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Omni FTIR - User Manual

1. s ii Bt n Hi 5 ed 5 HE PLUMBING P ee LEAVE ELBOW BODIES ATTACHED TO e ux LE LUN UBIN Cl IISCONNECT WIRING TO VALVE Cal H ATER CONNECTOR f BERA AT TEMP CONTROL BOX VEHI eer je BPS DN 4x LDDSEN capt SNIP ANY CABLE TIES FT bes AK EULPSES M SECURING CABLE WE SCREWS REMUVE COUVER O ier uneo PLACE INSULATIUN THAT IS JUST UNDER E COVER INTO THE COUVER AS IT WAS AND SET ASIDE Set B 8 Figure 5 58 Sample System Heater Assembly and Cover Removal 4 Using the Phillips screwdriver loosen the screw that holds the solenoid valve electrical connector in place and then remove the connector from the valve 5 Using the 9 16 inch wrench loosen the fitting nuts and disconnect the lines for the FTIR In FTIR Out Ejector Air In and Ejector Air Exhaust The 5 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 disconnect the Ejector Exhaust which has rigid plumbing use the Phillips screwdriver to loosen the 2
2. Figure 5 47 PC Console Removal 4 Using the Phillips screwdriver remove the 4 screws in the front of the system that mount the PC console Also remove the 4 screws that secure the PC to the rack Figure 5 46 5 Take the 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 PC console pull out the PC until it locks in place 7 Place the new PC console on top of the PC and slide it in until the rear section is flush with the front of the system 8 Push the PC console in just enough to get the rear rails on each side started in the rack sliders Once both sides are in place push the console in a couple of inches Figure 5 48 Thermo Fisher Scientific Replacing the National Instruments Boards AN Thermo Fisher Scientific Preventive Maintenance and Servicing Replacing the National Instruments Boards eZ V 0c2o 00 16 E A 9 Push the PC console back in as far as it will go Lift up the front until the side mounting holes are lined up with the threaded holes Re install the 4 PC console mounting screws using the Phillips screwdriver Also re install the 4 screws that secure the PC to the rack 10 Re connect the cables to the
3. Return Code test value returned by this control nonzero if true aii cd o RET Add Status Value Test f DA Result Codes temporary Overwrite CONs temporary Global Codes retained in memory T ALARM A ALARM a 5 ALARM d jline dev2 port2 line IV Add results to CONs z z pattern Ox ten If the gas cell temperature is less than 175 degC or the system temperature alarm is triggered the alarm would be flagged Logically there would be three alarm output results based on the system temperature status The validation of CEMS measurement data is determined by the variable Omni FTIR Multi Gas CEMS Instruction Manual E 11 IMACC Script Setting Modbus Control Version alarm When alarm equals 0 the measurement data would be valid defined by variable Data Valid Non valid data is defined by either Alarm 1 or Alarm 2 The corresponding settings are defined by three setting blocks starting with if expression as indicated if expressions lline dev2 port2 line pattern 0x1 e Script setting for system command and status This setting is included in the second container as shown container script Calc 46 expressions SYSTEM STATUS script script There are three script setting blocks and one calculation block The first script setting is used to assign the digital input channels to five system commands stating fr
4. x 7 Figure 5 55 Temperature Control Box Internal Component Replacements 3 To install the new fuse line up the 2 pins on the fuse with 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 Removing and Installing the Cover Replacing the Use the following procedure to replace the temperature control board Temperature Control inside of the temperature control box Board Equipment Required Phillips screwdriver Small Phillips screwdriver Temperature Control Board Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific Thermo Fisher Scientific Preventive Maintenance and Servicing Temperature Control Box Components 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 components A 1 Remove the temperature control box cover per the previously mentioned procedure Removing and Installing the Cover 2 Itis important to note or mark the location of all 16 cables that connect to the temperature control board to facilitate re 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
5. The system includes a temperature control module which is used to control the temperatures in the following components e FTIR cell e Sample conditioning assembly e Heated lines to FTIR e Sample line In addition the FTIR cell pressure is measured with this controller The sample conditioning subsystem consists of multiple components that are used to control and condition the sample and calibration gases e Sample system heater assembly pump sample valve check valve pre heaters e Hydrator e Pneumatic panel e FTIR purge gas generator e Instrument air filter assembly The FTIR analyzer is a Thermo Scientific Antaris IGS instrument which is based on a Michelson interferometer which measures the interaction of infrared IR radiation with the sample The FTIR analyzer includes a 5 2 Thermo Fisher Scientific Thermo Fisher Scientific PC Data Logger Introduction oystem Overview meter heated gas cell and a TE cooled DTGS detector with a resolution of 0 5 cm 1 The PC is a 2U Rackmount industrial PC with the following components e Black ATX 2U heavy duty steel case e Intel Pentium 4 Processor 2 4 GHz e 1GB DDR2 800mHz RAM e 250GB SATA2 hard drive e 24X DVD RW drive e 1 44 MD floppy drive e 3RS 232 serial ports e 2 Ethernet ports e 2front facing USB ports 4 rear facing USB ports e 32 channel analog output board e 96 channel digital output board e 300W power supply e Windows XP Pro The
6. 4 Note the orientation of the board One at a time carefully unsnap the board from the 4 corner mounting posts and remove it 5 Place the new board on top of the 4 corner mounting posts in the previous orientation then push down on the corners to lock the board in place Be careful not to pinch the wires of any of the various cables 6 Using the Phillips screwdriver re install the 2 mounting screws 7 Re connect all of the cables to their proper locations on the temperature control board 8 Re install the temperature control box cover per the above procedure Removing and Installing the Cover Omni FTIR Multi Gas CEMS Instruction Manual 5 67 Preventive Maintenance and Servicing Temperature Control Box Components Replacing the Power Relays 5 68 Omni FTIR Multi Gas CEMS Instruction Manual Use the following procedure to replace either of the 2 power relays inside of the temperature control box Figure 5 55 Equipment Required Phillips screwdriver Small Phillips screwdriver Flat blade screwdriver Nut driver 5 16 inch Power relays 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 components A 1 Remove the temperature control box cover per the previously mentioned procedure Removing and Installing the Cover 2 Using your fingers pop the end covers of the relay up to acc
7. 5 72 Figure 5 57 Electrical Panel Component Location Rear Side 5 72 Figure 5 58 Sample System Heater Assembly and Cover Removal 5 77 Figure 5 59 Sample System Heater Assembly Component Replacement and Heated BIOGK MOLINO Wall sese pip d ceto Iti rb iate Doer D bn ei oed 5 80 Figure 5 60 Check Valve Replacement sssssssssse 5 84 Figure 5 61 Solenoid Valve Replacement 5 87 Figure 5 62 Pneumatic Panel Components Replacement 5 90 Figure 5 63 Solenoid Valve Replacement 5 93 Thermo Fisher Scientific Thermo Fisher Scientific Figures Figure 7 1 FTIR Multi Gas CEMS System Component Layout 7 2 Figure 7 2 Sample PrOD sese tete ER Eti OX rl det d ho iuum d 7 3 Figure 7 3 Pnoumatie PANG xiii sh DR ieee ee i Mae ae ee eee 7 5 Figure 7 4 Sample and Calibration Gas Flow Diagram 7 6 Figure 7 5 FIIR Analyzer Figure 7 6 FTIR Flow Schematic sede tenens t Debe dtu backing nace 1 8 Figure 7 7 Spectrometer Compartment 1 9 Figure 7 8 Major System Components 1 11 Figure 7 9 FTIR Purge Gas Generator 1 13 Figure 7 10 FIR PO et ne tv m mostra t etre asd TE A 1 13 Figure 7 11 Electrical Panel 7 15 Figure F122 AG GINS s cists eee ea dine ited ch at 7 15 Figure C 1 Rear Panel Terminal Connectors sssssssssssss C 2 Figure C
8. Calogix Setup Burned out heater element see Chapter 7 System Component Description and check terminals 1 amp 2 of heater cable Blown fuse in temperature controller See Chapter 5 ec e e e 3 Preventive Maintenance and Servicing Broken temperature sensor see Chapter 7 System Component Description and check terminals 5 amp 6 of heater cable e High temperature Calogix controller error see Appendix D Calogix Setup Broken temperature sensor see Chapter 7 System Component Description and check terminals 5 amp 6 of heater cable Proper cell pressure range must be determined during setup and installation See Chapter 2 Low pressure in Cell Check for blocked flow in sample system Check for correct eductor pressure eductor pressure too high e High pressure in Cell Leak in sample system Check for correct eductor pressure eductor pressure too low Check for blocked exhaust system make sure exhaust lines are less than 10 feet long Check all temperature readings make sure they are within 10 degrees of setpoints Check probe breaker Omni FTIR Multi Gas CEMS Instruction Manual 6 5 Troubleshooting Communication Errors Check for 24 VDC signal on temperature alarm connections to probe off of the electrical panel using a multimeter If only one connection has 24 VDC check temperatures at probe e System in failsafe mode zero air Check alarm system continuity at
9. Influence of ambient temperature Influence of sample gas pressure Flow Response time 195 Availability Ambient temperature Specification Introduction Specifications MDL 1c 1 min avg ppm 0 15 0 40 0 40 0 10 0 10 0 10 vol 0 10 0 10 0 15 0 10 vol 0 003 lt 2 of minimum measuring range lt 3 of minimum measuring range lt 2 of minimum measuring range lt 5 of minimum measuring range for zero and span with 20 C as reference None pressure compensation 5 min 3 minutes for all non reactive gases b minutes for NHs HCI and HF spiking 10 minutes for NHs HCl and HF dry gt 98 60 to 95 F 15 to 35 C Omni FTIR Multi Gas CEMS Instruction Manual 1 7 Introduction opecifications Connections Table 1 3 Electrical Connections Electrical Packing Gland Power 230 VAC PG16 Analog Signals PG16 Digital Signals PG16 Spare PG16 Signals Type Analog Signals 4 20 mA for each measured concentration Digital Signals FTIR data valid Temperature alarm for sample probe heated lines sample conditioning assembly and FTIR cell Status measurement maintenance 3as mode inputs and outputs check span check spike check zero background and flowback blowback and sample Power Table 1 4 Power Requirements Device Total Consumption 9080 W FTIR electronics 700 W PC with console 1200 W Air Purifier 100 W 24 VDC Supply 250 W Temp Controllers lt 6000 W samp
10. Preventive Maintenance and Servicing oystem Calibration Procedure Using Calibration Factor Table in Method e Replacing the National Instruments Boards on page 5 59 e Temperature Control Box Components on page 5 62 e Electrical Panel Components on page 5 71 e Sample System Heater Assembly Components on page 5 76 e Pneumatic Panel Components on page 5 90 e Service Locations on page 5 97 5 2 Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific Preventive Maintenance and Servicing Replacement Parts List Replacement Table 5 1 lists the replacement parts for the Omni FTIR Multi Gas Thermo Fisher Scientific Parts List Table 5 1 Replacement Parts List Sample Probe Part Number Replacement Period sample Probe Assembly SP2000 H 4 Flange 1 0M 113200 00 stinger sample Probe Filter Element Ceramic 2 0 micron 106968 00 3 6 months Sample Probe Graphite Gasket 30 Filter Element Seal 3 106969 00 1 year sample Probe High Temperature Thermostat 106972 00 sample Probe 3 ANSI Novapress Flange Gasket 113322 00 sample Probe 4 150 ANSI Flange Gasket 113323 00 1 year sample Probe Blowback Valve 113317 00 Sample Probe Graphite Gasket 69 Lid Seal 113318 00 3 6 months sample Probe Stinger PID Controller 113319 00 sample Probe Pre Filter Element 25 micron Coated SS 113321 00 1 year ext Screw sample Probe Heated Stinger Assembly 1 0M 113335 00 sample Probe Filter Housing Lid Assy 320 C 1133
11. optical path FrontMain com port settings o600 8 None 1 None CollectEZ 182 Collect Settings pathName FrontMain pathLength 5 209 riteConFile 1i scanTime 0 48 pticalPath FrontM elapsedTime ON FilePath C CO jJ Bench Settings Statistics 188 lightSource IR iteration o aperture 15 time gain 4 elapsed Modbus Register Settings request o bytes response o bytes setup serial Optical Path Register Setting Front ain S Type of Data Measurement Channel Mapping IEEE floa CODE SampleT IEEE float SampleT OxOalc IEEE float InletT Ox0a24 IEEE float PumpT Ox0ale IEEE float CELLTEMP 0Ox0a20 IEEE float CELLPRES Ox0a2a IEEE float OutletT Ox0a26 Reaister Ox prefix for hex numbers 0x01 c measu code register a 1 1 1 1 1 1 V add to CON file Cercei Add Remove E dit Default DK Cancel Thermo Fisher Scientific Thermo Fisher Scientific IMACC Script Setting Modbus Control Version For all the parameters the data type is IEEE float The code name can be edited to reflect the parameter meaning The register number is determined by the Calogix setting Click the serial button on the top so its setting block pops up as shown Modbus Register Settings setup serial Device Address 1 COM Port Parity b Mane Baud
12. SSRs are mounted on a DIN rail on the interior of the electrical panel Figure C 4 Al Ale AI ATA NC NC Nc NC NC NC NC NC NC ie s NC NC NC NC NC NC NC Figure C 4 SSR Rail SSR Rail The SSR panel located in the interior of the system may be observed during maintenance or troubleshooting by removing the side panel of the rack Each SSR has an indicator light that is illuminated when it is active The follow illustration shows the configuration of lights for different states of operation listed in rows Figure C 5 Alarm Zen inst Zero sample Blowback Background _4 ES Prahe Zen Probe Spike Probe Span Figure C 5 SSR Indicator Light Configurations C 6 Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific Appendix D Calogix Setup This appendix provides a description of the Calogix software used to control the temperature of heated sample lines and monitor the pressure in the FTIR sample cell For details see the following topics e Hardware Description on page D 1 e Finding the Correct COM Port on page D 2 e Setting the Virtual COM Port on page D 4 e Programming the Controllers and Setting Parameters on page D 6 Hardware The pressure and temperature controller hardware is located in a 2U chassis TNT located in the rack It consists of four 2 channel controllers and a base unit Description Figure
13. Temperature Equipment Required Sensor Wrench 7 16 inch Phillips screwdriver Temperature sensor cool A N CAUTION High surface temperatures present Allow sufficient time to 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 system in fail safe mode so that it will not be sampling stack gas 2 Remove the 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 the system 4 Slide the FTIR drawer out of the system to access the rear of the unit 5 At the rear of the FTIR cell disconnect the temperature sensor connector from the sensor by pulling it off exposing the 3 metal prongs Figure 5 30 Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual 5 39 Preventive Maintenance and Servicing Replacing the Temperature Sensor Loosen fitting to remove Temperature Sensor Figure 5 30 FTIR Cell RID Temperature Sensor Replacement 6 Using the 7 16 inch wrench loosen the nut and remove the temperature sensor from the fitting Figure 5 30 7 Slide the probe of the temperature sensor through 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 loose
14. 51251 A e Aal e Anl Ye 11 11 11 LU 11 14 14 14 14 1 NC NC NC NC E O M S m AE j n o Oo HB iw H o o H Do m ou B o Hu OH H Oo gm OH H O B O Do B oH H IO m Oo B PAT Ho F F O Pro q O m OHH3 DO Pa i m OoHSH DO m2 Hn c gm OS O pis O gm oHSH D m4 o T O H O pis n c gm o m O pis L e OH D mz Ht o O a D Pz Hr al e a D P22 Hc gH OBS D p23 p k LH z p j O T O E rs D E OB D rzs Hc H lo ID O K x i Ze Ile BURN J Figure 5 57 Electrical Panel Component Location Rear Side Thermo Fisher Scientific Replacing the Ethernet Switch AN Replacing the Solid Thermo Fisher Scientific State Relays Preventive Maintenance and Servicing Electrical Panel Components Use the following procedure to replace the Ethernet switch on the electrical panel in the rear of the system Figure 5 56 Equipment Required Phillips screwdriver Ethernet switch 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 components A 1 Note the location of each wiring connection to the Ethernet switch to facilitate re assembly Remove any Ethernet cables connected to the right side of the switch Ports 1 3 and then move the green ground wire out of the cable routing strip 2 Using the Phillips screwdriver loo
15. 62 9 Re install the tubing in the original positions in the fittings of the new flow meter and then tighten until snug using the 9 16 wrench 10 Turn the gas cylinder back on or reset the house air regulator back to the pressure noted earlier then push the knob down to lock it 11 The new flow meter regulator must now be set to the correct flow rate Refer to the Test Certification Sheet p n 108865 70 supplied with the system to see what the original settings were If the Purge Air flow meter was replaced that can be adjusted without further action as there is no corresponding solenoid valve to activate Turn the knob on the flow meter clockwise until the proper setting is achieved If any of the other flow meters were replaced 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 knob on the flow meter clockwise until the proper setting is achieved Alternately if a DCS is not being used the solenoid valve must be activated manually For Probe Zero Probe Span and Probe Spike those solenoids can be activated by pushing in and turning the manual activation button on the bottom of the valve which is accessible from the rear of the pneumatic panel Once the flow rate is set on the new flow meter regulator de activate the solenoid valve To activate the solenoids for Flow Back and Ins
16. Assembly and Cover in reverse order to complete the procedure Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual 5 85 Preventive Maintenance and Servicing sample System Heater Assembly Components Replacing the Sample Solenoid Valve 5 86 Omni FTIR Multi Gas CEMS Instruction Manual Use the following procedure to replace the sample solenoid valve inside of the sample system heater assembly Equipment 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 tube fittings Liquid leak detector such as Snoop 6 foot section of PTFE or PFA tubing with 1 4 inch nuts and ferrules attached Sample solenoid valve CAUTION High surface temperatures present Allow sufficient time to cool A 1 Remove the sample system heater assembly and its cover per the previously mentioned procedure Removing the Sample System Heater Assembly and Cover 2 Remove the heated block assembly from the heater box per the previously mentioned procedure Removing the Heated Block Assembly 3 Turn the heated block assembly around to access the back of the assembly 4 Using the 9 64 inch hex wrench loosen slightly but do not remove the 5 screws that mount the double coil clamp plate to the heated block This will allow some freedom of movement of the copper tubing Figur
17. C Program files Imacc IMACC FTIR Software Suite Imacc Modbus Server exe C Program files Imacc IMACC FTIR Software Suite Imacc Modbus TCP Server exe C Program files Imacc IMACC FTIR Software Suite Imacc CurrentLoop Server exe 2 12 Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific Thermo Fisher Scientific Maintenance Switch Set Program Access and Defaults W Windows Catalog Internet Mozilla Firefox 2 E mail Outlook Express Windows Update Accessories m Adobe f Alanager zii Far Manager SSB winrar C Adobe ImageRead a S Outlook Express Remote Assistance D windows Media PI 43 windows Messeng E Windows Movie Maker All Programs m Borland m Far 7 Games EF Minew Startup E WinR Internet Explorer Mozilla Firefox WwW MSN Explore Explore All Users System Installation Start Up and Shut Down oystem Startup Open All Users Delete Rename Sort by Name Properties P Log Off 9 Turn Off Computer Drag the shortcuts into the Startup folder Close the folder amp Startup File Edit View Favorites Help t po Search c Folders ERE Address C Documents and Settings All Users Start Menu Programs Startup File and Folder Tasks e Make a new Folder D Publish this Folder to the Web i Share this folder Other Places gr Programs E3 My Documents Shared Documents Sj My Computer amp My
18. Removing the Left Side Panel for better accessibility optional step 3 Using the Phillips screwdriver remove the FTIR 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 Using the wire cutters remove any tie wraps securing the heated line s to be replaced 6 Disconnect the connector for the line s being replaced from the temperature control box Labels on the temperature control box correspond to the labels on the sample system heater assembly 7 Using the 9 16 inch wrench loosen the nut and disconnect the heated line s to be replaced from the elbow fittings at the rear of the FTIR Figure 5 45 Note their position to facilitate re connection Thermo Fisher Scientific Preventive Maintenance and Servicing Replacing the PC nf fon m tq 7 D Q Figure 5 45 Heated Line Replacement 8 Using the 9 16 inch wrench
19. loosen the nut and disconnect the heated line s to be replaced from the bottom of the sample 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 facilitate re connection 9 Install the new heated line s by following the previous steps in reverse order Attach insulation and tie wraps where appropriate Replacing the PC Use the following procedure to replace the PC Equipment Required Phillips screwdriver Flat blade screwdriver PC Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual 5 55 Preventive Maintenance and Servicing Replacing the PC 5 56 Omni FTIR Multi Gas CEMS Instruction Manual Shut the PC down through Windows and then shut off the PC Console circuit breaker on the breaker box Using the Phillips screwdriver remove the blank panel in the front of the system directly above the PC and console Remove the screws holding the PC to the front rails Slide the Lock lever on the front of the PC console to the Release position Slide the PC and console out to gain access to PC cables Disconnect the 9 cables from the rear of the PC Figure 5 46 Note or mark the location of each to facilitate re connection It is especially necessary that the Ethernet USB and Serial if used connections are made to the same ports they were disconnected
