...

Страница 12: ... software Maintenance status Gasmet CVAF mercury analyzer and application software Result valid Gasmet CVAF mercury analyzer and application software Concentration alarm Gasmet CVAF mercury analyzer and application software 1 2 7 1 Concentration alarm Concentration alarm is a user defined concentration alarm signal It can be defined from MAUI Program settings menu Concentration alarm limits Low an...

Страница 13: ...ated line is 35 m with 230 VAC and 14 m with 115 VAC power supply Analyzer and test gas generator are connected to dilution probe with combined heated line which divides into two parts on both ends 1 2 11 Electrical connections Main supply 3 16 A 2 14 m sample line 3 32 A 15 30 m sample line Power consumption 8 kW the full CMM with heated lines 25 m 1 2 12 Measuring data outputs The CMM system is ...

Страница 14: ...lengths according to the application 6 Accessories The Gasmet USB flash drive o The Gasmet CMM manual o The Gasmet CMM technical drawings Printed manuals Filter and O rings for the sample probe The gasket of the probe bolts and nuts Insulation rings 6 pieces 2 3 Transportation and storing All parts of the Gasmet CMM must be stored installed and operated in a dry and frost free place It is essentia...

Страница 15: ...nd proper protective clothing Wear protective gloves because surfaces temperatures can be high The Gasmet CMM must be mounted vertically An extreme inclination of the system cabinet may interfere with the operation of the analyzer The installation location must preferably be free of strong vibrations as well It is recommended that the instrument is operated in the following environmental condition...

Страница 16: ...2 5 Listing of connections All external power and signal connections and gas connections are located on the connector plate Figure 2 and Table 1 The plate is located on the back side of the cabinet Figure 2 Connector plate layout ...

Страница 17: ...alog output3 4 20 mA load max 350 Ω B12 KL4414 7 Hg concentration analog output3 4 20 mA load max 350 Ω B12 KL4414 6 Hg concentration analog output4 4 20 mA load max 350 Ω B12 KL4414 8 Hg concentration analog output4 4 20 mA load max 350 Ω B13 KL3054 1 O2 concentration 4 20 mA B13 KL3054 3 O2 concentration 4 20 mA X2 L1 Mains in L1 230 400 VAC 16 A TN S 2 5 6 0 mm2 X2 L2 Mains in L2 230 400 VAC 16...

Страница 18: ...inimum bend radius of the sample line is 30 cm When the sample line is installed must be ensured that line does not bend too much The sample line s shorter heated branch is connected to the analyzer and the longer one to the test gas generator Connectors must be thermally insulated with insulation rings Electrical and signal lines and gas tubes are connected according to Table 1 and Table 2 2 5 5 ...

Страница 19: ... black Alarm com X1 12 X2 6 orange FAFlow X1 13 X2 7 OXYGEN SENSOR CONTROL shield shield O2BOX 5 PE NC red O2ch2 calib O2BOX 1 B16 2 black O2sig O2BOX 2 B13 1 orange O2com O2BOX 4 B13 3 Grey 0V calib O2BOX 3 B16 4 VALVE CONTROL red BC1 X1 8 X2 10 orange BC com X1 9 X2 9 grey BC2 X1 10 X2 11 24V SUPPLY red void NC NC blue void NC NC LINE HEATING green TCK sensor X2 1 white TCK sensor X2 2 green yel...

Страница 20: ...l of the analyzer see Figure 4 and Table 4 Analyzer connections All wires and tubes which are indented to be attached to the analyzer except heated line are already attached to the bracket on the back of the analyzer s self Figure 4 Analyzer back plate layout Ref Signal Connector Information 1 Mains in IEC C14 2 Fuse holder 2 240 4AT 3 Heated line control D 25 4 Vacuum pump connector 6 mm Swagelok...

Страница 21: ...cept the heated line are already attached to the bracket on the back of the test gas generator s shelf Figure 5 Test gas generator back plate layout Ref Signal Connector Information 1 Mains in IEC C14 2 Fuse holder 2 240 4AT 3 Control Ethernet connector RJ 45 4 Cooling FAN 5 Calibration gas out 8 mm Swagelok 6 HgCl2 Waste Swagelok PFA optional 7 HgCl2 Input Swagelok PFA optional 8 Zero gas input 6...