20. 1 Controller Values D 10 Omni FTIR Multi Gas CEMS Instruction Manual xvii Tables xviii Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific Thermo Fisher Scientific Chapter 1 Introduction The Thermo Scientific Omni FTIR Multi Gas CEMS is a continuous multi component gas monitoring system that contains the Thermo Scientific Antaris IGS Gas Analyzer The system is designed to help users meet 40 CFR Part 60 63 Standards and EPA performance specifications for gases such as HCl The system is capable of simultaneously monitoring at least 10 gases using an advanced software platform to calibrate and analyze concentrations with high precision The system is manufactured in a stringent ISO 9000 environment using manufacturing tests to ensure system to system matching and reliability of operation The Antaris IGS uses a precise component layout with permanently aligned optics to minimize spectrometer variability The system conducts high speed data acquisition at high spectral resolution for real time gas analysis Using a Michelson interferometer within the Antaris IGS the Omni FTIR Multi Gas CEMS continually monitors itself and provides real time automatic optimization of the optical signal The interferometer designed with dynamic alignment 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
21. 4 Periodic System Zero CECR espeia sanus ens batUte don Rp etit uue d RUE 4 2 Periodic System Span heck erore pu bet XP E d am 4 3 System Dynamico DIEITIB sore OR tr DER NE br RES 4 3 External Audit Gas Pr ced le sonenergie ian e oon E tru Ue onu p oe 4 3 Ca DEON GaSe S ecco dA EAE O e UN 4 4 Manual Background Spectrum Collection Procedure 4 5 Manual Background Spectrum Collection using Thermo Modbus roni H 4 10 System Calibration Procedure Using IMACC Collect 4 11 System Calibration Procedure Using Calibration Factor Table in INV CUO E M oats 4 18 Preventive Maintenance and Servicing 5 1 Ixeplacemen t DOSES Pot se ime ta dios enn ne E RT Ree err 5 3 Dale PIGedutiOll vendesi coda od Mn ceu tea CC E CE 5 6 Cleanino ehe S SCSI conocidos ditior amr tau bp hide bd desde 5 6 Maintenance for the Sample DE0De 42 cs oberen ue es ru ERU DR eus 5 7 Replacing the Filter Element and Graphite Seals 5 7 Replacing the Pref tet ues duo te bo Rp bep n Deeds 5 10 Maintenance and Servicing of the FTIR Analyzer Components 5 11 Checking and Replacing the Desiccant esses 5 11 Replacing the Humidity Indicator ouoe sopra ids 5 13 Cleaning or Replacing the Fan Filter eeu ntu rn Ee EE 5 14 Replaciis the Source cessa atat outa anaes 5 16 Repbicimg the Lase oes eese
22. 45 75 52 and 75 62 Thermo Fisher Scientific Lifting Unpacking and Thermo Fisher Scientific Inspection Chapter 2 System Installation Start Up and Shut Down This chapter provides the recommended procedures and settings for installing the Omni FTIR Multi Gas CEMS Installation includes lifting the FTIR instrument unpacking and inspection installing and connecting the FTIR in the rack and connecting sample and exhaust lines to the complete system For details see the following topics e Lifting on page 2 1 e Unpacking and Inspection on page 2 1 e Site Requirements on page 2 2 e Installing the FTIR Analyzer into the Rack on page 2 3 e External System Connections on page 2 8 e System Startup on page 2 10 e 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 while keeping your back straight and upright It is desirable to have two or more persons moving the analyzer The FTIR instrument is shipped separately from the rack on its own pallet Carefully uncrate and inspect the system in a non condensing environment 20 30 C Check for possible damage during shipment Remove crate from around system Remove four shipping bolts attaching rack to pallet Remove wood from sides of rack Use fork lift to lift system off pallet or move manually Ensure hydrator filters and FTIR purge gas generator are s
23. 5 Connect the Purse Lines to the FTIR asset eb evite 2 6 Connect the Power TO tlie FIR usc exte oe eua a eal 2 6 Connecting the Computer Cable to the FTIR 2 7 Connect the Pressure Transducer Cable to the FTIR 2 7 Connect the Cell Heater Cable to the FTIR 2 7 Omni FTIR Multi Gas CEMS Instruction Manual vii Contents Connect Sample lines to the Heated Pump Valve Assembly 2 7 TACO tect coat ERE E MEE EIE 2 7 Extemal system COnmections cose nitet evite ot ORR 2 8 Connect the Sample Line to the FTIR Analyzer Cabinet and Heated Daniple BOX sistance 2 8 Instrartelit ULE rn costes Fvee bebetuvticabuse ie nc deb ess iuDRE CV Uv ETUDES duc 2 9 Idus e De coron ASA LN I LI A A LM MEN M 2 9 GET Tove die nln She ccc reuersus um Et E A pl LI E EA E E th 2 9 CSO Mt CHIC MELONS eoo musei es MIN P DU S PMID CLE DR DIA CUM D URS 2 9 E Nene enses seus use UU EU LEM LE SEDE LIE EE 2 9 SAU EN S EAT AEE AE AAEE AEA A 2 9 ANOD eeina E EN E SEDE 2 10 Dietalar E E E 2 10 SV SCCM O P eiaa a e T is DER UU UE 2 10 TORTON Tr O N EORR aa a NU NEN PIE 2 10 Adjust Confirm Flow and Heat Settings eessess 2 11 P NLIS ERUNT RED HE 2 11 TMG TENE REOR ERNEUT 2 12 Ihre a CENTUM TEES 2 12 AO CAM ED P T 2 12 Mamterance S wIECLDs osse oto encres iutebdk tus ca E penes uius s 2 13 Sys ENE ODU DOW ade E ces ais once Mee ees Me tu Uoc ers 2 1
24. 7 1 FTIR Multi Gas CEMS System Component Layout The direct extractive probe assembly is used to extract and condition a continuous sample from a stack or duct for transport to the system Figure 2 It is designed for easy installation reliable operation and trouble free maintenance The probe assembly includes a heated 2 micron ceramic filter with a large surface area and high capacity The special design of the heating element permits controlled heating of the complete filter housing including the mounting flange up 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 included in the probe assembly are a 3 way backflush calibration valve and a blow back tank Inside the stack are a heated stainless steel probe barrel stinger which can be heated up to 250 C and a 25 micron pre filter assembly Separate temperature controllers are included for the probe barrel and filter assemblies Temperature alarm contacts are also provided in the controllers to signal to the system if the probe or barrel are not running at the correct temperature The standard probe has a 4 inch ANSI flange and a 1 0 meter probe barrel length Other flange sizes and barrel lengths may be purchased depending on requirements Thermo Fisher Scientific Temperature Controller Heated Sample Therm
25. An electrical box is mounted to the ceiling of the rack Figure 7 12 for connection of the main electrical feeds to the system The system requires 60 Amp 220 240 VAC connections This box includes screw terminals for these connections x KEL Ex Figure 7 12 AC Mains Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual 7 15 Thermo Fisher Scientific Appendix A Warranty Seller warrants that the Products will operate or perform substantially in conformance with Seller s published specifications and be free from defects in material and workmanship when subjected to normal proper and intended usage by properly trained personnel for the period of time set forth in the product documentation published specifications or package inserts If a period of time is not specified in Seller s product documentation published specifications or package inserts the warranty period shall be one 1 year from the date of shipment to Buyer for equipment and ninety 90 days for all other products the Warranty Period Seller agrees during the Warranty Period to repair or replace at Seller s option defective Products so as to cause the same to operate in substantial conformance with said published specifications provided that a Buyer shall promptly notify Seller in writing upon the discovery of any defect whic
26. CEMS System Overview 1 3 Figure 2 1 Removing the shipping Screws 2 3 Figure 2 2 Analyzer Installation 2 4 Figure 2 3 Purge and Power Connections sssssssssssee 2 5 Figure 2 4 Connecting to the FTIR Unit ccce 2 6 Figure 2 5 Rear Panel Terminal Blocks ssssssssssess 2 8 Figure 2 6 Pneumatic Panel Rear View cener 2 11 Figure 3 1 Component Relational Diagram 3 2 Figure 4 1 Adjusting the Rotameter on the Pneumatic Panel 4 2 Figure 5 1 Probe Assembly s 5 8 Figure 5 2 Filter Housing Lid Assembly 5 9 Figure 5 3 Locating the humidity Indicator 5 12 Figure 5 4 Replacing the Desiccant ssssssee 5 13 Figure 5 5 Removing the Fan Filter 5 15 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 eee 5 18 Figure 5 9 Locating the Laser Assembly seenen 5 20 Figure 5 10 Unlocking the Laser Spring Clamps ssssssss 5 21 Figure 5 11 Removing the Laser Assembly 5 21 Figure 5 12 Locating the Detector Assembly 5 24 Figure 5 13 Removing the Detector Access Plate 5 24 Figure 5 14 FTIR Wiring and Tubing Connections 5 26 Figure 5 15 Corner Screws on Coupling Optics Plate 5 27 Figure 5 16 Removing the Beamsplitter Access P
27. Cro ae Marche eoa Select 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 D B s oS 55 Z5 D D om F Wi Kiet Pas aie Ion de Bahmi Bh mute T iret cese aie t Wi Taipi gaia mir ENTE Ce Program Files imace IMACE FTIR Software Suite ftir calibrate collect AURIAC te alaj configuration calibeation Met C Method SE method 09730 jed TES E Soan Tine PASS o Aversgng Count IT Oo E 5 HHI TET 0319473 HHO Erir abla start a C A conc imacc capture er macerat cipro a Merosot Kecel boka Upon completion of the process a new calibration factor will be calculated Then press Save Factor to Method File button to save the calibration factor Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual 4 15 Calibration oystem Calibration Procedure Using IMACC Collect Oo Metra C Methodi Spit method 05 00 0 a sl MeL HHHO Value perm N20 z Scan Tieren MM 55 im Anaan Count fi c n 0080380 1 SAAN Rena SSTA Cua Foct LI Code 8 000000 Mew Facius 1 177454 im i Calibration Factor has bean saved bo method Ale terme cima 09 0 03 081 method calibrated Press Cancel bo stop showing this mesrage Lom _ aban athe fae ats
28. Definition Auto Bus J Poets COM amp LPT QJ Communion Port COML VJ Commurscations Port COMI QJ Commurscatices Port COMI QJ Commarecat ces Port COMM oF Pritkee Port LPT1 AF USB Serial Poet COMS dh Processors Sound video and ome controllers System devices Ureversal Serial Bus controllers 6 Close Control panel without making any changes Setting the Use the following procedure to set the virtual COM port Virtual COM Port 1 Open CALGrafix software with the icon on the desktop a euis 2 Click the second icon from the left in the icon bar D 4 Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific Thermo Fisher Scientific Calogix Setup setting the Virtual COM Port CAL Grafix Fie Alem View Hep EDO Sa For Help press F1 4 3 Click Browse in the Select Devices popup menu 4 Select the correct number for the COM port Select OR Omni FTIR Multi Gas CEMS Instruction Manual D 5 Calogix Setup Programming the Controllers and Setting Parameters Programming the Controllers and Setting Parameters D 6 Omni FTIR Multi Gas CEMS Instruction Manual CALGrafix EERO Sc For Help press F1 5 The main Calogix control window will open The window is a visual representation of the hardware with readings and setpoints overlaid CALOGIx The following section details the procedure for setting up temperature va
29. Figure 5 27 Note that the red dot on the connector lines up with the red dot on the sensor 11 Disconnect the purge air line from the bottom rear of the unit by pressing the quick disconnect latch on top of the fitting until you hear a click and pulling it out Figure 5 27 The purge air line is connected to the right side fitting labeled Purge In 12 Using the 9 16 inch wrench disconnect the two 1 meter heated lines from the elbow fittings at the rear of the unit Figure 5 27 Note or mark their position to facilitate re connection 5 36 Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific Thermo Fisher Scientific Uscrew cable amp disconnect Preventive Maintenance and Servicing Removing the FTIR ey Unplug all cables attached to rear panel rot c X yes mx e Act eet J omad g EC J x P NA DA 3 vi NI y Y NS Figure 5 27 FTIR Wiring and Tubing 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 2 people carefully lift the FTIR unit off of its base For details see Lifting on page 2 1 15 Re install the FTIR by following the previous steps in reverse order Omni FTIR Multi Gas CEMS Instruction Manual 5 37 Preventive Maintenance and Servicing Replacing the FTIR Power Su
30. HCl so a shorter duration for the NH daily calibration check can be chosen In this case the NH gas cylinder will last much longer than the HCI cylinder For other less reactive gases a 6 minute duration for the daily calibration check would be sufficient A newly purchased A size gas cylinder may last for 6 months The gas concentrations for daily calibration checks should correlate to the typical emission level of the monitoring sources To generate HCl HF NH and H 0 standards using HovaCAL Calibration Gas Generator IAS model HovaCAL digital 211 MF the following concentrations are recommended HCl 0 002 mol l HF 0 002 mol l NH3 0 005 mol l In addition to a HovaCAL a high concentration gas cylinder for HCl 1000 ppm is recommended A gas calibrator such as Thermo Scientific Model 146i should be used to dilute HCI to the desired value for both span check and spike check To perform the spike check the same HCl gas cylinder mixed with 100 ppm SF6 is recommended Thermo Fisher Scientific Manual Background Spectrum Collection Thermo Fisher Scientific Procedure Calibration Manual Background Spectrum Collection Procedure When running IMACC Monitor press Stop Script and press OK go to tab OMNIC TT 1 utm IPIE C Oetumonis and Settings EHE IECIT ET IIR a DGH u Cj esee qe sese NU iem Uy view seige A Ro Cument S tatur 1015 07 1315 33 Duantty buried Oe Scan 12 Precor Complete Ino
31. IP because the higher level protocols ensure error free transmission 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 measurement data from the instrument Issuing either of these function codes will generate the same response These functions read the contents of one or more contiguous registers These registers are 16 bits each and are organized as shown below All measurement values are reported as 32 bit IEEE standard 754 floating point format This uses 2 sequential registers least significant 16 bits first The request specifies the starting register address and the number of registers Registers are addressed starting at zero Therefore registers numbered 1 16 are addressed as 0 15 The register data in the response message are packed as two bytes per register with the binary contents right justified within each byte For each register the first byte contains the high order bits and the second contains the low order bits Omni FTIR Multi Gas CEMS Instruction Manual B 3 Modbus Protocol Function Codes B 4 Omni FTIR Multi Gas CEMS Instruction Manual Request Function Code otarting Address Quantity of Registers Response Function Code Byte Count Register Value N Quantity of Registers 1 Byte 0x03 2 Bytes 0x0000 to maximum allowed by instrument 2 Bytes 1 to maximum
32. Instruction Manual 5 41 Preventive Maintenance and Servicing Replacing the Gas Cell Replacing the Gas Cell 5 42 Omni FTIR Multi Gas CEMS Instruction Manual Unscrew amp n disconnect cable Mie meee ee tubing J Figure 5 31 FTIR Cell Pressure Sensor Replacement 5 Using the 9 16 inch and 3 4 inch wrenches loosen the nut on the rear of the sensor and remove it Figure 5 31 Note the orientation of the sensor 6 Install the new sensor using the above wrenches and tighten the fitting until snug putting it in approximately 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 way Tighten the captive screw until it is snug 8 Follow steps 1 3 in reverse order to complete the procedure Use the following procedure to replace the FTIR gas cell When the gas cell is replaced you need to run through the mirror alignment procedure preferably by a trained service technician Equipment Required Wrench 9 16 inch 7 16 inch and 3 4 inch Hex wrench 5 32 inch and 7 64 inch Phillips screwdriver Gas cell Thermo Fisher Scientific Preventive Maintenance and Servicing Replacing the Gas Cell cool A N CAUTION High surface temperatures present Allow sufficient time to 1 Shut down the FTIR heaters by turning off the Temperature Control circuit breaker on the brea
33. Network Places Details Fe Shortcut to Sample Mode 3e Shortcut 1 KB Imacc Modbus TCP Server Shortcut Bocce C Imacc CurrentLoop Server Shortcut CUTEM C s Imacc System Process Monitor Shortcut 1 KB Imacc Modbus Server Shortcut TEN Turn the switch to the Measurement position to complete the Start up procedure Omni FTIR Multi Gas CEMS Instruction Manual 2 13 System Installation Start Up and Shut Down system Shut Down System Shut Down 2 14 Omni FTIR Multi Gas CEMS Instruction Manual To shut down the system switch the Measurement Maintenance switch to the Maintenance position Turn off the power to Heater this will 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 other circuit breakers OFF one by one and then turn off the main breaker on the breaker panel Note Once the initial startup procedure has been done remember to turn the Maintenance switch to the Measurement position each time the system is powered up A Thermo Fisher Scientific Normal Operation Software Description Thermo Fisher Scientific Chapter 3 Operation This chapter describes the default operation of the system after the initial setup described in Chapter 2 For details see the following topics e Normal Operation on page 3 1 e Software D
34. PC gathers 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 control the FTIR over a USB interface Calogix CALGrafix software is used to communicate with the temperature controller over a USB interface National Instruments NI DAQ software is used to control the analog and digital I O boards IMACC IFSS is used to bring everything together and calculate the individual gas concentrations and report the results A data logger is required to e Capture measurement data in real time e Allow the operator to trigger a calibration check sequence e Manually control calibration gases e Mark data taken during any calibration purge or activity e Generate reports Omni FTIR Multi Gas CEMS Instruction Manual 1 5 Introduction Typical System Flow Data Communications Typical System Flow System Power Distribution Specifications 1 6 Omni FTIR Multi Gas CEMS Instruction Manual The system provides several methods for establishing data communication with a DCS PLC including e Modbus protocol Ethernet or serial e Analog output connections e Digital I O connections Typical communications functions provided by the FTIR Multi Gas CEMS include e Concentration readings e System status or alarms calibration checks blowback etc There are six gas flow modes sample mode blowback inst
35. Thermo Fisher Scientific Maintenance for the Sample Probe AN AN Replacing the Filter Element and Graphite Seals A Thermo Fisher Scientific Preventive Maintenance and Servicing Maintenance for the Sample Probe Use the following procedures to perform maintenance on the sample probe Maintenance procedures are performed periodically to keep the sample probe running efficiently WARNING Aggressive condensate is possible Wear protective glasses and proper protective clothing A WARNING High surface temperatures Wear protective gloves A WARNING Flush probe in the case of toxic gases A CAUTION Before turning off power to the probe i e turning off the heaters the probe should be flushed with inert gas or air in order to avoid condensation of aggressive components of the process gas This can best be accomplished by performing a probe zero A Important Note For any sample probe service procedures that are not covered in this manual please consult the M amp C operator s manual See the Other Manuals on page 1 10 A Use the following procedure to periodically check and or replace the filter element and graphite seals in the sample probe The filter and seals are located inside of the probe box The graphite gasket lid seal must be replaced every time the filter housing lid assembly is removed Equipment Required Ceramic filter element Graphite lid seal Graphite filter seals as required CAUTION High surf
36. Timespan This is a shorter time period subset of the Timespan over which data is displayed on the top graph in the concentration plot control Omni FTIR Multi Gas CEMS Instruction Manual 3 7 Operation Imacc FTIR Software Suite IFSS Datasource Tab The datasource tab is used to configure 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 Directory Pointing the control to a directory containing con files File Pointing the control to a single con file Settings display timespan datasource f Server FrontM ain C Directory C Cons browse C File s remove ET oad Refresh Interval sec 5 Z i Cancel Data files See the following Local Disk C File Edit View Favorites Tools Help pack T e D E Folders 33 Address a CY gj Backgrounds System Tasks L Documents and Settings File and Folder Tasks _jLayouts Methods 53 My Documents Other Places Details Program Files C WINDOWS 3 8 Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific Thermo Fisher Scientific Operation Imacc FTIR Software Suite IFSS C Directory The IFSS reads and writes data files from several directories during data collection and analysis C Backgrounds Spectral scans of zero air a
37. allowed by instrument 1 Byte 0x03 1 Byte 2 x N N x 2 Bytes N N or N 1 Here is an example of a request and response to read registers 9 12 Request Field Name Function otarting Address Hi otarting Address Lo No of Registers Hi No of Registers Lo Response Field Name Function Byte Count Register Value Hi 9 Register Value Lo 9 Register Value Hi 10 Register Value Lo 10 Register Value Hi 11 Register Value Lo 11 Register Value Hi 12 Register Value Lo 12 Hex 0x03 0x00 0x08 0x00 0x04 Hex 0x03 0x06 0x02 Ox2B 0x00 0x00 0x00 x64 0x00 x64 The contents of register 9 are shown as the two byte values of 0x02 0x2B Then contents of registers 10 12 are 0x00 0x00 0x00 0x64 and 0x00 0x64 respectively Thermo Fisher Scientific Thermo Fisher Scientific Modbus Parameters Supported Modbus Protocol Modbus Parameters Supported Table Table B 1 through Table B 4 lists the Modbus addresses supported for the Omni FTIR Multi Gas CEMS IMPORTANT NOTE The addresses in the following table are Protocol Data Unit PDU addresses For Application Data Unit ADU addresses add 40000 to these numbers for holding registers Verify the register number on your Modbus master to ensure that it matches the register number on the instrument A Note For additional information on how to read registers and interpret the data refer to the 0x03 Read Holding Registers section in this a
38. and mirror 3 is used to position the beam image on the objective Omni FTIR Multi Gas CEMS Instruction Manual 5 47 Preventive Maintenance and Servicing Gas Cell Alignment mirror A few adjustments will show which way to move the image to get it to where it needs to be 8 Once the incoming light beam image is positioned adjust the first objective mirror to get the initial image on the field mirror at the position shown as 1 in Figure 5 38 To adjust the first objective 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 removed earlier but the adjustment screws remain Use Figure 5 39 as a guide to locate the screws Also note there is always one more image on the bottom of the field mirror than on the top output I Sample inlet Input adjust iH Pass adjust Input adjust V Viewing port Figure 5 39 Location of Components on Back Plate of Gas Cell 5 48 Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific Thermo Fisher Scientific Preventive Maintenance and Servicing Gas Cell Alignment Note Once the first objective mirror is positioned to get the beam in its proper position on the field mirror this mirror should NOT be readjusted in any of the following steps A J 10 11 Adjust the field mirror to get the image centered on the
39. and then line up the mounting holes Install the mounting screws using the 3 32 inch hex wrench taking care to support the panel until the screws are in place Tighten until snug 12 Re connect the purge air line to the right side fitting labeled Purge In on the bottom rear of the analyzer Press the fitting in until it clicks into place 13 If they were previously removed use the 9 16 inch wrench to re connect the two short heated lines to their original positions on the sample system heater assembly and the FTIR analyzer Tighten until snug 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 indicator light on the analyzer front panel will be on Wait 15 minutes for the new components to stabilize thermally and then align the analyzer by following the instructions in Chapter 3 See OMNIC software on page 3 11 Use the following procedure to replace the detector in the FTIR analyzer The detector is located behind the front panel of the analyzer WARNING To avoid shock hazard always turn off the FTIR circuit breaker on the breaker panel before replacing any components inside the FTIR analyzer A 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 i
40. and tighten the screws with the flat blade screwdriver until snug Ensure that the wires are in the appropriate position as noted earlier Press the end cover down until it locks in place 10 Re install che temperature control box cover per the above 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 are the same There are 3 of one type M1 M2 and M3 and 1 of the other M4 4 20mA See Figure 5 55 to identify and the correct module Equipment Required Phillips screwdriver Small Phillips screwdriver Nut driver 3 8 inch or wrench Temperature control modules 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 components A 1 Remove the temperature control box cover per the previously mentioned procedure Removing and Installing the Cover 2 The 4 temperature control modules are mounted on the temperature control base unit Figure 5 55 Using the 3 8 inch nut driver remove the 2 nuts that mount the control module and base unit assembly to the temperature control box Note the orientation of the assembly Omni FTIR Multi Gas CEMS Instruction Manual 5 69 Preventive Maintenance and Servicing Temperature Control Box Components Replacing the
41. as well as TCP IP over Ethernet e Appendix C Interfacing a DCS PLC with the Omni FTIR Multi Gas CEMS provides details on interfacing DCS PLC with the Omni FTIR Multi Gas CEMS Omni FTIR Multi Gas CEMS Instruction Manual About This Manual oafety e Appendix D Calogix Setup provides a description of the Calogix software e Appendix E IMACC Script Setting describes the script setting for two versions of IMACC scripts e Appendix F Concentration Data Transfer Using a Web Server describes transferring data Safety Review the following information carefully before using the system This manual provides specific information on how to operate the system however if the system is used in a manner not specified by the manufacturer the protection provided by the equipment may be impaired Safety and Equipment This manual contains important information to alert you to potential safety Damage Alerts hazards and risks of equipment damage Refer to the following types of alerts you may see in this manual Safety and Equipment Damage Alert Descriptions PPP Equipment Damage Description A hazard is present that will result in death or serious personal injury if the warning is ignored A A hazard is present or an unsafe practice can result in serious personal injury if the warning is ignored A The hazard or unsafe practice could result in minor to moderate personal injury if the warning is ignored A T
42. astare i C aA omae ncc capture Biinacccoleet ca progra 20 Merosot Kecal Bock To save any 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 should equal the value of the calibration gas spike value 2 E E m um Oy machte Pierii mam A prd Kai a a M uj inr quera PE Imeoret nller amp configuation calibration Method diy Mesrine TaN Hki E Mehed Ssi method 09030 X E HHH 1180 xxxn 7 v MHL Eid Ewi te noon _ lepal Co2HI 3045719 55 524572 N20 T 25 S TUDIN Conse Noe ere Owr HO 10W05 aki iga Scan Time gus 01 00 co 0 025605 0 007337 eT P Natl miran 311638 PATHL ENGTH SATAN Tn E most cate DU 1 MEN EmorSting Ooo 3 DOCODO Flesuk Emy ifa 1 17744 Hew Facto 1 176023 2 Sae Facti To Method Fie paa a An PERE IENE a ee When you return to maccMonitor the reading should equal the value of the calibration gas 4 16 Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific Calibration oystem Calibration Procedure Using IMACC Collect 10150 154803 dec spectrum 41 uam Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual 4 17 Calibration oystem Calibration Procedur
43. beam to pass between the analyzer and the gas cell sample beam path e An electrical interface used by the software to control the gas cell temperature with the heater e A power interface to support the gas cell heater temperature controller and pressure sensor Computer Interface Interface between the FTIR analyzer and the computer is provided through a USB interface Humidity Control The FTIR analyzer ships with desiccant in place to control the humidity inside the optical compartment When installed the FTIR analyzer supports purge with a dry air flow rate of 1 0 l min Air Purifier The Parker Balston 75 45 FTIR Purge Gas Generator delivers clean dry compressed air with a dew point of 73 C The generator removes also CO to a concentration of less than 1 ppm The generator uses a combination of coalescing filtration regenerative pressure swing adsorption and high efficiency particulate filtration to produce laboratory quality dry CO free air from a standard compressed air supply 1 12 Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific System Component Description Industrial PC Figure 7 9 FTIR Purge Gas Generator Industrial PC The PC is used to control the FTIR and system valves perform quantitative analysis on the FTIR spectrum collect data from the temperature controller amp optional FID and report this data The PC provides several methods for establishing data communication with a DCS P
44. damage to sensitive components or improper alignment which will affect the performance of the system A 1 Be sure that the FTIR heaters are still off from the Replacing the Gas Cell procedure that is the Temperature Control circuit breaker on the breaker box is off 2 Using the 5 32 inch hex wrench remove the 2 screws near the fitting plate only that mount the gas cell to the mounting plate 3 Using the Phillips screwdriver remove the 20 screws that mount the cover on the coupling optics relay mirror compartments and then remove the cover Figure 5 34 Do not remove the 2 screws on the front that are further away from the edge than the other screws 4 Using the 5 32 inch hex wrench remove the 4 screws that mount the nickel plated aluminum cell to the plate Carefully remove the gas cell casing leaving the mirrors in place Figure 5 33 Omni FTIR Multi Gas CEMS Instruction Manual 5 45 Preventive Maintenance and Servicing Gas Cell Alignment Sample Cell Mirror 1 Mirror 6 Mirror 5 MINOS Light to flip chen mirror Mirror 4 Mirror 83 Figure 5 34 Optical Layout in the Relay Mirror Compartment 5 If performing the gas cell alignment in a lab environment 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 depicted in Figure 5 35 is recommended for the g
45. down menu system command setting choose background so that the related solenoid valves 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 for all gases reach either zero or their detection limits The concentration changes can be seen on the software live data display since the system is continuously collecting data in this mode Go back to system command setting select save background mode The system starts to collect the spectrum and saves it as c backgrounds bkg spa After completion switch the system command to sample Thermo Fisher Scientific Calibration oystem Calibration Procedure Using IMACC Collect System Calibration Doubleclick on icon ImaccCollect and answer Yes when prompted Procedure Using IMACC Collect Thermo Fisher Scientific Would you like to load ftir calibrate collect gt 8 8 z X z 4 A ZEFA Oy Sauna hers ee Fee di od le barik naria BAID meme ADAE muon ism nena bir naria Ines lisa X eee de sg Saepe tus tias fg ELTE ee a Pegs ayy larai ETUR Td Wi P eakpuiim dits SUE Bop A start FIER OMNI naat captura E mac croient EA Pros Click on the configuration tab click on config button of Spectrometer Control Click the Collect tab to display the method and background used for the calibration fa
46. errors limit and error text This control only works with a running FTIR It displays the most recent concentration values produced from analyzing the acquired spectrum compound cova gt cg C2 2573 23 716 813 HH3 HI 40 345153 571853 aut of Ineanty range NH3L0 Camcentrations Settings kd aut of inearty range CO 2I oul of ineanty range S024 0 nut af fneanty range S02 Dry Dipi Ste aut of ineanty range NO Z dy ls T aut af Ineanty range Ho Shovels CUI 1 L n aut of fneanty range Cn Starr out of Ineanty range sine fes N20 Oz ML Z uet L uu3ui L1uuzi HF 1 io Ds Y HCI Asap g aut af Ineanty range So TE out of Ineanty range wo Dass Fee pi SOME omnii reds 82r UO desinis iara H20 T a Cancel HH3 p nd aul af Ine anty range PATHLENGTH 5 208 Right clicking brings up the settings menu Settings Optical path The optical path for which this control displays results Display style There are three styles list grid and dialog Compound name Determined by the spectral processing method used in the script 3 4 Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific ProcessStatus Thermo Fisher Scientific Operation Imacc FTIR Software Suite IFSS ProcessStatus is used to display various process parameters such as board temperature FTIR status percentage complete numbers of scans completed and pressure laha 11 08 13 23 24 Save concentrati
47. flows may be controlled with the system DAHS connected via MODBUS or manually controlled with buttons located on the bottom of the corresponding solenoid valves located on the inside of the pneumatic panel Figure 2 6 T T N Figure 2 6 Pneumatic Panel Rear View Omni FTIR Multi Gas CEMS Instruction Manual 2 11 System Installation Start Up and Shut Down oystem Startup Heat With the IMACC IFSS running open the IMACC script editor Refer to Appendix E IMACC Script Setting to open the Modbus control block in the script to read system temperatures Once the power has been applied wait until temperatures are at their set points The cell heater control is set on a 90 degree C hour ramp rate Ejector Pump Temp 180 C Heated Cell Temp 185 C Heated line Inlet Temp 180 C Heated line Outlet Temp 180 C IMACC X The IMACC FSS software is preconfigured and starts automatically on computer power up Refer to Chapter 3 Operation for details on software operation Autostart For automatic system start on power up and after power interruptions verify that the following shortcuts are pre loaded into the Windows Startup menu C layouts nnnn layout Where nnnn is the desired layout C Program files Imacc IMACC FTIR Software Suite Imacc System Process Monitor exe
48. from to avoid any issues with driver software A flat blade screwdriver may be necessary to remove the large data cable connectors Figure 5 46 PC Removal 5 Slide the PC console back into the rack Depress the tab at the rear of each slide rail of the PC console to unlock it Figure 5 46 Thermo Fisher Scientific Replacing the PC Thermo Fisher Scientific Console 10 11 12 Preventive Maintenance and Servicing Replacing the PC Console Pull the ring to release the pin that holds the cable routing arm to the bracket on the rear of the PC Figure 5 46 Remove the PC from the rack by depressing the button on each slide rail and pulling the PC out Figure 5 46 Using the Phillips screwdriver remove the slide rails from each side of the PC noting the orientation Figure 5 46 Using the Phillips screwdriver re install the slide rails onto the new PC Lift the PC and place each slide rail into the 2 extender pieces then push in the PC until it stops Depress the 2 side tabs on the slide rails and push the PC in until it locks in place still outside of the rack Figure 5 46 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 Re connect all of the cables to the rear of the PC in the proper locations Follow steps 1 3 in reverse order to c
49. gt gt This program uses the ASCII concentration data files con to drive the current loops in directory C CONS Use the Add and Remove 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 paths to locate the most recent file and updates the data in its output buffers if they have changed since the last query The DAQ Board specifies the National Instruments device number assigned to the current loop board Value 1 must be specified The AutoStart feature automatically begins data transmission when the current loop program is opened Thermo Fisher Scientific Operation Data Server Software amp ImaccCurrentLoop Valid Data Settings Wines min Good Scans Waid Data Channel 11 pood data Configuration CON File Dieci nes petal Retesh when noted by script Output Range Fieftesh Interval ms Min maj 0 000000 1000 Max rn 20 000000 DAD Board F Save Settings Analog Output Board The PCI 7604 analog output board has eight digital channels DIOO DIO7 and 16 analog channels which may be used in either 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 Sulphur dioxide S02 16 Nitric oxide N
50. m ean cu eaten eee mae 5 19 Replace mie the tC Obecana s t CIE Cei eate debet la EE eret 5 22 Replacing the Beams pli tien soto ipte emp oin ide 5 25 Replacmp the Air Hite rs cete Ete oe xenon E E 5 29 Removing the Purge Gas Generator iu oid er opi ere dues ep bons 5 31 Reniovine the Lett side lanebsosaeeseubiotu step Edited 5 33 Removine the FEIR resero a bi on iet REIP Ep e 5 34 Replacing the FTIR Power Supply eere Ee end 5 38 Replacing the Temperature Sensor cer terio ten d rene rit perdi un 5 39 Replacine the Pressure Sensor e4ueseieteet pha iq lea fh s eats 5 41 Io ecru okecg da Acro Go C 5 42 Gas Cell BoDnTHe eoa eise nb orn tb peer pep qa pun E 5 44 Replacme the Gas Cell EIe3tete oie orto tA ER Ob 5 51 R pheine the Teated 168 espe nea apnd ait iban F beide 5 54 Replacme the TOn seg rena OMM eas 5 55 Replacing the PC Consoles iue eeedo csctcnaqcedoraiacuasetenuetondananusieesek 5 57 Omni FTIR Multi Gas CEMS Instruction Manual ix Contents Chapter 6 Chapter 7 x OmniFTIR Multi Gas CEMS Instruction Manual Replacing the National Instruments Boards 5 59 Temperature Control Box Components eese 5 62 BReplacme External PUSES ases enm etes n Der HR Ped 5 62 Replacing Internal Components suec caeci ext Eoi one ba S cr HE seeds 5 64 Removing and Installing the Cover esses 5 64 Replacing the Internal Bus65 si con orit te E Ore tesi ER
51. 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 the bulkhead fittings to the box for the Ejector Air In FTIR In and FTIR Out 4 Using the 3 16 inch hex wrench loosen and remove the 4 large screws in the corners that mount the heated block assembly to the box 5 Carefully slide the heated block assembly out of the sample system heater assembly box 6 To re install the heated block assembly slide it back into the sample system heater assembly box Ensure that the washers on the bulkhead fittings are positioned against the outside wall of the box and be sure that the grommet for the heater wires and RTD is properly seated 7 Using the 3 16 inch hex wrench install and tighten the 4 mounting screws in the corners of the heated block assembly until snug Thermo Fisher Scientific Replacing the Check Thermo Fisher Scientific Preventive Maintenance and Servicing sample System Heater Assembly Components 8 Using the 5 8 inch wrench tighten the bulkhead nuts on the Ejector Air In the FTIR In and the FTIR Out fittings until they are snug Use a second 5 8inch wrench to hold the hex part of the fitting in place to keep the fittings from trying to spin during reassembly 9 Follow steps 1 2 in reverse order to complete the procedure Use the following procedure to replace the check valve insid
52. of the analyzer WARNING To avoid shock hazard always turn off the FTIR circuit breaker on the breaker panel before replacing any components inside the FTIR analyzer A CAUTION The source element becomes extremely hot during normal analyzer operation Always turn off the analyzer and allow the elements to cool for at least 15 minutes before removing the source from the analyzer Handle the source assembly only by the ceramic base A 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 components A Important Note The FTIR analyzer source is pinned in place and pre aligned Replacing the source should not affect measurement results however an improperly installed or handled source will affect the performance of the system A system operator can replace the source however it is recommended that only our certified service engineers or on site maintenance personnel who have been trained by us replace the source A Important Note Never touch the new source element with your bare fingers Skin oils or other deposits on the element will shorten its life A Equipment Required Phillips screwdriver Hex wrench 3 32 inch Source assembly 1 Using the Phillips screwdriver remove the FTIR cover panel in the front of the system rack Slide the FTIR drawer out of the rack to gain access to the analyzer Ther
53. on page 1 6 e Specifications on page 1 6 e Other Manuals on page 1 10 amp 5 Figure 1 1 Omni FTIR Multi Gas CEMS Thermo Fisher Scientific Introduction oystem Overview System The Omni FTIR Multi Gas CEMS is a complete continuous emissions monitoring system CEMS designed to extract a sample from a source and Overview 77 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 S
54. orr Default Temperture 23c Default Pressure 760T orr 185 750 185 750 Cancel 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 the mirror velocity is also selected using the pull down menu e Change of HCl zero offset To monitor sticky gas such as HCl and NH3 from stack gas the system zero offset needs to be determined by daily zero cal results and be subtracted from raw data either using PLC or via script By default a zero offset of 0 25 ppm is applied in the script setting for HCl measurement If the users need to make an adjustment click the Calculating Setting block right below the Collect EZ setting block Its setting subpanel pops up as shown Omni FTIR Multi Gas CEMS Instruction Manual E 5 IMACC Script Setting CEMS SampleMode E 6 Omni FTIR Multi Gas CEMS Instruction Manual Calc 20 jexpressions Calculation Settings Optical path Front ain FrontM ain Define Initial Codes Expressions HCI_offset HCl AVG 0 3 i Add Status Value Test Return Code test value returned by this control nonzero if true Result Codes temporary Overwrite CONs temporary Globals this path Global all paths pum v Add results to CONs Save CON file immediately Cancel Users can edit the calculation expression displayed in the expressi
55. process are to be consulted prior to any maintenance work A 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 component A Note If a data acquisition system DAS is being used with the FTIR turning the maintenance key on the front of the rack will indicate that maintenance is being performed on the system A During normal operation the system may become dirty over time depending on the environment in which it is installed T he system may be cleaned keeping in mind the following warning and important notes WARNING Avoid shock hazard Always turn off the circuit breaker on the breaker panel on the front of the rack for any component to be cleaned Do not allow cleaning solutions or liquids to run into the analyzer its power supply or any powered components A Important Remember to turn off the circuit breaker for a component when cleaning it Use a damp not wet soft cloth and a mild soap to clean the outside of any components Do not use harsh detergents solvents chemicals or abrasives these can damage the finish A Important Do not attempt to clean or even touch the mirror surfaces inside the analyzer These front surfaced mirrors are easily scratched Dust will not harm the mid infrared signal but fingerprints and scratches can degrade spectral performance or permanently damage the mirrors A
56. retrieve real time concentration data The file appears in the IE window just as it would in Excel or a word processor The user can then write software to take the data from IE and use it in his or her applications Installation of IIS FTIR and Remote Computers 1 Install Windows Internet Information Services on both the FTIR PC and remote computers by going to Start Control Panel Add or Remove Programs 2 Click Add Remove Windows Components 3 Click the Internet Information Services IIS box to add it to the list of installed components Do not uncheck any of the existing components or you will uninstall them 4 Click Next to begin installation 5 Allow Windows to reboot after installation is complete Omni FTIR Multi Gas CEMS Instruction Manual F 1 Concentration Data Transfer Using a Web Server Modbus Control Version Configuration of ISS for Autostarting FTIR and Remote 1 Open Windows Explorer and expand the paths to show C Documents and Settings lt Username Start Menu Startup where lt Username is the name of the logon account this is typically F77R User for IMACC configured computers 2 Also expand the path to C Windows System32 INETSRV 3 Create a shortcut of the file izetmgr 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 1 Create a data tr
57. samples More specifically it measures the frequencies or wavelengths at which the sample absorbs radiation and the intensities of the absorptions to determine concentrations of specific gases Intensity and frequency or wavelength of sample absorption are depicted in a two dimensional plot called a spectrum Intensity is generally reported in terms of transmittance the amount of light that passes through the sample or its inverse absorbance the amount of light absorbed by the sample Frequency is usually reported in terms of wave numbers cm 1 With quantitative analysis the 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 absorbance for an unknown sample can be used to calculate concentration Figure 7 5 FTIR Analyzer Infrared light from the source is directed to the Michelson interferometer a key component of FTIR spectrometry In the interferometer the light beam strikes the beamsplitter About half of the light is reflected from the beamsplitter and is directed onto the fixed mirror The remainder of the light is transmitted through the beamsplitter and is directed onto the moving mirror The two beams are reflected from the mirrors to the beamsplitter where they recombine When the beams recombine constructive or destructive interference occurs depending on the relat