Страница 22: ...he front view right Open the grey enclosure of the mercury compress by removing four screws Use 3 mm Allen key 4 Open the mercury compress by using 2 5 mm Allen key 5 Inside the compress is a U shape glass tube Figure 6 and Figure 7 Remove the tube carefully and fill it with mercury according to Figure 6 below Use pipette and pipette bulb It is important that the level of mercury is above the top ...

Страница 23: ...ure 7 U shape glass tube mercury container Figure 6 The right amount of mercury Figure 11 A low edged plastic box and equipment Figure 10 Fill the glass only a little at a time Figure 9 Filling the glass Figure 8 Emptying the glass ...

Страница 24: ...e parallel to U pipe 7 Press the tube in place in line the connector nuts with the pack plate Figures 13 15 Note that if no alignment has been made the glass tube can break and mercury has access to the test gas generator Figure 12 and Figure 16 8 Run the points 1 4 in the reverse order Figure 14 Correctly aligned connector nuts Figure 12 Incorrectly connector nuts Figure 15 Correctly aligned conn...

Страница 25: ...After connecting pressured air adjust the pressure controllers Main system pressure must be set lower than minimum pressure of supply at any time System will not function correctly if main pressure starts to float with supply pressure Dilution gas N2 generator must be about 0 4 bar lower than main system pressure Dilution gas ejector pump pressure must be about 0 4 bar lower than N2 generator pres...

Страница 26: ...asuring time group Measuring time x min Defines the measuring time Please note that the measuring time must be a multiple of 1 minute Flush time x min Defines sample flushing time before first measuring on continuous mode Blowback group Perform before measure Yes No If ticked performs a blowback of the probe filter before starting or resuming a measurement sequence Perform before calibration Yes N...

Страница 27: ...ter oven temperature setpoint Cell 180 C Defines the sample cell temperature setpoint Line 180 C Defines the heated line temperature setpoint Table 6 Analyzer settings example parameters only not for reference Read only in basic user mode but editable in service mode 3 4 2 Settings of the test gas generator The test gas generator settings control the operation of the test gas generator and the var...

Страница 28: ...g0 adjustment Interval days 0 X days Defines the interval of the zero adjustment zero indicates adjustment should be performed every day Zero adjustment Time Defines the time of day when the zero adjustment should be performed Zero adjustment time cannot be set after Hg0 span adjustment time if both adjustments are set to be performed separately Resume sample Shows estimated calculated time when s...

Страница 29: ...ange Target liquid conc Min ug l Minimum calculated target liquid concentration based on selected measuring range Target liquid conc Max ug l Maximum calculated target liquid concentration based on selected measuring range Optimal liquid conc ug l Recommended optimal liquid concentration based on selected measuring range HgCl2 liquid concentration ug l Used HgCl2 solution concentration value Calcu...

Страница 30: ...n Figure 19 Please note that none of the settings pages can be accessed during measuring Program settings control the saving of measured results to files and define the measurement range of the system The controls are explained in detail in the table below Table 8 Figure 19 Program settings example parameters only not for reference ...

Страница 31: ...result file Save calibration parameters Yes No Saves the calibration parameters to the result file Save test gas generator parameters Yes No Saves the test gas generator parameters to the result file Output ranges group A01 min max Output range for analog output 1 A02 min max Output range for analog output 2 A03 min max Output range for analog output 3 A03 is dedicated for Zero result Zero check r...

Страница 32: ...e measures analyzes results and performs automatic span zero or linearity checks in addition to calibration To perform these functions the software controls both the mercury analyzer and the attached test gas generator unit via an Ethernet interface 4 2 1 Operation chart The system operates normally in accordance with parameters entered in the system The operation chart is shown below Figure 20 Th...

Страница 33: ...ure Measure Blowback Sample Flush HgCl2 Span check time Yes Blowback time No No Hg0 span adjustment time Yes Yes Blowback Yes No Hg0 flush Hg0 measure Blowback Yes No Zero flush HgCl2 measure Zero flush No Yes Zero adjustment time Yes Blowback Yes No Zero flush Zero measure No Sample Flush ...