58. second objective mirror Figure 5 33 The adjustment screws on the field mirror are behind the mirror and are fitted with 11 32 nuts so they can be adjusted from the sides Use a small open end wrench to access them Once the image is aligned on the center of the second objective mirror adjust the second objective mirror to get the exiting image positioned in the field mirror cutout at the same position as the incoming beam in the cutout in front of the input window These positions are shown in Figure 5 38 The cell gas should at this point 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 appear on the surface of the field mirror These two rows should be parallel so the exiting image remains at the proper position as the passes are adjusted If the rows are not parallel adjust the tilt adjustment screw top screw on the second objective mirror to get them parallel This should also reposition the exiting image so it is in the proper position as shown earlier in Figure 5 38 The pass adjust screw may need to be readjusted some to keep a beam exiting as you alter the vertical adjustment Continue increasing passes while adjusting the vertical position of the second objective mirror until the maximum number of passes is obtained with the images remaining parallel on the field mirror and the
59. system capable of collecting data at 1 scan per every 4 seconds at 0 5 cm 1 resolution ideal for detailed analysis of rapidly changing complex gas mixtures With no instrumental variation introduced into spectral collection or calibrations method transferability is ensured In addition method maintenance is virtually eliminated allowing uninterrupted operation and analysis The Omni FTIR CEMS uses the hot wet extractive measurement technique The sample handling system consists of a direct extractive probe heated sample line not included with the system pump assembly hydrator and purge gas generator The probe extracts and conditions a continuous sample from a stack or duct for transport to the Antaris IGS The entire sample stream from the probe stinger to the analysis bench is maintained at a temperature of 190 C to prevent sample loss or condensation The Omni FTIR Multi Gas CEMS has the unique ability to switch to a Flowback mode that purges the sample stream all the way from the analyzer through the sample line to the tip of the probe This feature enables clean and continuous operation of the system and eliminates the likelihood of sample line contamination Omni FTIR Multi Gas CEMS Instruction Manual 1 1 Introduction oystem Overview 1 2 Omni FTIR Multi Gas CEMS Instruction Manual For details see the following topics e System Overview on page 1 3 e Typical System Flow on page 1 6 e System Power Distribution
60. the cal zero port at a reduced rate typically not more than 1096 of the sample flow rate of 6 LPM This mode is executed for the daily system spike check Check Span During the check span mode the system is configured for sample mode with the probe span valve open to allow 6 LPM span gas into the stinger via the cal zero port This mode is executed for the daily system span check SAMPLE PROBE WITH RACK BOUNDARY 2um HEATED FILTER AND 20um PREFLTER p EJECTOR AIR PE rg EE d Jr B NS 1 PEE N Ex t Pec xu EHEATE VENT YAN YONI INIPYA i A PNEUMATICS PANEL BOUNDARY ie LI K gt INSTRUMEN N BACK J N ZERO se S EATED Cp 4 LPM Vp 4 LPM T LINES Bava BEEF 1M TEN Lars lu RESSURE E NC WW NC MW NC M VC MW NO Wy TRANSDUCER FTIR T T F F j a PROBE S AN PROBE AN PRO ES We HEATED SPIKE VJ VJ SPAN V VJ ZERO V V CFL 0 5 LPM 5 LPM LPM v HCL SF6 8 FTIR ANALYZER IN L K ON FPA MIX O8 z M A CO2 FREE AIR ki 22 29 PS M REGULATOR 75 PSI AR FILTER ASSY E PUR FIER HOUSE A l PSI Figure 7 4 Sample and Calibration Gas Flow Diagram 7 6 Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific Thermo Fisher Scientific FTIR System Component Description FTIR The FTIR analyzer Figure 7 5 measures the interaction of infrared IR radiation with
61. the clamp release hooks near the bottom of the analyzer compartment Figure 5 10 Thermo Fisher Scientific Thermo Fisher Scientific Preventive Maintenance and Servicing Maintenance and Servicing of the FTIR Analyzer Components Wir ud Figure 5 10 Unlocking the Laser Spring Clamps 7 Remove the laser assembly from the analyzer by lifting it straight up until it clears the alignment pin on the left mounting bracket Figure 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 the left bracket engages the hole in the laser tube Push it down all the way until it sits flat on the mounting bracket Important Note Do not attempt to twist or turn the laser assembly once it engages the alignment pin If the laser is misaligned the analyzer will not scan A 9 Place the springs over the laser tube and re attach the clamp release hooks Omni FTIR Multi Gas CEMS Instruction Manual 5 21 Preventive Maintenance and Servicing Maintenance and Servicing of the FTIR Analyzer Components Replacing the Detector A A 5 22 Omni FTIR Multi Gas CEMS Instruction Manual 10 Connect the laser power supply cable to the power distribution cable 11 Re install the analyzer rear panel Be careful to place all internal cables completely inside the analyzer to avoid damaging them
62. through a mathematical function called Fourier Transform or FT The function calculates the amplitude of each of the component signals The amplitude gives the intensity at the corresponding wavelength of light A Thermo Fisher Scientific Optical Components Thermo Fisher Scientific Source System Component Description FTIR display called a spectrum then appears on the computer s screen The spectrum is a graphic representation of the sample in terms of light absorbed or transmitted by the sample at various frequencies wave numbers along the spectrum The size and position of the peaks in the spectrum are used to identify or quantify the composition 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 provides the electrical and optical functions The major components it includes are the interferometer source and laser Where possible the optical components are pinned in place for easy service and maintenance Figure 7 7 Spectrometer Compartment The FTIR analyzer uses Thermo Fishser Scientific s EverGlo source The source unit can be replaced as needed It is pre aligned and needs no adjustment when it is installed Omni FTIR Multi Gas CEMS Instruction Manual 7 9 System Component Description FTIR Interferometer This assembly modulates all the IR frequencies down to
63. wing nuts and mounting bracket from the pressure gauge Remove the gauge from the front of the pneumatic panel Figure 5 62 5 Remove the nut and ferrules from the fitting on the new pressure gauge and discard them 6 Insert the new pressure gauge through the front of the pneumatic panel and hold it in place positioning 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 fingers until snug 7 Re connect the PTFE line to the fitting on the new pressure gauge and then tighten the nut using the 9 16 inch wrench until snug 8 Set the house air regulator back to the pressure noted earlier then push the knob down to lock it 9 Re install the left side panel to complete the procedure Replacing the Use the following procedure to replace the solenoid valves on the Solenoid Valves Pneumatic panel The procedure is the same to replace any of the five solenoid valves except where noted Four of the solenoid valves have the same part number but the solenoid valve for the instrument zero has a different part number from the rear of the panel it is the furthest to the right See Figure 5 62 Be sure to order the correct valve Equipment Required Phillips screwdriver Small Phillips screwdriver Wrench 9 16 inch and 3 4 inch 5 92 Omni FTIR Multi Gas CEMS Instruction Manual Th
64. 2 Analog Outputs oo cece ccc cecesescesesseseseesertetesesteerttereaeen C 4 Figure C 3 Digital O Rear Panel Terminals C 5 Figure 6 4 SSR Hallie ister ntiatea ct ncen adesset dssdo detur d uobis uec C 6 Figure C 5 SSR Indicator Light Configurations C 6 Figure D 1 Base Unit and Four Controllers sssssssssse D 1 Figure D 2 Temperature Controller Connection sssssssse D 2 Omni FTIR Multi Gas CEMS Instruction Manual xv Figures xvi Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific Thermo Fisher Scientific Tables Table 1 1 FTIR Compounds ssssssssssssses 1 7 Table 1 2 FTIR Performance Specifications 1 7 Table 1 3 Electrical Connections s a etc tete duri eem t ets 1 8 Table Es iSo B REI TREE Pee 1 8 Table 1 5 PneurialtlbS ec coctus e Uto du Gee Eo Ut RED PED UTI Ru 1 9 Table 1 6 Free Standing Cabinet 1 9 Table 3 1 Analog Current Channel Assignments sss 3 15 Table 4 1 Calibration Factors 4 20 Table 5 1 Replacement Parts List 5 3 Table B 1 Modbus Read Registers B 5 Table B 2 Modbus Write Registers B 6 Table B 3 System Command Values sssssssssseee B 6 Table B 4 System Flag Bits B 7 Table C 1 Analog Output Connections ssssssssssssses C 3 Table C 2 Digital O CODITeCBDIISueetiedsetude tete vectus eum tto einen C 5 Table D
65. 36 00 sample Probe Lid Seal Retaining Washer 113337 00 3 6 months sample Probe Heater Cartridge 220V 113338 00 sample Probe Aluminum Heater Block 113339 00 sample Probe SS Check Valve 1 4 NPT 10 PSI 113340 00 sample Probe SS Check Valve Spring 10 PSI 113341 00 Sample Probe Shield 2 5 112871 00 Instrument Air Handling and Rack Part Number Replacement Period Rack side panel key 113314 00 Maintenance Panel Assembly 109699 00 Maintenance Key 113315 00 FTIR Purge Gas Generator 112944 00 FTIR Purge Gas Generator Maintenance Kit kit contains 113309 00 1 year one BX instrument air filter DX Instrument Air Filter box of 10 9810 9 12 months BX Instrument Air Filter box of 10 9811 9 12 months Omni FTIR Multi Gas CEMS Instruction Manual 5 3 Preventive Maintenance and Servicing Replacement Parts List 5 4 Omni FTIR Multi Gas CEMS Instruction Manual Cl Instrument Air Filter Hydrator Assembly Sample System sample System Heater Assembly Assembly Replacement Eductor Pump Assembly Replacement Sample Solenoid Valve Check Valve Thermostat 400 Degrees F FTIR Instrument FTIR Instrument Assembly FTIR Maintenance Kit Laser Fan Filter Source Desiccant Humidity Indicator FTIR Desiccant packages and humidity label FTIR Desiccant package FTIR Humidity Indicator FTIR IGS HeNe Laser Assembly FTIR IGS Source Assembly FTIR IGS DTGS Detector Assembly FTIR KBr Beamsplitter Assembly FTIR Pressure Sensor FTIR Pressure Sen
66. 4 Chapter 3 AT uror mme D H 3 1 Notnab OPAO sco E DN MER en Ia uM UE 3 1 SOltware escEIDHOB o a usa ERA SERO ERAN N S ID DN Muf 3 1 Imacc FTIR Software Suite IFSS eee 3 2 MONO as oetonctendii ac uinea E ate eeu itc edi ictu Lie c 3 2 CODCeBELEAtLOHS PAC ies cscs d eicit ead eto de lccsraintdseciercuens od eti 3 4 PROCESS EAS oionn Sese o m ed aiuti Reset oA Li eoo deut ene irte teo Al 3 5 Concentra onPlot Spectrum Plot ei reet etra eec 3 6 DRDD Een 3 6 T E E E N N E EN NE E N 3 7 Datasouroe Tabernara A MM aM ILLE 3 8 Me INE 3 8 Remote Control e mare Oe abe Mi m a a aa es 3 10 bI nc MEOS P RR REN E on c e 3 10 SCPE ENSINO pe 3 10 OLS UC EEE N AE MM ADM M E A AS 3 11 RE O E OE 3 13 INI oies UM E M EUM RN LM EI 3 13 COND Gee career eee nee te mere E dM LM Ee Le D A aoe E 3 13 COMUS B DIN cae aieit ie ouod es Dcee deni cer Seo OEA 3 13 Data Server So tWalte er ore rete rep hr ken o exea aeo pe vasa erep eie us 3 13 Imacet urtentE o0 Dogs toco a a 3 13 COT OUTS eiie cibi enon da sepe ditte acide est orsi tatit pdd ise 3 14 viii Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific Thermo Fisher Scientific Contents Analog Output Board pitt c sa Ucet Ed uda quta EE SD BL Dee usu 3 15 ImaccModbus ImaccModbusTCP eese 3 16 Galibrati fessnssenidi a aedteedadecaedatentdeauvaelaslt 4 1 Automatic FTIR Instrument Zero Background Collection
67. 6 3 Boot Up Error IMACC Software Error eene 6 4 Tonmperature DrrORS cedant tfr n M EU atom 6 4 Cell Pressure Errors Sampling System Errors 6 5 Commmuilicatioh EPFOES coca csr eee ih nae ernie DOLUS DU RU E Mesue 6 6 AREO obo Pcbete deris vase E brian b hem scu Ue ancien mines 6 7 SERV cede bl 6 gs EA A ers E C ER E E EE 6 8 System Component Description eren 1 1 Sample Probes odisse E Eu s uota pesi t etse 7 2 Temperature Contool iesea turpes bt sd AS 7 3 Heated Sample Dei pus i i t pee rx US iba sus epe a etta 7 3 Feared Pampi Valve ASe mb eor nM EUR tRU 7 4 o EO e N TS E E 7 4 Pneuiiatie Panel iocos a A DN i EID 7 4 Saraple Od veedadust citus asta its tinis EAMINN Ud dep T 7 5 Thermo Fisher Scientific Contents BIOUBJCI euet asst seinen UON MEM MU LEM EE MEE 7 5 Instrument Background Scan and Flowback 7 5 Check Zelt exe erste tuu e OE E EE LEE MeL A CE M MEL cM ELE 7 6 ire di c m 7 6 C Beck S DT teen MEA etna UEM LS UE 7 6 Kc RERO A 7 7 Optical Componer iios aate n EN M NC UL E 7 9 SDOIUBRCOn A AEE Om FO LC M E M LO ULM 7 9 nt etleto meter osos etu UI dst obse a tebu Art a DEA A PN IRAE EIE 7 10 EOS ERN RNC 7 10 PATIO NT iberotsetbk E E E A 7 10 ADOTOU cot MN 7 10 IGISCLOL oedcueeeta on used d tec RE IM LL UM tmd ERE om onto 7 11 O TEE MERI LIU 7 11 Gas Cell Heads ACK e
68. D 1 The hardware is connected to the system computer with a USB cable with a type B connector on the controller unit and type A on the computer The USB cable should always be connected to the computer at the lower left USB socket Figure D 2 The hardware is also connected to a 220 VAC supply from circuit breaker panel Figure D 1 Base Unit and Four Controllers Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual D 1 Calogix Setup Finding the Correct COM Port Finding the Correct COM Port D 2 Omni FTIR Multi Gas CEMS Instruction Manual Temperature Controller Connection Figure D 2 Temperature Controller Connection The Calogix software communicates with the controller hardware via USB with 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 controller Use the following procedure to determine the COM port number 1 Turn the power ON to the Temperature control box 2 Select Start menu and open Control Panel Run System B Q Os rates FF Address D Control Panel Accessib ty Add Hardware Add Opbors Reese w ue Fort Atini ote Tools o InteXR GMA Internet Controllers Driver Opbora ty xE Lb h C Network Setup Phone and PowerOptions Privtersand R ad Modem Faxes L ur ent g O e Scanners and Scheduled Sec Cameras Tas
69. Databits 8 Flow Control None Press OK to close ModbusMultiSensor Settings box Omni FTIR Multi Gas CEMS Instruction Manual 4 13 Calibration oystem Calibration Procedure Using IMACC Collect 4 14 Omni FTIR Multi Gas CEMS Instruction Manual ImaccCollect C IFSS FTIR_calibrate collect Optical Path FrontM ain IEEE float CELLPRES OxOa2a 1 Click on Single Collect button to verify that the system is operating properly 2 Ld Wy Danas Caan Ux Dioni do DEI Ur ic E j f f F S Em Bah nin Re Me MMC EU hnas nzis sewage t se eee a Pedil iiri Astar a C A orac imace captura Dpztmacctosicct cipro ax Microsoft Ecel Bocka 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 enter the required compound and click the add button Check that the corresponding compounds in the method are selected for the highlighted compound Thermo Fisher Scientific Calibration oystem Calibration Procedure Using IMACC Collect 2 9s B E E Wy Masana fii ane Banim Bh maa E iri 2 dA dies d agre te 3 Current m um S uu P E a Se quer Pjan incer ET J p E ele ul usn Pree Theta 2E E ehe siegt Tiam ey Method Scan Time HIM 55 or o0 Joverageng Count E c iy OldFaet 1 008273 HeFe ej TEE Ban CJ A oema mae apare P macaa
70. De Energised FALSE FALSE FALSE None 185 PID Module 4 NC Pres None 0 1 Custom Sensor 1000 0 0 Custom sensor 1000 921 17 69 None None None De Energised De Energised De Energised FALSE FALSE FALSE None PARK Thermo Fisher Scientific Thermo Fisher Scientific Module Settings Channel 2 Control Enabled Setpoint Mode Alarm Control Input Mode Operating Mode Mode Subsidiary Mode Setpoint Band Cycle Time Maximum Power Minimum Power Output Power Manual Power Display Alarm Reset Latched Alarm Programmer Program number Run mode Module 1 Yes 185 PID Channel 1 BAND OnOff None 10 2 10 100 100 Off No No On Calogix Setup Programming the Controllers and Setting Parameters Module 2 Yes 185 PID Channel 1 BAND OnOff None 10 2 10 100 0 100 Off No No On Module 3 Yes PID Channel 1 BAND OnOff None 10 2 10 100 100 Off No No On Module 4 No PARK Channel 1 None PARK None 0 2 10 100 Off No No Off Omni FTIR Multi Gas CEMS Instruction Manual D 11 Appendix E IMACC Script Setting This chapter describes the script setting for two versions of IMACC scripts One is named CEMS sample mode in which the scheduled events for daily zero span checks background spectrum collection and frequent blowback are all set and adjusted in the script setting The other is the Modbus co
71. EEE ESEEAZZTPLZZZCZZZZEEZLLLLLLLLLLAe TROT 3T 320 13 TS 5E 0320 171 1812 15 0320 13 T8ACHE 03 20 13 181551 32013 141812 ORM 1871 32 OR H T 204421 TZ 4 m V1 1653 iid MM FE a TROU 3T D 20 13 THe Se 0 20 13 121215 220 13 19 1474 00 20 13 1216 51 02200 13 121212 0220 13 1821 2203 20 E There are 28 calibration factors listed in the Table 4 1 Calibration Factors For each calibration factor the appropriate concentration range and H O content are listed Gases with no H O value should be calibrated with dry certified gases For those with an H2O content range such as HCl wet the calibration must be done in that wet condition Omni FTIR Multi Gas CEMS Instruction Manual 4 19 Calibration oystem Calibration Procedure Using Calibration Factor Table in Method Table 4 1 Calibration Factors 4 20 Omni FTIR Multi Gas CEMS Instruction Manual Gases Range H20 C02 0 to 30 NH3 HI 16 to 105 ppm NH3 lo 0 to 0 ppm C02 HI 0 to 30 9502 LO 0 to 50 ppm 502 dry 0 to 350 ppm lt 13 NO2 wet 0 to 60 ppm 1 NO_wet 10 500 ppm 1 CO_HI 57 to 766 ppm N20 0 to 50 ppm 9502 HI 0 to 350 ppm HCl Lo 0 to 13 ppm HCl Hi 15 to 100 ppm H20 LO 5 to 40 lt 2 HF dry 0 to 14 ppm 0 5 96 H20 HI 3 to 35 gt 2 CH4 0 to 1000 ppm CO_LO 10 to 100 ppm NO_dry_LO 1 to 103 ppm lt 1 HF_wet 0 to 15 ppm gt 0 5 96 HCl dry 0 to 13 ppm 0 596 HCl wet 13 to 100 ppm g
72. ER GRAPHITE WASHER Figure 5 2 Filter Housing Lid Assembly 10 11 Replace the large graphite gasket lid seal with a new one Line up the through hole in the lid seal with the hole in the lid Inspect the 3 graphite gasket filter element seals and replace if necessary Install the retaining washer the 3 graphite filter seals and the new filter element onto the assembly See Figure 5 2 for the correct order of installation Thread on the knurled filter lock screw and tighten until snug Before re installing the filter housing lid assembly the filter housing itself can be cleaned using a clean cloth dampened only with clean water Re install the filter housing lid assembly into the filter housing by pushing it all the way in Flip the retaining clamp back into position so that it engages the small bar handle and then turn the bar handle clockwise to tighten Turn the T handle approximately 1 turn clockwise or until snug Re install the probe protection shield onto the probe Close the two pressure clamps to secure the shield to the probe assembly Omni FTIR Multi Gas CEMS Instruction Manual 5 9 Preventive Maintenance and Servicing Maintenance for the Sample Probe Replacing the Pre filter 5 10 Omni FTIR Multi Gas CEMS Instruction Manual 12 Power up the probe by turning on the Probe circuit breaker on the breaker box to complete the procedure Use the following procedure to replace the pre f
73. Errors on page 6 6 e Service Locations on page 6 8 The Technical Support Department at 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 the model number and serial number of the instrument Use the following check sheet to verify that parameters and settings are within specification This will assist in diagnosing any problems with the system Check Sheet e Visual Inspection of Operating Parameters e Pressure on system regulator on right side of rack e System pressure 75 PSI e Pressures on pneumatic panel e CO Free Air 2 0 3 0 bar 30 44 PSI e Pump Air 1 0 3 0 bar 12 44 PSI e Flows on pneumatic panel e FTIR Purge Air 1 0 1 5 LPM Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual 6 1 Troubleshooting service Locations 6 2 Omni FTIR Multi Gas CEMS Instruction Manual e Instrument Zero Air 6 LPM when in instrument zero mode e Flowback 3 LPM when in instrument zero mode e Probe Zero Cal Gas 6 LPM when in probe zero mode e Probe Span Cal Gas 6 LPM when in probe span mode e Probe Spike Cal Gas 0 5 LPM when in probe spike mode Temperatures in IMACC software e Heated sample line 185 Deg C e Heated pump valve assembly 180 Deg C after 30 minute ramp up e FTIR Sample Cell 180 Deg C after 2 hour ramp
74. FTIR circuit breaker and power supply connections If scan LED off not flashing check USB connection between PC and FTIR make sure script is running in ImaccMonitor Status mark on OMNIC see Chapter 3 Operation Check cable between computer and FTIR see Chapter 7 System Component Description No concentration updates in IMACC software Make sure script is running in ImaccMonitor See Concentration errors in this chapter No temperature readings See Temperature errors in this chapter I O Errors 420ma analog output errors e Wrong concentration reported for one or more gases Check ImaccCurrentLoop server value and outputs mA cc 55 5 cc readings If value doesn t look correct see Concentration Errors Otherwise if output mA doesn t look correct check the channel min cutoff and max cutoff settings in ImaccCurrentLoop see Chapter 3 Imacc CurrentLoo P P Server Use a current meter to check the current directly at the terminal block in the rear of the system Pull out the disconnect to remove any external wiring from the current loop If reading looks OK on meter check wiring and settings in DCS Datalogger Check wiring from therminal block to breakout board on opposite side of electrical panel Check cable from breaker board to NI PCI 6704 board inside PC Digital I O errors Gas mode output or FTIR data valid digital output is not reportin
75. Fisher Scientific Operation Result Result is an additional FTIR spectrometer driver that must be loaded with OMNIC No user accessible functions are available with Result The National Instruments NI DAQ driver software runs the NI PCI 6704 analog board and the NI PCI 6509 digital board The 6704 board is used for 4 20 mA data output The 6509 board is used for digital I O and sample system valve control The NI DAQ Measurement Explorer can be used by Thermo Fisher Scientific service personnel for system troubleshooting CALGRafix software can be used for configuration of the CALogix controllers The CALogix controllers are located in the Temperature Control Box TCB The controllers are used by the system for cell pressure readout and system temperature control See Appendix J Calogix controllers The CDM USB driver is loaded to 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 output and control capabilities as needed e ImaccCurrentLoop provides analog data output in 4 20ma format e ImaccModbus allows for data output and control input via serial Modbus e ImaccModbusTCP allows for data output and control input via Ethernet Modbus This software runs concurrently under the control of the Imacc server ImaccCurrentLoop exe operates the National Instruments PCI 6704 a