Страница 34: ... not be changed The continuous measurement can be started and stopped from the Measure button The red buttons in the bottom of the screen open a control each to view the individual reasons for each of the alarms When there are no alarms the buttons are all green in color The Manual button opens a control dialog to manually perform measurements and pilot hardware on the test gas generator and or an...

Страница 35: ...ure C Oven temperature C Cell temperature C Line temperature C Cell pressure mbar Ambient pressure mbar Detector counts Test gas generator Bath temperature C Evaporator temperature C Bath flow ml min Dilution flow l min Pump flow µg min Bath pressure mbar Last Adjustments Hg0 span µg m Zero µg m Table 9 HW Status dialog parameters The Update button sets the dialog in a continuous update mode where...

Страница 36: ...m At startup of MAUI this information is loaded from calibration file Information regarding internal Hg0 span adjustment is not available in this window It is available under HW Status Zero check is always performed after zero adjustment irrespective of zero adjustment started manually or automatically Figure 23 Calibration Information ...

Страница 37: ...support package creation might take a while depending on number of files to be copied Figure 24 Support Package 4 2 6 User Mode User access levels in MAUI can be categorised as B Basic mode S Service mode MAUI is always started in Basic mode User can change access level by opening User Mode dialog and entering password 4 2 7 About About button in the menu bar at the top of the screen displays info...

Страница 38: ...e disabled if any manual function is active The functions of the manual mode panel are discussed in the following table Table 10 Function Description Measure Zero Measures Zero gas Measure Hg0 Span Measures Hg0 Span gas Blowback Performs probe filter cleaning Zero Check Performs zero adjustment routine Hg0 Span Adjustment Performs normal Hg0 adjustment routine and defines new adjustment factors Hg...

Страница 39: ... way to switch the power off is using the main switches Switching the main switches off will shut down the complete system and the system will be easy to restart There is no need to switch off each part of the system individually 4 3 2 Restarting of the system When restarting the system ensure first that all connectors are in place and that it is safe to turn on the power Instrument air supply and...

Страница 40: ...ntenance required depends strongly on the application Table 11 The maintenance work procedures are described in this manual Maintenance interval Maintenance work Regularly System visual inspection Approximately 6 months Inspection of the probe filter plate Approximately 6 months Change of the Hg lamp Approximately 3 months Adding HgCl2 liquid to container if needed CMM AutoQAL Approximately 12 mon...

Страница 41: ...probe If temperature is OK check the alarm wires Otherwise contact the service Instrument air Pressure Instrument air pressure is too low Check that instrument air input gauge shows proper pressure values If not find out why instrument air supply is down in the plant If there is sufficient pressure reading min 6 bars then open the flowmeter fully and adjust all pressures according to the recommend...

Страница 42: ...e tightly closed Do manual zero measurement and check the flow on HW Status tab Restart the test gas generator If it doesn t help contact the service Cabinet Temperature The temperature inside the cabinet 40 C Check the radiator function and filters as well as the ambient temperature Instrument air Pressure Instrument air pressure is too low Check the pressure Cabinet Cooler Cabinet A C unit doesn...

Страница 43: ...o normal measurement routine of a minute Span Check Span Check is going on In automatic mode Span Check is timed and the system returns to normal measurement routine of a minute Zero Check Zero Check is going on In automatic mode Zero Check is timed and the system returns to normal measurement routine of a minute R e s u l t V a l i d Function Alarm Meaning Treatment The result valid signal indica...

Страница 44: ...mited for easy porting to other applications See Figure 27 below for an example on a typical results file The result file is ASCII text in format and it contains the following columns some of which can be optionally logged by selecting saving options from the Program settings Autosaving settings group The date and time of the measurement Serial number of the analyzer The analyzed result of the mea...