76. H E lo E Aa BA BA 3M M el 1 O O FAN JUL Ve oooooo d o z Tor enS mem g En H H Fol a nil f T D x1 4 ES m 5 gl h e g 5 po pt E w e leen T Hod N ra nm Un i N e j rmm TE D Figure 5 25 Remove Screws and Two Lowest Panels 4 Slide the FTIR drawer out of the system to access the rear of the unit Figure 5 26 Figure 5 26 FTIR Shelf Out Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual 5 35 Preventive Maintenance and Servicing Removing the FTIR 5 Note or mark the position of wiring and fittings to facilitate re connection 6 Using the Phillips screwdriver loosen the mounting screws and unplug the power cord from the top rear of the unit Figure 5 27 7 Unplug the USB cable from the top rear of the unit Figure 5 27 8 Using the small Phillips screwdriver loosen the captive screw that holds the pressure sensor cable in place then pull the cable assembly off of the sensor Figure 5 27 9 Using the Phillips screwdriver remove the 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 sensor connector from the sensor by pulling it off exposing the 3 metal prongs
77. LC including e Modbus protocol RS 232 Serial or Ethernet e Analog output connections e Digital I O connections The PC is a 2U industrial rackmount chassis with an Intel Pentium 4 processor Front panel DVD R drive 3 5 floppy drive and USB connectors are provided as additional means to move data off the system as well as install system updates Figure 7 10 FTIR PC Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual 7 13 System Component Description Console I O Boards A National Instruments PCI 6704 board is used to provide 4 20mA analog outputs for all of the gas concentrations This connects to a 68 screw terminal connector board on the electrical panel assembly A National Instruments PCI 6509 board provides up to 96 digital inputs outputs which are used to control system valves provide status outputs and control inputs from the user This board connects to a 30 screw terminal connector board on the electrical panel assembly Console Aiu keyboard drawer with integrated 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 Datalogger An optional data logger may be used to e Capture user selected measurement data in real time e Allow the operator to trigger calibration sequences e Manually and automatically control calibration gases e Mark data taken during any calibration purge or activity Electr
78. Laat Veran 310m Laat Yma ALTTADOQ Lait Tarp sshuls 1 Lact Presse Pi BEDE a n TT sgt Re DUET punc P ae a Cerne rio is m nr PUG fis THES 101 oam ie RT LA An eck Erro recente dex bI o A caecos Toa 5 In OMNIC select Exp Set tab Collect and set the following No of scans 30 Resolution 0 5 Final Format Interferogram Correction None E m a P E uw Omni FTIR Multi Gas CEMS Instruction Manual 4 5 Calibration Manual Background Spectrum Collection Procedure 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 Pie tide Cube Ves Press Anais Report Vandoe depo Ga Prisi neut Cedar Then go to Col Smp Collect Sample Set the name of the new background in the following format zero air background and date year mm dd Press OK 4 6 Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific Calibration Manual Background Spectrum Collection Procedure Make sure the system is flushed with zero air wait 5 min then press OK again Chara i Callgct Sanplel Me pie qd Cobect Wee Prpces Anais Report Wirde dap Ge Priced The system will now collect 30 scans when prompted with Add to IMACC capture press Yes IET m1 UH lie Edt Cabe Ves Puce Anabar Bapat ince depo Gat Procell Ther
79. Module 1 Output settings Ej Modde 1 Programmer CALOg Xx For Help press F1 Omni FTIR Multi Gas CEMS Instruction Manual D 9 Thermo Fisher Scientific Calogix Setup Programming the Controllers and Setting Parameters D 10 Omni FTIR Multi Gas CEMS Instruction Manual Module Settings Module Name Operating Units Input settings Display Resolution Channel 1 Sensor Type Channel 1 Setpoint Upper Limit Channel 1 Setpoint Lower Limit Channel 1 Span Offset Channel 1 Zero Offset Channel 2 Sensor Type Channel 2 Setpoint Upper Limit Channel 2 Setpoint Lower Limit Channel 2 Span Offset Channel 2 Zero Offset Output settings Channel 1 Control Output Channel 2 Control Output Alarm Setpoint Output Output1 Burnout state Output2 Burnout state Output3 Burnout state Output Inversion Output2 Inversion Output3 Inversion Output Inhibit Channel 1 Control Setpoint Mode Table D 1 Controller Values Module 1 sample Inlet Deg C 0 1 RTD 2 wire 200 0 0 RTD 2 wire 200 Output Qutput2 Output3 De Energised De Energised De Energised FALSE FALSE FALSE None 185 PID Module 2 Pump Outlet Deg C 0 1 RID 2 wire 200 0 0 RTD 2 wire 200 Output Qutput2 Output3 De Energised De Energised De Energised FALSE FALSE FALSE None 185 PID Module 3 FTIR NC Deg C 0 1 RID 2 wire 200 0 0 RTD 2 wire 200 Output Qutput2 Output3 De Energised De Energised
80. O 17 Nitrogen dioxide NO2 18 Nitrous oxide N20 19 Ammonia NH3 20 Hydrogen chloride HCI 21 Hydrogen fluoride HF 22 Carbon monoxide CO 23 Carbon dioxide c02 24 Water H20 25 Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual 3 15 Operation Data Server Software ImaccModbus ImaccModbus TCP 3 16 Omni FTIR Multi Gas CEMS Instruction Manual ImaccModbus exe and ImaccModbusTCP exe provide Modbus connectivity via serial and Ethernet communications respectively Refer to Appendix B Modbus Protocol for detailed Modbus configuration instructions Eiai file type register nn data 1BLIT icon 40053 no data 1HEX mcn 40055 na data con 40057 no data m 40059 no data select compound Start Stap Configure lt lt Configuration Directories FSN ova Modbus 2 4 Add gt gt Remove Refresh Interval ms B Modbus Settings ELEM 9600 S Mone 1 None W Auto Start To change the compound file type or register information simply enter the new setting in the Modbus window the entries are automatically updated in the registry when the program is closed Clicking on cells in the compound and file type 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 record until the first FTIR
81. Omni FTIR Multi Gas CEMS Instruction Manual Part Number 108004 00 11Apr2013 2013 Thermo Fisher Scientific Inc All rights reserved Specifications 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 thermoscientific com aqi Thermo Fisher Scientific WEEE Compliance This product is required to comply with the European Union s Waste Electrical amp Electronic Equipment WEEE Directive 2002 96 EC It is marked with the following symbol Thermo Fisher Scientific 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 s compliance with these Directives the recyclers in your country and information on Thermo Fisher Scientific products which may assist the detection of substances subject to the RoHS Directive are available at www thermoscientific com WEEERoHS WEEE Compliance Thermo Fisher Scientific WEEE Compliance Thermo Fisher Scientific About This Manual This manual provides information about installing maintaining and servicing the Omni FTIR Multi Gas CEMS It also contains important alerts to ensure safe operation and prevent equipment damage The manual is organize
82. PLC with the Omni FTIR Multi Gas CEMS C 1 latro US PIOTIcuesca muU D M M MEL eM DN MEE ERE C 1 Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual xi Contents Connecting a DCS PLC to the Omni FTIR Multi Gas CEMS C 2 Establishing Communications erede ud d Deas tio re ede C 3 Analog OU PU T I C 3 Metta VO e E C 4 oolidestate Ixelavs SS R oessevvicotec epu Violet PIRMEE Gna vidatte C 6 SOLES II ocior eei sped aces nese MU EM REED MM E M UE C 6 Appendix D CalOgix S tUD m D 1 m Ere eI BI Serpo TER DO ert er eterna D 1 Finding the Correct COM Port Su sie DRE P p eed D 2 Setting the Virtual COM POr dads uei eae pi eie dus D 4 Programming the Controllers and Setting Parameters D 6 Creatine Ramp Probramnis cesen nea o a tbi a cv dense esent tasa ed D 7 lnputtine Controller Valueisu iones odstu i I ORAE D 9 Appendix E IMAGE Script Setting eee eec neiren enean E 1 CEMS SampleModeitop e Hr ate ted medetetu tiene t tod E 1 Modbus Control Version eee E 10 Appendix F Concentration Data Transfer Using a Web Server F 1 xii Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific Thermo Fisher Scientific Figures Figure 1 1 Omni FTIR Multi Gas CEMS ssssssssssne 1 2 Figure 1 2 Omni FTIR Multi Gas
83. R IN THE EVENT OF A DEFECTIVE PRODUCT EXCEPT AS EXPRESSLY PROVIDED IN THIS WARRANTY STATEMENT SELLER DISCLAIMS ALL OTHER WARRANTIES WHETHER EXPRESS OR IMPLIED ORAL OR WRITTEN WITH RESPECT TO THE PRODUCTS INCLUDING WITHOUT LIMITATION ALL IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE SELLER DOES NOT WARRANT THAT THE PRODUCTS ARE ERROR FREE OR WILL ACCOMPLISH ANY PARTICULAR RESULT A 2 Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific Appendix B Modbus Protocol This appendix provides a description of the Modbus Protocol Interface and is supported both over RS 232 RTU protocol as well as TCP IP over Ethernet TCP The Modbus commands that are implemented are explained in detail in this document The Modbus protocol support for the Omni FTIR Multi Gas CEMS enables the user to perform the functions of reading the various concentrations and other measurement values and status as well as trigger the various system sampling modes The maccModbus server software allows the data acquisition computer to 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 Modbus registers to transmit concentration and measurement data in floating point format The TCP version also has the ability to accept an F06 Write Single Register command For details of the Om
84. Server Imot Server Hd x ua IMACC Sener herir 22 5 Tha solteere i heensed Io use per machine Coppigh 2062 MACE Cog w ebziha Flsgish ation Al Fugit Fieserved The main client for the Imacc Server s data is the Imacc Monitor Script Engine The Imacc Script Editor is used to create an FTIR control strategy or script The Imacc FTIR Script Engine controls the operation of the system through the server The scripting engine can also be used to control additional hardware components such as valves to control sample collection on a timed basis The script editor can be launched by double clicking on the ImaccScriptEeditor icon See diagram A script file can be loaded in the editor or by using the file menu 3 10 Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific Thermo Fisher Scientific OMNIC Operation OMNIC maccScript The script can be observed in operation by selecting View Script in the Monitor Layout window The currently active part of the script will be highlighted in yellow Viewing the running script can also be used to observe the collection of data from the Sample System Heater Assembly as shown in the illustration B ImaccScriptEditor C Scripts Omni script running File Edit Settings View Help Conditional Structures container hile Script running ontainer System Runnning Status iteration 414 time 03 28 13 13 04 23 Ema b
85. T Gev methods Holcin SFS Path Length mj 9 2090001 X bapa MUT 0853 I Tinevame 1 0000 E add remove remove al sott by ppm m tave sel set eerereerererereeerereeeereerererreee reerereeerereryreeeeeeerereeeereeern 0 0000 0 0000 0 0000 0 0000 No spectra in Inearly set can have a zero concentration value set all 10000 xad er NEM NNI 2 5000000000000 5227366735494 4980399018545 02 1 0000 De 100000 00000000 10000000000001 10031286556205 0 EET 15000000000000 143740 36251745 15023166448125 022 0 0000 0 0000 0 0000 0 0000 200000 00000000 184523 40655358 200023930067248 001 Click the linearity tab and you will see the tab button Calibration Factors Click the button and open the table as shown below Calibration Factors 4 18 Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific Thermo Fisher Scientific Calibration oystem Calibration Procedure Using Calibration Factor Table in Method Next to the gas item list shown above there are three columns The first column is used to store the zero offset the second column is used to store the calibration factors and the third column is used to store quadratic term factors Only the second column needs to be edited for the calibration Users can change the value by typing the new calibration factor and clicking the OK button to save it Prior to performing the calibration it is always recommended to keep a record of the original calibra
86. TWIST CONNECT TEMP CONT FTIR INLET TWIST CONNECT TEMP CONT FTIR DUTLET Qu 112 EATED SAMPLE LINE 2 112 HEATED SAMPLE ASSEMBLY 112 WIST CONNECT EMP CONT PUMP 108009 00 TWIST CONNECT TEMP CONT FTIR CELL TIR 112796 USB C CLOWER LEFT USB FTIR PRESSURE SENSOR 112795 DB 9 TEMP CONT PRESSURE PC UPPER RIG SB 112796 USB TEMP CONT USB WRAP IN PLACE SLIDE COMPONENTS IN AND DUT TO ENSURE NO SNAGS Figure 2 4 Connecting to the FTIR Unit The FTIR power supply is located inside the rear of the FTIR shelf to the FTIR Connect the power cord from the power supply to the circular socket on the back chassis of the FTIR Tighten the two thumb screws attached to the connector Thermo Fisher Scientific Connecting the Computer Cable to the FTIR Connect the Pressure Transducer Cable to the FTIR Connect the Cell Heater Cable to the FTIR Connect Sample lines to the Heated Pump Valve Assembly Hydrator Thermo Fisher Scientific System Installation Start Up and Shut Down Installing the FTIR Analyzer into the Rack This is a USB A B cable This cable should always be attached to the USB port located the upper right hand corner of the cluster of four on the rear panel of the computer The other end connects to the port labeled Computer on the FTIR This cable is terminated with a square contact female DIN connector One end is hardwired to the electronics in the r
87. Temperature Control Base Unit 5 70 Omni FTIR Multi Gas CEMS Instruction Manual To remove one of the temperature control modules lift the assembly so you can access the bottom of it Squeeze the two mounting tabs of the module inward while lifting the module off of the base unit to release it To remove the wires from the control module pull the terminal block connectors off of the front and rear of the module Install the new module by inserting the tabs into the slots in the base unit and snapping it into place Ensure that it is in the same orientation as the other 3 control modules Remove the unwired terminal block connectors from the front and rear of the new module and discard them Re insert the wired terminal block connectors in the front and rear of the new module in the appropriate position until they snap into place Place the control module and base unit assembly onto the threaded studs in the correct orientation Thread the nuts on and tighten with the 3 8 inch nut driver until snug Re install the temperature control box cover per the above procedure Removing and Installing the Cover Use the following procedure to replace the temperature control base unit inside of the temperature control box Figure 5 55 Equipment Required Phillips screwdriver Small Phillips screwdriver Nut driver 3 8 inch or wrench Temperature control base unit Equipment Damage Some internal components can be damaged by small am
88. The Imacc FTIR Monitor is a user interface that displays the operational information and analysis results of the FTIR system As installed by Thermo Fisher Scientific the system computer is configured to automatically load ImaccMonitor with a pre configured layout file when the computer boots up This layout will be designed in advance for each installation by Thermo Fisher Scientific and will call a pre configured script file Both the layout and the script are also user configurable jus InaccHonitar Thermo Fisher Scientific Operation Imacc FTIR Software Suite IFSS The ImaccMonitor can be manually started from the Windows Start menu or by double clicking the ImaccMonitor Icon shown above on the desktop and loading a layout file layout or launched directly from a selected layout file or shortcut Once loaded the run P and stop m script controls on the Monitor toolbar can be used to manually start and stop the execution of the Monitor The loaded script can be observed by selecting the View Script button in the script controls The ImaccScriptEditor will open the script currently saved 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 will also display data as it is collected As an example the function block that collects temperature data from
89. They should be set by manufacturer before shipment to customers e Spectrum collection setting Following the Modbus multisensor setting is the script setting for the FTIR optical bench or interferometer Double click the setting block named Collect EZ setup to set its setting subpanel to pop up as shown opral paths Proni bbuin com port 5 settings 9600 8 None 1 None Collect EZ Setup collect bench directories omnic options spectral math Scan Time MM 55 Low Cutoff High Cutoff 0 58 400 4500 response o bytes IW Use Method Shift Settings Shift File Data Collection Collect Settings pathName FrontMain IpathLength 5 209 scan Time 0 58 elapsedTime browse Shift Start Shift Stop gt Shift Max Delay Shift Interpolate Shift Count Bench Settings WlightSource IR Background spa PointsFile pts C8 ackground bkg spa browse Methods C method R ate method Mitsubishi tentative me lt lt add lt lt lt gt gt gt remove gt gt v Use Dyanamic References v Use Bias Correction Cancel method s C method Rate method Mitsubishi tentative method V Forget Analysis State background C Background bkg spa On the top there are six named function buttons The setting panel is the display under the collect button A scan time of 0 58 is the duration of an FTIR interferometer scan time for eac
90. ables completely inside the analyzer to avoid damaging them 8 Power up the FTIR analyzer by turning on the FTIR circuit breaker on the breaker box 9 Slide the FTIR drawer back into the rack then use the Phillips screwdriver to re install the FTIR cover panel and its mounting screws to complete the installation procedure 10 Wait 15 minutes for the new components to stabilize thermally and then align the analyzer by following the instructions in Chapter 3 See OMNIC software on page 3 11 Verify that the new detector is working properly by switching the system to zero 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 beamsplitter in the FTIR analyzer The beamsplitter is located underneath the top access panel of the analyzer The top plate that mounts the gas cell assembly and the coupling optics must be removed to get to that top access panel WARNING To avoid shock hazard always turn off the FTIR circuit breaker on the breaker panel before replacing any components inside the FTIR analyzer A CAUTION High surface temperatures present Allow sufficient time to cool A CAUTION The beamsplitters are extremely delicate Hold them only by the handle Do not touch the mounting pads and do not touch or breathe on the substrate Keep the exposure to humid air to a minimum A Important Not
91. ace temperatures present Allow sufficient time to cool A 1 Flush the probe with inert gas or air to clear any toxic gases Omni FTIR Multi Gas CEMS Instruction Manual 5 7 Preventive Maintenance and Servicing Maintenance for the Sample Probe 5 8 2 Shut down the probe by turning off the Probe circuit breaker on the breaker box Allow the probe components to cool for at least 1 hour before proceeding 3 Open the two pressure clamps that secure the probe protection shield to the probe assembly Remove the probe protection shield and 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 filter housing lid assembly out of the filter housing Error Reference source not found FLIP OPEN LOOSEN Figure 5 1 Probe Assembly 5 Unscrew the knurled filter lock screw from the end of the filter housing lid assembly Remove the filter element the 3 graphite gasket filter element seals the retaining washer and the graphite gasket lid seal from the assembly Properly dispose of the used filter element and the graphite gasket lid seal Figure 5 2 Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific Thermo Fisher Scientific Preventive Maintenance and Servicing Maintenance for the Sample Probe GRAPHITE WASH
92. ack Attach the connector to the pressure transducer plumbed to the FTIR This cable is terminated with a 7 pin male circular connector One end is wired to the FTIR with spade lug connectors and a white 3 terminal RTD connector Attach the circular connector to the socket marked FTIR on the temperature control box Connect the spade lug connectors to matching connectors on the heater wires emerging from the optical cell 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 absorption cell to the heated valve pump assembly using the insulated lines connected to the correspondingly labeled fittings on the assembly Refer to the label affixed to the top of the FTIR to determine cell input and output Cut silicone rubber supplied with the system into pieces long enough to cover exposed fittings and tubing at both ends of heated lines and fittings attached to the vent of the heated sample box insulate call outs Check fittings for tightness and wrap silicone rubber around fitting tubing and tie wrap in place The flowback hydrator is located on the right side of the rack At this time we do not recommend filling the hydrator with water for normal operation of the system but it may be used in the future Omni FTIR Multi Gas CEMS Instruction Manual 2 7 System Installation Start Up and S
93. all other control valves are in normal sampling mode and the output results are saved in cons file in the directory of C cons or via data logger Zero air is generated from the system purge gas generator All plumbing work should be ready after system installation is complete When doing a system zero check the user just needs to follow the auto procedure set by the PLC to perform system daily zero check To ensure a sufficient zero air flow into the sample probe it would be necessary to adjust the rotameter shown in Figure 4 1 Figure 4 1 Adjusting the Rotameter on the Pneumatic Panel Thermo Fisher Scientific Periodic System Span Check System Dynamic Spiking External Audit Gas Procedure Thermo Fisher Scientific Calibration Periodic System Span Check Following a system zero check a system span check is scheduled to proceed Similarly the system span check is controlled by the operator via Thermo Modbus Controller check span or PLC By triggering the system span check solenoid valve a sufficient span gas flow gt 6 LPM out of the corresponding gas cylinder is introduced into the sample probe via the heated umbilical same heated line as system zero check right before the probe primary filter The deviations in system span drift and or precision of the measuring system can be detected recorded either by system computer or data logger Adjustmen
94. amage to the interferometer do not apply electric power to the analyzer before internal shipping restraints have been removed ed A Lift from each side of the analyzer not from the front and back Damage to the unit may occur A Ethernet and serial Modbus can not be implemented at the same time A Sample gas should not be introduced to the cell until the cell has reached 185 C Before air pressure is applied to the system insure that the system Is in system zero state Disconnect alarm connection from terminals 1 and 2 on rear terminal block X3 This with place the system in the state with sample valve closed and system zero valve open A The safety instructions specific to the plant and process are to be consulted prior to any maintenance work A Before turning off power to the probe i e turning off the heaters the probe should be flushed with inert gas or air in order to avoid condensation of aggressive components of the process gas This can best be accomplished by performing a probe zero A High surface temperatures present Allow sufficient time tocool A Avoid burn and fire hazards Do not attempt to regenerate spent desiccant packets A he source element becomes extremely hot during normal analyzer operation Always turn off the analyzer and allow the elements to cool for at least 15 minutes Omni FTIR Multi Gas CEMS Instruction Manual iii About This Manual WEEE Symbol Alert Description before removing th
95. and tear ii accident disaster or event of force majeure iii misuse fault or negligence of or by Buyer iv use of the Products in a manner for which Omni FTIR Multi Gas CEMS Instruction Manual A 1 Warranty Warranty they were not designed v causes external to the Products such as but not limited to power failure or electrical power surges vi improper storage and handling of the Products or vii use of the Products in combination with equipment or software not supplied by Seller If Seller determines that Products for which Buyer has requested warranty services are not covered by the warranty hereunder Buyer shall pay or reimburse Seller for all costs of investigating and responding to such request at Seller s then prevailing time and materials rates If Seller provides repair services or replacement parts that are not covered by the warranty provided in this warranty Buyer shall 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 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 AFFECTED PRODUCTS THE OBLIGATIONS CREATED BY THIS WARRANTY STATEMENT TO REPAIR OR REPLACE A DEFECITVE PRODUCT SHALL BE THE SOLE REMEDY OF BUYE
96. and the equipment that has been put on the market after 13 August 2005 A Thermo Fisher Scientific Where to Get Help Thermo Fisher Scientific About This Manual Where to Get Help 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 thermoscientific com 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 product documents and information on a constant basis Available 24 hours a day and seven days a week the online library provides quick access to information regardless of time zone or office hours To register for an account or log in please visit www thermoscientific com agilibrary Omni FTIR Multi Gas CEMS Instruction Manual v About This Manual Where to Get Help vi Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific Thermo Fisher Scientific Contents BUENO UN CHOON eroe 1 1 m Jn caa SEM 1 3 Salil Ole LPO We a ND t aene bun n e tea UR DUM 1 4 Sampie LNE ear pei beu pk duda update P Mrs ubi mS 1 4 Temperature CODITOll entice aint ba RD aedi 1 4 Sample C ondit OD usen daseesz co doma sper iti isa errr terre ere 1 4 FE HO e leds ae rc dasannreeetele Rano ao 1 4 b EEE PAAA east daly ainda sarsaueeenda
97. anel 5 20 Figure 5 17 Removing the Beamsplitter ssssssee 5 28 Figure 5 18 Turning Off House Arr 5 29 Figure 5 19 Removing Filter Cap 5 30 Figure 5 20 Unscrewing Filter Element ssssssssssee 5 30 Figure 5 21 Installing Filter Element u 5 31 Figure 5 22 Removing the Purge Gas Generator 5 32 Figure 5 23 Lock and Hand Grips sssssssssssssee 5 33 Figure 5 24 Posts and Keyhole Slots 5 34 Figure 5 25 Remove screws and Two Lowest Panels 5 35 Omni FTIR Multi Gas CEMS Instruction Manual xiii Figures xiv Omni FTIR Multi Gas CEMS Instruction Manual Figure 5 26 FTIR Shelf DUDscadtit emet rebote be Duet e tard tai sd 5 35 Figure 5 27 FTIR Wiring and Tubing Connections 5 3 Figure 5 28 Rubber Mount Nut Removal 5 37 Figure 5 29 FTIR Power Supply Replacement 5 38 Figure 5 30 FTIR Cell RTD Temperature Sensor Replacement 5 40 Figure 5 31 FTIR Cell Pressure Sensor Replacement 5 42 Figure 5 32 FTIR Heated Gas Cell Replacement 5 44 Figure 5 33 Gas Cell Mirror Configuration 5 45 Figure 5 34 Optical Layout in the Relay Mirror Compartment 5 46 Figure 5 35 Visible Laser Module for Gas Cell Alignment 5 46 Figure 5 36 Visible Laser Used to Align the Gas C
98. ansfer folder e g C Current Data 2 Open znetmgr exe 3 The second line in the left pane will display the name of the FTIR computer click on its plus sign and then on the plus sign that will appear before Web Sites 4 Highlight Default Web Site 5 Click on Action New Virtual Directory Next 6 Enter FTTR Data into the Alias window and click Next 7 Browse for the data transfer folder and click Next 8 Check Read and Run scripts and click Next and Finish to complete the setup F 2 Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific Concentration Data Transfer Using a Web Server Modbus Control Version Test of Concentration Data Retrieval 1 To test the retrieval process copy any concentration data file on the FTIR computer to the data transfer folder and rename it current con 2 Open Internet Explorer on the remote computer 3 In the IE Address bar enter ttp lt address gt FTIR Data current con where address is either the FTIR computer s name on the network or its IP address 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 necessarily required users may develop their own IIS compatible programs to access and transfer the data Configuration of IFSS for IIS Data Transfer FTIR Computer 1 Open IMACC Script Editor and open the data c
99. any are present tighten the fitting until the leaking stops Turn the air regulator back down to zero PSI Remove the 1 4 inch Swagelok plug from the FTIR In fitting and then disconnect the air line with the union fitting from the Instrument Zero line Remove the union fitting from the end of the air line Disconnect the air line from the tee on the side of the rack Re connect the inlet of the purge gas generator to its original position This completes the leak test Using the 9 64 inch hex wrench tighten the 5 mounting screws that were loosened that attach the double coil clamp plate to the heated block until snug Follow the procedures referenced in step 2 Removing the Heated Block Assembly and in step 1 Removing the Sample System Heater Assembly and Cover in reverse order to complete the procedure Omni FTIR Multi Gas CEMS Instruction Manual 5 89 Preventive Maintenance and Servicing Pneumatic Panel Components Pneumatic Panel Use the following procedures to replace the pneumatic panel components Components FRONT REE PUMP PURGE INSTRUMENT FLOWBACK PROBE PROBE PROBE C M AIR AIR AIR AIR ZERO SPAN Figure 5 62 Pneumatic Panel Components Replacement Replacing the Use the following procedure to replace the pre
100. as cell alignment Place the visible laser module to the open hole Open area 1 where the IR light comes out of the bench illustrated in Figure 5 36 Figure 5 35 Visible Laser Module for Gas Cell Alignment 5 46 Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific Thermo Fisher Scientific Preventive Maintenance and Servicing Gas Cell Alignment Figure 5 36 Visible Laser Used to Align the Gas Cell 6 Check that the visible laser beam or white light beam is centered or nearly centered in the spherical mirror 2 in the coupling optics compartment Figure 5 34 Then adjust the spherical mirror until the beam is roughly centered in the flat mirror 3 just before the input window of gas cell Adjustments are made with the associated finger screws Beam Image 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 33 and Figure 5 37 Check the position of the image in the field mirror cutout If the image is hitting the edge of the field mirror or if it is not roughly in position adjust the sphere 2 flat 3 and 45 degree mirror 1 so the image is properly positioned in the field mirror cutout while also being centered on the objective mirror Mirror 1 is used to adjust the beam image on mirror 2 mirror 2 is used to adjust the beam image on mirror 3
101. by the system The pneumatic panel Figure 7 3 includes pressure regulators and flow meter regulators to control various system flows e Ejector Pump Pressure 7 3 43 5 PSI e CO Free Air Pressure 22 29 PSI e FID Combustion Air Pressure optional 45 PSI FTIR Purge Gas Flow 1 0 L min e FTIR Zero Air Flow 4 0 L min e Sample Line Flowback Flow 4 0 L min e Probe Zero Flow 6 0 L min e Probe Span Flow 6 0 L min e Probe Spike Flow 0 4 L min Thermo Fisher Scientific Sample mode Blowback Instrument Background Scan and Flowback Thermo Fisher Scientific System Component Description Pneumatic Panel 7 AN L P Ad a JE J K VN S VA AA J Figure 7 3 Pneumatic Panel In the sample mode normal operation the status of the sample valve is open and all other control valves are closed Flue gas is pumped through a pre filter 20 micron heated probe barrel stinger primary filter 2 micron heated sample line and heated optical gas cell of the FTIR analyzer Exiting the optical cell the sample flow is diluted with zero air and dumped to the exhausted tube During blowback mode sequentially the sample valve is closed and the three way solenoid control valve inside the probe head is energized to be open The pressurized air out of the accumulator tank is rapidly released into the heated stinger to blowback through the pre filt
102. cal panel by following steps 1 4 in reverse order Use the following procedures to replace the sample system heater assembly components Use the following procedure to remove the sample system heater assembly and its cover to access the internal components The sample system heater assembly is located at the rear of the system Figure 5 58 Equipment Required Phillips screwdriver Wrench 9 16 inch 1 2 inch and 5 8 inch Wire cutters Tie wraps zip ties CAUTION High surface temperatures present Allow sufficient time to cool A 1 Shut off the Temperature Control circuit breaker on the breaker box and allow the components to cool for 1 hour 2 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 down to zero Figure 5 18 3 Using the 9 16 inch wrench and the 1 2 inch wrench loosen the nuts and remove the lines with fittings attached from the connections on the front cover of the box They are the instrument zero air the flow back air the heated sample line and the auxiliary sample line if equipped Note or mark the location of each line to facilitate reconnection Thermo Fisher Scientific Preventive Maintenance and Servicing sample System Heater Assembly Components
103. ce and Servicing Removing the Left Side Panel 7 Re install the purge gas generator by following the previous steps in reverse order Reset the regulator to its original pressure and lock it by pushing down on the knob Note Due to the effect of humidity on certain components inside the FTIR it is important to minimize the amount of time that the purge air 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 A Use the following procedure to remove the side panel on the left side of the system in order to view or gain access to internal components Removing the Left Side Panel The side panel is held on the rack by posts and keyhole slots therefore no tools are needed to remove it Using the supplied key unlock the side panel Simply grasp the hand grips on the panel and carefully lift it about an inch then pull the panel away from the rack to remove it Figure 5 23 and Figure 5 24 l 7 ume g 7 fo A LL ZZ 2 E AUN L 7 d LL k Z LO 8 L a Z ZZ gt Pa ue Figure 5 23 Lock and Hand Grips Omni FTIR Multi Gas CEMS Instruction Manual 5 33 Thermo Fisher Scientific Preventive Maintenance and Servicing Removing the FTIR Removing the FTIR 5 34 Omni FTIR Multi Gas CEMS Instru
104. cientific Systems integrated by others will vary from the information provided in this document A OJUSE AIR IN HYDRATUR STR CIRCUIT BREA l fs C Hes PNEUMATICS PANEL F T4 le RBI ANK PANE ip NK PAN i L9 J I Pi i PC l l MAINTENANCE PANE l T n n a TL ewe conto E HL BLANK PANEL U U h Ing 4 amp I f U B 8 V EM Figure 1 2 Omni FTIR Multi Gas CEMS System Overview Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual 1 3 Introduction oystem Overview Sample Probe Sample Line Temperature Controller Sample Conditioning FTIR 1 4 Omni FTIR Multi Gas CEMS Instruction Manual The direct extractive probe assembly is used to extract and condition a continuous sample from a stack or duct for transport to a gas analysis system The standard probe assembly consists of a 1 meter heated probe barrel and pre filter a heated filter assembly and a blow back tank and valve assembly The standard sample probe has an ANSI 4 inch flange mount and 1 0 meter heated probe barrel but can be custom ordered to meet customer requirements A flexible heated line is used to convey the sample from the sample probe to the sample conditioning assembly in the system rack This line includes a 1 4 inch sample line a 1 4 inch calibration line and a 3 8 inch blowback line The sample line length may be from 33 feet 10 meters to 100 feet 30 5 meters
105. could be cleaned with water in an ultrasonic bath and then re used If doing so perform several blow backs on the system after installation is complete to dry the pre filter Thermo Fisher Scientific Maintenance and Servicing of the FTIR Analyzer Components A Checking and Replacing the Desiccant A A Thermo Fisher Scientific Preventive Maintenance and Servicing Maintenance and Servicing of the FTIR Analyzer Components 6 Using the 5 16 inch hex wrench install the new pre filter into the stinger and tighten until snug 7 Re install the probe tip shield onto the end of the stinger Using the 3 8 inch wrench and the 5 32 inch hex wrench tighten the locknut and screw on the probe tip shield until snug 8 Remove the flange cap from the stack opening Carefully re install che probe into the stack making sure the gasket is properly seated Thread the 4 flange nuts and washers onto the threaded studs and then tighten using the 15 16 inch wrench until snug 9 Power up the probe by turning on the Probe circuit breaker on the breaker box to complete the procedure Use the following procedures to perform maintenance and servicing on the FTIR analyzer Maintenance procedures are performed periodically 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 section If there are other p
106. ction Manual Figure 5 24 Posts and Keyhole Slots 2 To re install lift the panel and line up the posts to the 6 keyhole slots Push the panel against the rack until it is flush using the weight of the panel to drop it into place Use the following procedure to remove the FTIR from the system Equipment Required Wrench 9 16 inch and 7 16 inch Phillips screwdriver Small Phillips screwdriver CAUTION High surface temperatures present Allow sufficient time to cool A 1 Shut down the FTIR and heaters by turning off the FTIR circuit breaker and the Temperature Control circuit breaker on the breaker box Allow it to cool for 1 hour Turn off all calibration gases and the air regulator on the right side of the system Note the pressure so it can be reset when completed 2 Remove the 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 the system and the blank panel above it Figure 5 25 Thermo Fisher Scientific Preventive Maintenance and Servicing Removing the FTIR Hu HH H H
107. ctors Verify or set the following Background C backgrounds bkg spa Method c methods Omni method Scan time 0 56 Low Cutoff 400 High Cutoff 4500 Use Method Shift Settings Not enabled Use Dynamic References Enabled Use Bias Correction Not enabled Use Dynamic Shifting Enabled Forget Analysis State Enabled Omni FTIR Multi Gas CEMS Instruction Manual 4 11 Calibration oystem Calibration Procedure Using IMACC Collect 4 12 Omni FTIR Multi Gas CEMS Instruction Manual Ig Carrere m Es Loop Gy ig Al a E Le Vorst nets id noxae Re e P viri minas i us Iss e a E im SAT ut Fe in uw c e tollect ce serue o 0x enilect bench directories emma options apasta math Scan Tine HM 55 Low Cut High Cui mo 0 p je i Shit Mas Delay 5 hit interpolata Shit Count pai Pasie ptt Mrackgrsundi BEG EPA beonvpa M C Matheds yell method HHHO ealtheme cc add xc T H reme Esdr xin Ce ag a a stet CJ A ormi mace capture IE ect ctn E Microsc Canal Docks i to mE em 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 0 5 Correlation Simple Default Temperature 185 Default Pressure 750 Press OK to close Collect EZ Setup box 3 mT E i f ZA eS Phorum Wanni iB maing Pami na
108. d Vent Gas allows for spent analyte gas to be released to the atmosphere The bottom exhaust marked Vent Condensate provides for spent analyte gas condensate liquid venting All liquids gravity drain do not clog tubing The recommended maximum tubing length is ten feet Consult Thermo Fisher Scientific for longer lengths The Omni FTIR Multi Gas CEMS has the capability of simultaneous measurement of ten or more gases The actual gases required will depend on the application Two ports are 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 amp C SP2000 H probe via the heated calibration line Adjust calibration gas regulators to an output pressure of 40 psi Refer to Appendix B Modbus Protocol for detailed Modbus instructions The system may be connected via Ethernet for MODBUS communications with the IMACC server software ImaccModbusTCP exe Communication to the system is provided by connecting to the ADAM 6520L Ethernet switch Windows Remote Desktop and Windows File Sharing may be used while connected to Ethernet Refer to Appendix F Concentration Data Transfer Using a Web Server for detailed instructions The system may be connected serially for MODBUS communications via the computer s RS 232 serial port 1 using IMACC server software ImaccM
109. d into the following chapters and appendixes to provide direct access to specific operation and service information e Chapter 1 Introduction provides an overview of the product describes the system components and product specifications e Chapter 2 System Installation Start Up and Shut Down describes the setup and different instrument configurations and provides a quick start procedure e Chapter 3 Operation describes the functions of the instrument keypad and the enhanced probe display e Chapter 4 Calibration provides the calibration process and procedures for calibrating the instrument e Chapter 5 Preventive Maintenance and Servicing provides maintenance procedures to ensure reliable and consistent instrument operation and step by step instructions for repairing and replacing components and a replacement parts list It also includes contact information for product support and technical information e Chapter 6 Troubleshooting provides guidelines for diagnosing analyzer problems isolating faults and includes recommended actions for restoring proper operation e Chapter 7 System Component Description provides an overview theory of operation and describes the function of the system components e Appendix A Warranty is a copy of the warranty statement e Appendix B Modbus Protocol provides a description of the Modbus Protocol Interface and is supported both over RS 232 485 RTU protocol
110. ded studs in the correct orientation Thread the nuts on and tighten with the 3 8 inch nut driver until snug 10 Re insert the 2 connectors in the front of the base unit in the appropriate positions 11 Re install che temperature control box cover per the above procedure Removing and Installing the Cover Electrical Panel Use the following procedures to replace the electrical panel components Components Figure 5 56 and Figure 5 57 Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual 5 71 Preventive Maintenance and Servicing Electrical Panel Components 5 72 Omni FTIR Multi Gas CEMS Instruction Manual Alt ATIS TATE r Nolan o olo c Ae Ae Se vo o roln y n u d S a Cy I l m I FLA UO ra P NC NC 4 14 Lal loooo J I EJ CJ EJ EJ EI olooooloooco loox 3 Jl Alt A1 A14 Al AT Az A A2 A2 A3 A2 gt g gt O Q t t t 24 4 4 24
111. e 5 60 Thermo Fisher Scientific Preventive Maintenance and Servicing sample System Heater Assembly Components 5 Using the 9 16 inch wrench and the 5 8 inch wrench loosen the brass nut that attaches the copper tubing to the inlet of the check valve and disconnect that tubing Figure 5 60 6 Using the 9 16 inch wrench and the 1 2 inch wrench loosen the brass nut that attaches the copper tubing to the union fitting on 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 inch hex wrench remove the 6 mounting screws and remove the top valve clamp block the one that has the tubing pass through it See Figure 5 59 9 Using the 9 64 inch hex wrench remove the 6 mounting screws and remove the bottom valve clamp block Figure 5 59 10 Lift the sample solenoid valve and plumbing assembly out of the heated block Figure 5 61 Note the orientation of the tubing and fittings to facilitate reconnection Fc x N N N N N N N N N a SS N K i Ne lt JISCENNE l N DISCUNNE V pee up Fi M P4 A N 4 k M Z CT DOSEN 7 Figure 5 61 Solenoid Valve Replacement Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual 5 87 Preventive Maintenance and Servicing
112. e A system operator can replace the beamsplitter however it is recommended that only our certified service engineers or on site maintenance personnel who have been trained by us replace the beamsplitter Whenever the analyzer compartment is open there is a potential for damage to sensitive components which will affect the performance of the system A Omni FTIR Multi Gas CEMS Instruction Manual 5 25 Preventive Maintenance and Servicing Maintenance and Servicing of the FTIR Analyzer Components Equipment Required Phillips screwdriver Small Phillips screwdriver Flat blade screwdriver Wrench 9 16 inch Hex wrench 3 32 inch and 5 32 inch KBr Beamsplitter assembly 1 Shut down the FTIR analyzer and heaters by turning off the FTIR 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 Using the Phillips screwdriver remove the FTIR cover panel in the front of the system rack and the blank panel above it Slide the FTIR drawer out of the rack to gain access to the analyzer 3 Using the small Phillips screwdriver loosen the captive screw that holds the pressure sensor cable in place then pull the cable assembly off of the sensor Figure 5 14 Disconnect all tubing r Uunplug heater leads and RID remove screw enn ook to detach ground lead USLICW CURIE Q amp discon
113. e Gauge 0 to 100 PSI oolenoid Valve NO 24V oolenoid Valve NC 24V Fow meter Regulator 10 LPM Flow meter Regulator 1 5 LPM Electrical Panel Electrical Panel Assembly Switch Ethernet 5 Port Industrial Power Supply 24VDC 120W Solid State Relay DIN Rail 24VDC Solid State Relay DIN Rail 5VDC Digital I O 100 Pin to 32 Terminal Breakout PCBA Analog 1 0 68 Terminal Breakout PCBA Cable Temperature Alarm 10 Temp Controller to Electrical Panel Omni FTIR Multi Gas CEMS Instruction Manual 108403 00 109713 00 109714 00 109715 00 109933 00 112608 00 112796 00 Part Number 112813 00 112700 00 107260 00 112792 00 109996 00 110039 00 112496 00 Part Number 112689 02 113310 00 113311 00 112569 00 107259 00 112969 00 112970 00 Part Number 112790 01 103530 00 112227 00 112498 00 112224 00 112165 00 109665 00 110252 00 Preventive Maintenance and Servicing Replacement Parts List Replacement Period Replacement Period Replacement Period 5 5 Preventive Maintenance and Servicing oafety Precautions Safety Precautions Cleaning the System 5 6 Omni FTIR Multi Gas CEMS Instruction Manual Read the safety precautions before beginning any procedures in this chapter WARNING If the equipment is operated in a manner not specified by the manufacturer the protection provided by the equipment may be impaired A CAUTION The safety instructions specific to the plant and