Страница 45: ...hing 4 Hg0 Span Measuring 5 HgCl2 Span Flushing CMM AutoQAL 6 HgCl2 Span Measuring CMM AutoQAL Table 14 Sub Activity For Example 12 states that Zero measuring Sub activity during Zero Check Main activity For the sample measurement there is no sub activity and measuring state value is always 80 4 6 1 2 System Alarms There are 10 system alarms represented by 10 bits each bit represents one alarm 0 N...

Страница 46: ... 2 Calibration files The calibration file has its own path and file name for saving in Program settings The calibration file contains the results of zero calibration span calibration and linearity check see Figure 28 The calibration file contains the following columns The date start and end time of the calibration or check performed Serial number of the analyzer Mode of calibration 0 Manual 1 Auto...

Страница 47: ...centration at test gas CMM AutoQAL HgCl2 solution concentration CMM AutoQAL Oxygen concentration of test gas Figure 28 Calibration file example values 4 6 3 Log files The system log file SystemLog txt is saved to the same path used for saving calibration data The system log file logs number of system hardware related problems errors and status information See Figure 29 and Table 18 below for a typ...

Страница 48: ...surement stops automatically if instrument air pressure is too low Check instrument air pressure level Measurement stopped Cell Temp Alarm d Line Temp Alarm d Probe Temp Alarm d Ongoing measurement will stop automatically if any of these alarms is active Line temperature Cell temperature Probe temperature alarm In case of continuous measurement measurement will resume automatically if these alarms...

Страница 49: ...ut 700 C Sample line temperature is correct 180 C Cabinet temperature is correct max 30 C Air conditioning system is in good condition A C unit is clean of dust temperatures are OK There is no dust inside the cabin 5 1 2 Replacement of probe filter plate The replacement frequency of the filters depends a lot on the quality of the measured sample gas In the beginning of the operation after installa...

Страница 50: ...5 1 3 Cartridge filter changing The cartridge filters are changed 1 Stop the measurement and turn off the instrument air by using the main system pressure regulator 2 Open the filter housings by pressing the black levers and rotating the housings Figure 31 Filter housings ...

Страница 51: ...R S MANUAL E2 51 51 3 Remove the cartridge filters by rotating them Figure 32 Cartridge filter 4 Install the new cartridge filters put the housings back on turn on the instrument air and start the measurement ...

Страница 52: ...uids CMM AutoQAL If reservoir bottle is refilled from the same batch of HgCl2 solution as the old one it can be simply filled on top of the old liquid After filling HgCl2 Refill function should be run from the manual menu to get rid of possible air bubbles caused by the filling If the HgCl2 solution bottle is filled with solution that has different concentration than before HgCl2 Refill function s...

Страница 53: ...Click the New button and enter the name of the software in the dialog box select the type ShellCommand and enter an optional program description if desired and accept by pressing OK In the Edit Item dialog choose Autostart in the Startup Options Navigate to the next tab Shell Command and enter the full path of the executable in the Enter Shell command text box For example Hard Disk MAUI MAUI exe C...

Страница 54: ...the counts again Continue this until you find the angle where you get the maximum counts and then tighten the screw Notice that there might be two opposite side maximums with different intensity 5 Remove the power cable and put the cover back 6 Turn the analyzer back on Wait until all temperatures have stabilized and then recalibrate the analyzer ...

Страница 55: ...old Vapor Atomic Fluorecence Hg Mercury HgCl2 Mercury dichloride Hg0 Atomic mercury Hg2 Oxidized mercury MAUI MAUI is the software for operating and controlling the Gasmet CMM system Mercury lamp The light source of the analyzer Photomultiplier detector The component that measures the low intensity of UV light and converts this value into electrical signal VAC Symbol for the voltage in an alternat...

Страница 56: ...sidiary in Asia Gasmet Technologies Inc Gasmet Technologies Asia Ltd 956A The Queensway Unit 1 7 F Toronto Ontario M8Z 1P5 Fook Hong Industrial Building CANADA No 19 Sheung Yuet Road Tel 1 866 685 0050 Kowloon Bay Kowloon Email sales gasmet com HONG KONG Tel 852 3568 7585 Subsidiary in the United Kingdom Fax 852 3568 4600 Gasmet Technologies UK Limited Email sales gasmet com hk Woolleys Farm Welfo...

Страница 57: ......

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