114. e Using Calibration Factor Table in Method System Calibration Other than using IMACC Collect to perform a system calibration an Procedure Usin g alternative way is to manually input the correct calibration factors for each gas Calibration Factor Click All Programs on Windows and locate the IMACC FTIR software Table in Method suite Move the cursor to Tools and open IMACCquantify Click the Open tab to locate the method in the directory of c methods Omni method and open the method as shown below IMACC Quantify C Wethods Omnic_method Omnic Method method eS uus F e Help we me pm mw nh ant o OK sone bahdecoy vaidas eh sample shit quant goups inearty biss gplume cht quant concentrations shit plot quant plot linearly plot bias plot s E 0 539858 1 0000 B C 5pec2012 09 17 9h2012 0917 154240 sg iv Dynamic Relerence IV Minimize Percent Ence T Lock Coelficienis 0 6667 conlhcienis 8 9847e 001 05000 1031e 007 4 7975e 014 03333 Generate Coelficients y 01657 e P i browse x 00000 i 01667 ly 5 CodeName C02 cmm E O 2007 CAholcin ST Gev methods Holcim SFE 554 4830 O 2007 C holcien ST Gevimethods Holcim_SF6 Pressure Tom pm 12007 C Volcim ST Gev methods Holcin_SF6 Temperature C 185 05000 O 2007 C holcim ST GevunethodeNHolcim SFB S000 0 2007 CAholcim ST Gevimethods Holcim_ SFe een 6657 ad C 2007 C holcin S
115. e of the sample Valve system heater assembly Equipment 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 tube fittings Liquid leak detector such as Snoop 6 foot section of PTFE or PFA tubing with 1 4 inch nuts and ferrules attached Check valve cool A CAUTION High surface temperatures present Allow sufficient time to l Remove the sample system heater assembly and its cover per the previously mentioned procedure Removing the Sample System Heater Assembly and Cover Remove the heated block assembly from the heater box per the previously mentioned procedure Removing the Heated Block Assembly Turn the heated block assembly around to access the back of the assembly Omni FTIR Multi Gas CEMS Instruction Manual 5 83 Preventive Maintenance and Servicing sample System Heater Assembly Components 4 Using the 9 64 inch hex wrench loosen slightly but do not remove the 5 screws that mount the double coil clamp plate to the heated block This will allow some freedom of movement of the copper tubing Figure 5 60 A 7 WA h V VN N E mi LL Figure 5 60 Check Valve Replacement 5 Using the 9 16 inch wrench and the 5 8 inch wrench loosen the brass nut that a
116. e source from the analyzer Handle the source assembly only by the ceramic base A The beamsplitters are extremely delicate Hold them only by the handle Do not touch the mounting pads and do not touch or breathe on the substrate Keep the exposure to humid air to a minimum A The following procedures must be followed in the correct order The ramp program must be saved and the program mode must be set to On before the controllers are set to run If the controllers are set to run with the ramp program not enabled heated line and sample cell temperatures could rise too quickly and damage those components A f 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 component A If an antistatic wrist strap is not available be sure to touch the instrument chassis before touching any internal components When the PC is unplugged the chassis is not at earth ground A When the temperature controller is unplugged the chassis is not at earth ground A WEEE Symbol The following symbol and description identify the WEEE marking used on the instrument and in the associated documentation Symbol E iv Omni FTIR Multi Gas CEMS Instruction Manual Description Marking of electrical and electronic equipment which applies to electrical and electronic equipment falling under the Directive 2002 96 EC WEEE
117. e the insulation in the positions noted in the previous step then reconnect the flag lugs to the thermostat and place the wiring back in to position Follow steps 1 8 in reverse order to complete the procedure Use the following procedure to replace the thermostat inside of the sample system heater assembly Equipment Required Phillips screwdriver Wrench 9 16 inch and 1 2 inch Thermostat CAUTION High surface temperatures present Allow sufficient time to cool A Remove the sample system heater assembly cover per the previously mentioned procedure Removing the Sample System Heater Assembly and Cover skipping steps 5 6 and 7 sample system heater assembly doesn t need to be removed from the rack for this procedure Thermo Fisher Scientific Thermo Fisher Scientific Replacing the Eductor Pump A Preventive Maintenance and Servicing Sample System Heater Assembly Components Important before replacing the thermostat refer to Chapter 6 Troubleshooting for problem diagnosis Another component fault may have caused the thermostat to need to be reset not replaced Try pressing the reset button on the center of the thermostat which is located on the plate at the bottom center of the heater box Figure 5 59 Skip to step 5 and determine if the thermostat is now functioning properly If the thermostat is bad again remove the sample system heater assembly cover Use the Phillips screwdriver to rem
118. e wrenches to install che 1 4 Swagelok plug onto the fitting on the bent piece of tubing on the other side of the solenoid valve Disconnect the air line with union from the Sample In line remove the union fitting and connect the air line to the FTIR In fitting Turn the air regulator up to 25 PSI Using the liquid leak detector wet every connection on that 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 regulator back down to zero PSI Using the wrenches remove the air line from the FTIR In fitting and remove the 1 4 Swagelok plug from the fitting on the bent piece of tubing near the solenoid valve The remainder of the leak test will be done after the solenoid valve and plumbing assembly are re installed in the heated block Attach the copper tubing with brass nut to the check valve but do not tighten it all the way Rotate the valve assembly until it lies in its original position in the heated block Figure 5 61 Attach the other piece of copper tubing with brass nut to the union fitting on the adjacent side but do not tighten it all the way Figure 5 61 Thermo Fisher Scientific Thermo Fisher Scientific Preventive Maintenance and Servicing sample System Heater Assembly Components 17 Using the 9 64 inch hex wrench re install the top and bottom valve 18 19 20 2 22 clamp blocks
119. eb EIUS 5 65 Replacing the Temperature Control Board 5 66 Replacing thie Power Belayso assets dun cre En 5 68 Replacing the Temperature Control Modules 5 69 Replacing the Temperature Control Base Unit 5 70 Electrical Panel Components sx gst nccuaiensveescestgrecsurevscthistintaeectanst 5 7 1 Replacing the Ethernet Switch assecar e E 5 73 Replacing the Solid State Relays etie reet te eiae 5 73 Replacing the 24V Power Supply cerceii 5 75 Sample System Heater Assembly Components 5 76 Removing the Sample System Heater Assembly and Cover 5 76 Replacing the Thermostat oie Eritrea ee enti p erede ee ase 5 78 Replacme the Ed ctor DID simritsnmsteiiritteiioinnii linia 5 79 Removing the Heated Block Assembly 5 82 Replacing thie Check V AN T 5 83 Replacing the Sample Solenoid Valve 5 86 Pneumatic Panel Components asset etiem aa RI MUR 5 90 Replacing the Pressure Reducers ag oe doe opo Pai SEP ts 5 90 Replacine the Pressure Gauges 4i cou E VN RE 5 91 Replacing the Solenoid V ales oreraa e tou te md yeneciues 5 92 Replacing the F low Meters iaceo ed om a acento nde 5 94 Service LOCATIONS apaa testa eer tod esuk atus undae tieu bua esa is 5 97 prn Me 6 1 Concentration EXE OEIS us oat tee Abest d MA reb tib obtusa fub tbo n
120. ed with an M amp C SP2000 H probe The standard system includes an ANSI 4 inch flange and a 1 0 meter probe barrel Custom flange and barrel configuration may be ordered To prevent damage during shipment the analyzer is shipped with a restraint in the Michelson interferometer You will need to open the Thermo Fisher Scientific System Installation Start Up and Shut Down Installing the FTIR Analyzer into the Rack analyzer to remove the shipping restraint before the analyzer is installed in the rack Remove the left access panel and set aside The panel will remain connected to the FTIR by wiring for the cooling fan Remove the interferometer shipping restraint The shipping restraint 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 Installing the Lift the analyzer from the pallet The analyzer weighs about 130 lbs 60 FTIR Analyz er kg so at least two people will be needed to lift it into the Rack CAUTION To prevent damage to the interferometer do not apply electric power to the analyzer before internal shipping restraints have been N removed A CAUTION Lift from each side of the analyzer not from the front and back Damage to the unit may occur A Position the analyzer on the rack slide per Figure 2 2 Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instructi
121. ell 5 47 Figure 5 37 Beam Image on the First Objective Mirror in the Multi pass Gas 521 5 47 Figure 5 38 Typical Image Pattern on the Field Mirror 5 48 Figure 5 39 Location of Components on Back Plate of Gas Cell 5 48 Figure 5 40 Real Red Laser Image Pattern o on 5 50 Figure 5 41 Typical Interferometer of Omni FTIR CEMS 5 50 Figure 5 42 Cutting Insulation Paper at the Seam n c 5 52 Figure 5 43 Insulation Removal ssssssssssssme 5 53 Figure 5 44 Hose Clamp Removal 5 53 Figure 5 45 Heated Line Replacement 5 55 Figure 5 46 PC Removal ssssssssssssssne 5 56 Figure 5 47 PC Console Removal sss 5 58 Figure 5 48 Connecting PC Console Rack Sliders 5 59 Figure 5 49 Removing the PC Cover 5 60 Figure 5 50 Removing the Card Cage Mounting Screws 5 60 Figure 5 51 Positioning the Card Cage occse 5 61 Figure 5 52 Removing NI Board Mounting Screw 5 61 Figure 5 53 Removing NI Board from Card Cage 5 62 Figure 5 54 External Fuse Replacement sss 5 63 Figure 5 55 Temperature Control Box Internal Component Replacements 5 66 Figure 5 56 Electrical Panel Component Location Front Side
122. emperature Controller on page 7 3 e Heated Sample Line on page 7 3 e Heated Pump Valve Assembly on page 7 4 e Hydrator on page 7 4 e Pneumatic Panel on page 7 4 e FTIR on page 7 7 e Air Purifier on page 7 12 e Industrial PC on page 7 13 e Console on page 7 14 e Datalogger on page 7 14 e Electrical Panel Assembly on page 7 14 e AC Power Input on page 7 15 Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual 7 1 System Component Description sample Probe Sample Probe 7 2 Omni FTIR Multi Gas CEMS Instruction Manual HOUSE AIR HYDRA al hse ko P i fa PNEUMATICS PANE Gl jones 54S lt g e 000000 B ists VIT i N se BLANK PANEL oy it td he PC CONSOLI Ls mem iSS n L MAINTENANCE PANEL JP E TEMP CONTOLL LI BLANK PANE Tur ETTE e IET ENS A dE a i Tie f S x M ATR FILTER ASS K PUR GAS NERATUR Figure
123. ench remove the cap screws that mount the gas cell to the coupling mirror assembly 11 Carefully lift the gas cell off of the mounting plate 12 Partially re install the gas cell by following steps 11 9 in reverse order 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 breaker at this time 13 Continue with the Gas Cell Alignment procedure that follows Use the following procedure to align the gas cell after it has been replaced Figure 5 33 Equipment Required Wrench 9 16 inch and 11 32 inch Hex wrench 5 32 inch and 9 64 inch Phillips screwdriver Visible laser module for gas cell alignment field service only Refer to Replacing the Gas Cell for additional tools needed Thermo Fisher Scientific Thermo Fisher Scientific Preventive Maintenance and Servicing Gas Cell Alignment Objective mirrors Field mirror Figure 5 33 Gas Cell Mirror Configuration CAUTION High surface temperatures present Allow sufficient time to cool A 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 components A Important Note It is recommended that only our certified service engineers align the mirrors in the gas cell There is a potential for
124. enoid valve operation setting for normal sample mode Thermo Fisher Scientific IMACC Script Setting CEMS SampleMode e Auto blowback setting By default the system blowback is performed every two hours starting from 00 30 00 am The schedule and the valve operation setting are included in the same green block Thermo Fisher Scientific Click the left top corner labeled if l imeCondition equal to so the schedule setting block pops up Time Setup settings Condition Curent Time equal to Time HH MM S5 00 30 00 Time Window HH MM 85 5 00 As seen in the pull down manual there is a list of times starting from 00 30 00 Users can adjust the blow back frequency by clicking the add and remove button The time window for each blowback action is set as 5 minutes Right below the schedule setting is the script for the blowback valve operation Omni FTIR Multi Gas CEMS Instruction Manual E 9 IMACC Script Setting Modbus Control Version Modbus Control E 10 Omni FTIR Multi Gas CEMS Instruction Manual Version ine dev 2z porti lineo attern oxos5o ine dev 2 porti lineo r attern oxoga ine dev 2 porti lineo attern oxa5so mode output ine dev z porti lineo attern oxogo mode output ine dev 2 porti lineo I soa mode output ine dev 2 porti lineo r attern oxoaa3o There are six subpanels included in this script block Each of them is the so
125. er 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 control valve is closed and the instrument zero control valve is opened The CO free zero air directly flows into the optical cell Subsequently a zero background spectrum is collected In parallel with the instrument valve operation the blowback control valve is triggered to perform system blowback for 20 seconds and then closed Subsequently the flowback control valve is triggered to be open Zero air flows back to the stack via the sample line primary filter stinger and pre filter at 4 LPM Once the background spectrum collection is finished the flowback valve is closed the sample valve is opened and the instrument zero valve closed This mode should be executed once every day for collecting instrument background spectrum Omni FTIR Multi Gas CEMS Instruction Manual 7 5 System Component Description Pneumatic Panel Check Zero During the check zero mode the system is configured for sample mode with the probe zero control valve opened The CO free zero air 6 LPM flows into the stinger via the cal zero port This mode is executed for the daily system zero check Check Spike During the check spike mode the system is configured for sample mode with the probe spike valve open for dynamic spiking operation The spike gas flows into the stinger via
126. eral this mode should be selected after mode 3 Is trigged 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 spectrum to replace the file CAbackgroundsWbkg spa At the end the system is switched back to sample mode In this mode the system is running just like the sample mode At the sample time the zero air flows into the probe and is pumped into the gas cell This mode is used to test the system zero offset The standard gas flows into the probe at a flow rate of 1096 sample flow rate In general a trace gas such as SF6 is used to determine the dilution ratio of standard gas flow versus the sample flow Calibration gas flows into the probe and is pumped into the gas cell This mode is used to check the system span This mode is used to perform an extra span check in addition to the target gas Thermo Fisher Scientific Modbus Protocol Modbus Parameters Supported Table B 4 System Flag Bits Value Description 0x00000000 Data Valid 0x00000001 Data Invalid Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual B 7 Appendix C Interfacing a DCS PLC with the Omni FTIR Multi Gas CEMS Establishing communications between the Omni FTIR Multi Gas CEMS and a DCS PLC involves making the physical connections between devices and using an appropriate method application to establish da
127. ermo Fisher Scientific Thermo Fisher Scientific Preventive Maintenance and Servicing Pneumatic Panel Components Nut driver 11 32 inch Solenoid valve Remove the left side panel per procedure Removing the Left Side Panel for better accessibility If the probe spike or probe span solenoid valve is being replaced turn off the HCI SF6 cylinder or the EPA mix cylinder respectively From the rear of the pneumatic panel the probe spike is the first solenoid on the left and the probe span is next to it If any of the other three 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 down to zero Figure 5 18 SY c f I aie dee C hH i E CH SH m H He INA mi H 1 489 t 4 Op REUSE FITTINGS BUT TUM VIE Figure 5 63 Solenoid Valve Replacement 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 or fittings in some cases from the top and bottom fittings on the solenoid valve Note their locations to facilitate re connection Figure 5 62 Using the 11 32 inch nut driver loosen and remove the 2 nuts that mount the va
128. escription on page 3 1 e Imacc FTIR Software Suite IFSS on page 3 2 e OMNIC on page 3 11 e Result on page 3 13 e NI DAQ on page 3 13 e CALGrafix on page 3 13 e CDM USB Driver on page 3 13 e 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 Data collection and system sample collection functions will start automatically whenever power is applied to the system The software components that are running during system operation are as follows e IFSS Imacc FTIR Software Suite e Monitor User Interface e Server Data Collection amp Analysis e Script Engine e Data Server Software e ImaccCurrentloop e ImaccModbus e ImaccModbusTCP Omni FTIR Multi Gas CEMS Instruction Manual 3 1 Operation Imacc FTIR Software Suite IFSS Imacc FTIR Software Suite IFSS e OMNIC Spectrometer Driver and Diagnostic software e Result Spectrometer Driver software e CALGrafix Heater Configuration and Diagnostic software e CDM USB Driver software e NI DAQ Drivers and Diagnostic software The design of the software suite is intended to make the operation and configuration of the FTIR flexible from a hardware standpoint and expandable from a software standpoint Figure 3 1 Monitor 3 2 Omni FTIR Multi Gas CEMS Instruction Manual Figure 3 1 Component Relational Diagram
129. ess the screws 3 Using the flat blade screwdriver loosen the 2 screws on the relay side that does not have the varistors enough to slide the wires out they are attached with fork terminals Note their locations to facilitate re connection 4 Using the flat blade screwdriver remove the 2 screws on the side of the relay that does have the varistors and remove the wires and the resistor 5 Using the 5 16 inch nut driver loosen and remove the 2 nuts that mount the relay to the temperature control box Set aside the hardware and remove the relay 6 Pop the end covers up on the new relay and place it in the temperature control box over the mounting studs in the proper orientation Thread on the 2 mounting nuts and then use the 5 16 inch nut driver to tighten them until snug Thermo Fisher Scientific Replacing the Temperature Control Thermo Fisher Scientific Modules Preventive Maintenance and Servicing Temperature Control Box Components 7 Using the flat blade screwdriver remove the 2 bigger screws with the captive hardware on the side of the relay marked 1 and 2 8 Place the appropriate wire and 1 leg of the varistor over the screw then insert and tighten the screw down until snug Repeat with the second screw and then press the end cover down until it locks in place 9 On the other side of the relay with the smaller screws marked 3 and 4 sandwich the wires with the fork terminals between the 2 small plates
130. exiting beam properly positioned in the output field mirror cutout For the 5 2 meter gas cell che maximum number of passes should be 20 with the number of 5 images on the bottom row as shown in Figure 5 40 Omni FTIR Multi Gas CEMS Instruction Manual 5 49 Preventive Maintenance and Servicing Gas Cell Alignment Figure 5 40 Real Red Laser Image Pattern Figure 5 40 shows a real red laser image pattern for the 5 2 meter 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 window it is time to adjust the relay mirrors 4 5 and 6 shown in Figure 5 34 Manipulate these mirrors to maximize the IR signal Max on the interferometer display as shown in Figure 5 41 Experiment Setup C my documents omnic ParamWefault exp Collect Bench Quality Advanced Diagnostic Configure Series O O G HeNe Max 5 00 Min 2 72 Loc 1024 F View reference detector 1100 1000 Data points Freeze f Align Reset Bench Verify Smart Accessory ren fo 5 Cressy Figure 5 41 Typical Interferometer of Omni FTIR CEMS 5 50 Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific Preventive Maintenance and Servicing Replacing the Gas Cell Heater Note that the gas cell is aligned by the manufacturer before being delivered to cus
131. frequencies that can be sensed by the detector This is achieved by using a beamsplitter which is located in the center of the assembly and secured at an angle of 45 The divided light is directed to the fixed mirror at the top of the assembly and to the moving mirror located within the cylinder to the left This mirror causes one of the beams to travel a continually changing distance so when the beams recombine the waves interfere with each other constructively and destructively creating an interferogram The center burst of an interferogram occurs when all the frequencies are in phase This happens only when the two mirrors are the same distance from the beamsplitter The information outside the center burst provides the fine details of the absorbance spectrum The longer the moving mirror strokes the higher the resolution Note The KBr beamsplitter material is hygroscopic or absorbs water from the air so the FTIR instrument must be continuously purged to remove water A Laser The FTIR analyzer uses a helium neon He Ne laser equipped with a neutral density filter to help reduce power and reflections The laser has a life expectancy of at least four years and can be replaced as needed It is pre aligned and needs no adjustment when it is installed Mirrors The analyzer uses a number of precision mirrors to focus and direct the infrared beam for optimum performance Aperture The aperture is a fixed diameter opening that optimizes spec
132. g Replacing the Gas Cell Heater Figure 5 43 Insulation Removal 5 Using the flat blade screwdriver remove the 4 hose clamps that mount the silicone heater pad to the gas cell then 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 7 Fasten the heater with the 4 hose clamps tightening until snug 8 Place the insulation back on the gas cell and attach it with a couple of pieces of high temperature tape making sure that it fits snugly 9 Refer to the procedure for Replacing the Gas Cell to re install the gas cell Omni FTIR Multi Gas CEMS Instruction Manual 5 53 Preventive Maintenance and Servicing Replacing the Heated Lines Replacing the Heated Lines 5 54 Omni FTIR Multi Gas CEMS Instruction Manual Use the following procedure to replace the FTIR heated lines 1 meter internal Equipment Required Wrench 9 16 inch and 5 8 inch Phillips screwdriver Wire cutters Heated lines Tie wraps zip ties CAUTION High surface temperatures present Allow sufficient time to cool A 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 put the system in fail safe mode so that it will not be sampling stack gas 2 Remove the rack left side panel per procedure
133. g the expected mode Click the View Script button in ImaccMonitor and verify that IMACC Script Editor shows that the script is running Omni FTIR Multi Gas CEMS Instruction Manual 6 7 Troubleshooting service Locations Check that the S YSTEM STATUS value is showing the expected mode see Table B 3 in Appendix B Odd numbered pins should have a continuous DC voltage supplied Max 24 VDC e Check wiring from terminal block to breakout board on opposite side of electrical panel e Check cable from breaker board to NI PCI 6709 board inside pC e Maintenance digital output is not reporting the expected mode e Check the key switch position The vertical position is maintenance mode and voltage should be conducted from the odd terminal 25 to the even terminal 26 Service For additional assistance Thermo Fisher Scientific has service available L from exclusive distributors worldwide Contact one of the phone numbers ocations ane t below for product support and technical information or visit us on the web at www thermoscientific com aqi 1 866 282 0430 Toll Free 1 508 520 0430 International 6 8 Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific Chapter 7 System Component Description This System Component Description chapter provides an overview of the components in the Omni FTIR CEMS and describes the function of the system components per the following e Sample Probe on page 7 2 e T
134. g system status Refer to Figure C 3 to locate the pins on the rear panel terminal connector Thermo Fisher Scientific Table C 2 Digital I O Connections Interfacing a DCS PLC with the Omni FTIR Multi Gas CEMS Digital No Block Terminal 1 1 2 2 3 3 4 4 5 A 6 6 f 7 amp 8 8 9 amp 10 9 11 amp 12 10 13 amp 14 11 15 amp 16 12 17 amp 18 13 19 amp 20 14 21 amp 22 19 23 amp 24 16 25 amp 26 17 2 18 28 Eejejejele eje e e e e e e geimeieeieerereremminieiumeiee e eed Establishing Communications Description Digital Input Ground 3as Mode Input Check Span 3as Mode Input Check Spike 3as Mode Input Check Zero 3as Mode Input Bkg amp Flowback 3as Mode Input Blowback Gas Mode Output Check Span 3as Mode Output Check Spike Gas Mode Output Check Zero 3as Mode Output Background amp Flowback Gas Mode Output Blowback 3as Mode Output Sample FTIR Data Valid Temperature Alarm Maintenance Status Key Switch N C N C N C T n Jm dig Figure C 3 Digital O Rear Panel Terminals Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual C 5 Interfacing a DCS PLC with the Omni FTIR Multi Gas CEMS Establishing Communications Solid State Relays TTL outputs from the National Instruments 6509 board are used to drive SSR solid state relays SSR for valve control and digital status outputs The
135. gether in x axis values Fix Auto Scale Y auto scales plots to max and min y values independent y in each window Fix Axes X amp sets common x and y scales of all plots to the selected plot Guides displays hormonal and vertical guides that can be moved to check alignment of data ursoar Value shows current da apoini value on selected plot Flip fips the X a5 reversing the plot direcban Show Points displays individual dala points m the Hal Aut Scale scales selected plets in Y value Aute Seale X scales selecied plot in X v alue Stack Plots slacks or overaps plots toggle bution Stretch Window alreiches te plot within the viewing window expandim iL TRT Shrink Windaw shrinks the plot within the viewing window com ressing i 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 to configure the ConcentrationPlot display The display tab is used to configure what compounds are displayed and the attributes associated with each Code Name The name of the compound HI Limit The high limit of the compound used to scale the data when Show as percentage is checked Low Limit The low limit of the compound Show as percentage Shows the data scaled to 100 Load Configuration Loads a saved configuration of the data limits and color
136. gure 5 54 External Fuse Replacement 4 Using the flat blade screwdriver loosen the screws for the pressure and alarm cables and disconnect them from the back of the temperature control box Note their location to facilitate reconnection 5 The external fuse holders are located under the above cable connectors To remove the fuses push the holder in while turning it approximately 1 4 turn counterclockwise and then pull it out Figure 5 55 Omni FTIR Multi Gas CEMS Instruction Manual 5 63 Preventive Maintenance and Servicing Temperature Control Box Components Replacing Internal Components Removing and Installing the Cover 5 64 Omni FTIR Multi Gas CEMS Instruction Manual 6 Pull the old fuse out of the holder and push the new fuse in place The fuse is held in by a spring mechanism 7 To re install put the fuse and holder back in its place and turn gently until the holder is almost flush with the receptacle Then push it in and turn it approximately 1 4 turn clockwise to lock it in place 8 Reconnect the pressure and alarm cables to their proper position and re tighten the mounting screws using the flat blade screwdriver 9 Follow steps 1 3 in reverse order to complete the procedure Use the following procedures to replace the internal components on the temperature control box Equipment Damage Some internal components can be damaged by small amounts of static electricity A properly grounded antistatic wri
137. h data point Low Cutoff and High Cutoff define the low end and high end of the Mid IR spectrum range They are not recommended to be adjusted by users The background spectrum used for the absorption spectrum conversion is saved in the Thermo Fisher Scientific Thermo Fisher Scientific IMACC Script Setting CEMS SampleMode directory of c Backgrounds bkg spa The method is stored in the directory of c method All these settings are supposed to be set and tested by the manufacturer before shipment to the user e Adjust detector gain and mirror velocity In general if the IR source intensity Vmax drops below 1 5 volts it is time to consider adjusting of detector gain value The gain setting is accessed by clicking the button bench as indicated Collect EZ Setup Collect EZ Setup collect bench directories omnic options spectral math collect bench directories omnic options spectral math V Set Bench Parameters V Set Bench Parameters Optical path Front ain Optical path Front ain FrontMain FrontM ain Pathlength m Source IR Pathlength m Source IF 5 209 IF 5 203 IR Aperture 100 Velocity Aperture 100 Velocity 15 000000 0 532300 15 000000 0 632900 Gain power of 2 Resolution Gain power of 2 8 000000 0 500000 8 000000 Correlation Exposure ms Correlation Simple Simple X Default Temperture 23c Default Pressure 750T
138. h notice shall include the product model and serial number if applicable and details of the warranty claim b after Seller s review Seller will provide Buyer with service data and or a 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 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 replacement Products shall be made in accordance with the Delivery provisions of the Seller s Terms and Conditions of Sale Consumables including but not limited to lamps fuses batteries bulbs and other such expendable items are expressly excluded from the warranty under this warranty Notwithstanding the foregoing Products supplied by Seller that are obtained by Seller from an original manufacturer or third party supplier are not warranted by Seller but Seller agrees to assign to Buyer any warranty rights in such Product that Seller may have from the original manufacturer or third party supplier to the extent such assignment is allowed by such original manufacturer or third party supplier In no event shall Seller have any obligation to make repairs replacements or corrections required in whole or in part as the result of i normal wear
139. he following sequence to turn power ON to the system components Ensure that the main power connections are made to the system with the circuit breakers OFF Once the main power connections are made turn on the Main Power circuit breaker on the breaker panel Then turn ON the circuit breakers Air Purifier 24VDC Temp Control Probe FTIR PC Console Check FTIR Unit The scan laser and source LEDs light for a few seconds while the internal diagnostic routines run Upon successful completion of the diagnostic tests the LEDs indicate instrument status The Scan light should blink intermittently in normal operation once the PC has booted and the IMACC ESS software is running the other lights should be steady 2 10 Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific Adjust Confirm Flow and Heat Settings Thermo Fisher Scientific Air flow System Installation Start Up and Shut Down oystem Startup See the following to adjust confirm flow and heat settings Ensure that instrument air is supplied to the system and set the default pressure settings CO free air pressure 2 0 3 0 bar 30 44 psi Ejector pump pressure 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 flow 6 0 l min Probe Spike flow 0 5 I min System
140. he hazard or unsafe practice could result in property damage if the warning is ignored A Safety and Equipment Damage Alerts in this Manual Alert f WARNING ii Omni FTIR Multi Gas CEMS Instruction Manual Description If the equipment is operated in a manner not specified by the manufacturer the protection provided by the equipment may be impaired A Avoid shock hazard Always turn off the circuit breaker on the breaker panel on the front of the rack for any component to be cleaned Do not allow cleaning solutions or liquids to run into the analyzer its power supply or any powered components A Thermo Fisher Scientific Thermo Fisher Scientific Alert f CAUTION About This Manual Safety and Equipment Damage Alerts Description Aggressive condensate is possible Wear protective glasses and proper protective clothing A High surface temperatures Wear protective gloves A Flush probe in the case of toxic gases A Perform only those procedures on the analyzer described in this section If there are other problems with the analyzer contact technical support Also refer to the Antaris IGS manual in the Other Manuals on page 1 10 A The desiccant is harmful if swallowed Follow the manufacturer s instructions to dispose of desiccant packets properly A To avoid shock hazard always turn off the FTIR circuit breaker on the breaker panel before replacing any components inside the FTIR analyzer A To prevent d
141. he rear and thread on the panel nut Position the pressure reducer in the same orientation as the other pressure reducer and then tighten the panel nut using the adjustable wrench until snug 8 Re connect the Teflon lines to their proper locations then tighten the nuts using the 9 16 inch wrench until snug Figure 5 62 9 Setthe house air regulator back to the pressure noted earlier then push the knob down to lock it Set the new pressure reducer on the pneumatic panel to the pressure noted earlier 10 Re install the left side panel to complete the procedure Replacing the Use the following procedure to replace the pressure gauges on the Pressure Gauges Pneumatic panel The procedure is the same for either pressure gauge Equipment Required Wrench 9 16 inch Pressure gauge 1 Remove the left side panel per procedure Removing the Left Side Panel for better accessibility Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual 5 91 Preventive Maintenance and Servicing Pneumatic Panel Components 2 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 down to zero Figure 5 18 3 At the rear of the pneumatic panel use the 9 16 inch wrench to loosen the nut and remove the short PTFE line from the pressure gauge to be replaced Figure 5 62 4 Using your fingers remove the 2
142. heatedbox ale IEEE float celloutlet Ove26 IEEE float CELLPRES xaza Add Remove E dit Default teca On the top there are two buttons named setup and serial Under the setup configuration in the box of OpticalPath FrontMain is chosen Move down the setting 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 target parameter such as Sampleline in the list Double click it so that its register setting subpanel pops up as shown Register Setting Type of Data IEEE floa CODE SampleT T Register Ox prefix For hes numbers Osa c iv add to CON file cancel As seen its data type is IEEE float Code name can be edited to reflect the parameter meaning Register context is determined by Calogix setting 0xOalc in this case Go back to the Modbus Register Setting panel g 8 P click the serial button on the top and view the following setting panel as shown Omni FTIR Multi Gas CEMS Instruction Manual E 3 IMACC Script Setting CEMS SampleMode E 4 Omni FTIR Multi Gas CEMS Instruction Manual setup serial Device Address COM Part 5 Baud 9600 Diatabits eo Modbus Register Settings Parity None Stopbits oo Flow Control Mone This setting is used to configure the data transmission commutation port
143. hut Down External System Connections External System Connections Connect the Sample Line to the FTIR Analyzer Cabinet and Heated Sample Box 2 8 Omni FTIR Multi Gas CEMS Instruction Manual See the following external system connections The sample line from the M amp C SP2000 H probe is routed through an opening on the right site of the system chassis Connect the circular connector to the socket marked Sample Line on the rear of the temperature 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 the following terminal blocks on the electrical panel Sample Line Connections from left to right Terminal Block X3 Probe Temperature Alarm Out 2 Probe Temperature Alarm In 3 Probe Blowback Valve 4 Probe Blowback Valve Terminal Block X4 5 Ground Green Yellow 6 Neutral Blue 7 Hot Brown Thermo Fisher Scientific Instrument Air Exhaust Line Calibration Gases Communications Thermo Fisher Scientific Ethernet Serial A System Installation Start Up and Shut Down External System Connections Connect to a supply of clean dry house air to the regulator located on the right side of the instrument rack Set the regulator pressure to 75 psi The rack is provided with connections for two 1 2 inch OD exhaust lines The top exhaust marke
144. ical Panel The electrical panel Figure 7 11 includes screw terminal connections for Ass embly the following user connections e 4 20 mA Analog Outputs one for each gas e Digital solid state relay outputs Temperature Alarm Pressure Alarm Maintenance FID Alarm FTIR Data Valid System Gas Mode e Digital Inputs System Gas Mode e Probe Connections AC Power Temperature Alarm and Valve Control 1 14 Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific System Component Description AC Power Input d i ES PORT y RI v P EM e eL N MZ XD Por rora T LVS LAN m T benc d NS S N GND X P o i jOooooogo3dce OIOOJOJOOODO0 LEooooo0ooooOOO JOLC mu TI i It I I H LII OOODKDOOJLODOLC OIoOoooOOOOOCOOOC JoQdOoOdoogaoo a teas 5g R7u d 4 s s 7 e ien 2jj iete i pe x ANA DIG I Figure 7 11 Electrical Panel Also included on this panel is a 5 port Ethernet switch to connect 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 AC Power Input
145. ick the script setting block named Background Spectrum Collection so its setting panel pops up as shown Omni FTIR Multi Gas CEMS Instruction Manual E 7 IMACC Script Setting CEMS SampleMode E 8 Omni FTIR Multi Gas CEMS Instruction Manual if TimeCondition equal to NextTime 03 15 00 SPectrum collectio alve action for BG and FB ode output ne devz porti linen 7 attern oxoBB ollect Settings athName FrontMain Six subpanels are included in this script setting The first one is the solenoid valve setting to flow zero air into the gas cell while the sample valve is closed and zero air flows back through heated sample line filter head and stinger and back to the stack The second box displays the Collect EZ setting which is the same as the spectrum collection setting as described above 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 since improper parameter setting would potentially result in bad data or an interferometer malfunction Following the Collect EZ is the time delay setting A five second delay time is set before implementation of the subsequent calculation setting which saves the current spectrum into the directory of C Backgrounds BKG spa Right after the calculation setting is another 5 second time delay setting At the end of the block is the sol
146. ignment pin and remove it from the analyzer Remove the new source from its protective packaging Do not touch the source element with your bare fingers Hold it by the ceramic base Figure 5 8 Figure 5 8 Source Element is Inside Can Cut Out 10 11 12 13 Install the new source assembly over the alignment pin and the thumbscrew with its clamp bar making sure that the source is seated properly Rotate the clamp bar 90 degrees clockwise and then tighten the thumbscrew until snug to secure the source to the analyzer base plate Connect the source power supply cable to the power distribution cable Re install the right side panel Slide the panel into the rear support bracket first and then line up the holes Install the mounting screws using the 3 32 inch hex wrench taking care to support the panel until the screws are in place Tighten until snug Power up the FTIR by turning on the FTIR circuit breaker on the breaker box Slide the FTIR drawer back into the rack then use the Phillips screwdriver to re install the FTIR cover panel and its mounting screws Wait 15 minutes for the new components to stabilize thermally and then align the analyzer by following the instructions in Chapter 3 See OMNIC software on page 3 11 Thermo Fisher Scientific Replacing the Laser Thermo Fisher Scientific gt gt gt Preventive Maintenance and Servicing Maintenance and Servicing of the FTIR Analyzer Compo
147. ilter element in the sample probe The pre filter is located inside the stinger probe barrel Replacement of the pre filter will require that the entire probe assembly be removed from the stack Depending on the type and level of contamination the pre filter can be cleaned with water in an ultrasonic bath and then re used Equipment Required Wrench 15 16 inch and 3 8 inch Hex wrench 5 32 inch and 5 16 inch Pre filter element CAUTION High surface temperatures present Allow sufficient time to cool A 1 Flush the probe with inert gas or air to clear any toxic gases 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 stack flange Carefully remove the probe from the stack with its gasket taking care to center the probe tip shield through the flange as it is removed Plug the stack opening with a flange cap for safety Be extremely careful of the high surface temperatures Allow the stinger to cool before replacing the pre filter 4 Using the 3 8 inch wrench and the 5 32 inch hex wrench loosen the locknut and screw on the probe tip shield at the end of the stinger and then remove the probe tip shield 5 The pre filter is recessed inside of the stinger Using the 5 16 inch hex wrench unscrew the pre filter and remove it Properly dispose of the used pre filter The pre filter
148. ing the optical gas cell for 10 minutes a new background spectrum is collected and compared with the previous one A good newly acquired background spectrum is saved for subsequent sample spectrum processing If the new zero background Omni FTIR Multi Gas CEMS Instruction Manual 4 1 Calibration Periodic System Zero Check Periodic System Zero Check 4 2 Omni FTIR Multi Gas CEMS Instruction Manual spectrum is not as good as the prior one the system would retain the original zero background spectrum for the data processing While collecting instrument zero background the system sample valve is closed to separate the sample flow from the optical gas cell Simultaneously the flowback solenoid valve is triggered to flow 3 LPM zero air back to the heated sample line The system zero check can be set to be operated automatically or manually by operator via Thermo Modbus Controller check zero or PLC By triggering the system zero solenoid valve a sufficient zero air flow 56 LPM is introduced into the sample probe via the heated umbilical right before the probe s primary 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 via a data logger or maintenance of the measuring system e g by the supplier may be necessary due to the results of the evaluation When performing a system zero check
149. integration period has been completed The Modbus program will return zeros during that time Note The addresses in the following table are Protocol Data Unit PDU addresses For Application Data Unit ADU addresses add 40000 to these numbers for holding registers Verify the register number on your MODBUS master to ensure that it matches the register number on the instrument A Note For additional information on how to read registers and interpret the data refer to Appendix B Modbus Protocol A Thermo Fisher Scientific Thermo Fisher Scientific Operation Data Server Software Modbus Settings X Device Address 1 Poll Delay ma Response Delay me i 0 10 COM Port Fart coM3 None Baud Stopbits 5600 fi atabits Flow Control z Mane T Cancel First the Add button can be used to select the directory that contains the concentration data files that are to be used as the Modbus data source The Modbus program will transmit data from the last line in the newest file in that directory when it receives a command to transmit data from the Modbus master 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 file type field to select the file extension e g con cav cor cnc Enter the ADU register number in the register field In the config
150. into their original positions tightening the mounting screws until snug Using the wrenches tighten until snug the 2 fittings on the back that were left loose in the previous steps These two fitting connections should now be leak tested Leak test the other side of the check valve by connecting the 1 4 inch Swagelok union fitting to the air line and connecting that to the Flowback line using the wrenches Install the 1 4 inch Swagelok plug onto the other 1 4 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 tubing to see if there are leaks which will produce air bubbles If any are present tighten the fitting until the leaking stops Turn the air regulator back down to zero PSI Remove the 1 4 inch Swagelok plug and 1 4 inch Swagelok union fitting from the Sample In line 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 wrenches Connect the air line with the union fitting to the Instrument Zero line and then install che 1 4 inch Swagelok plug onto the FTIR In fitting Turn the air regulator up to 25 PSI Using the liquid leak detector wet the connection between the union fitting and the copper tubing to see if there are leaks which will produce air bubbles If
151. ion Manual Copy just collected zero air background and rename x File Ede ew Pavone Took Help Pd Qe a F Saadi KR Pukders lp LE x W resis L3 cles w BE Fokin x Name boe Type Cate Modified mo By Canpuber A L3beschgrounds 2007 03 File Folder HE MEO 12 10 PM z JE 3 Floppy 4 backgourek 2007 04 File Fokje HIT 9 07 Ae Bab Loca Duk C Dibacok 2007 05 Fide Fr ter BAIT 0 21 AH C3 eos iCjbsckgrounde 2007 06 File l ekdes 7s 2007 1 52 PM IL bachgrounds 2007 03 C backgnaunek 2007407 Fin Fiklor Bi 10620 AM LC backgroud 2007 04 Libackgreunds 2007 08 File Fodder S100 igh 8M C backgrounds 2007 05 iCjbschareunds 2007 09 Pis Folder LOY E2007 0 14 AM Cabachgnoondhs 2007 10 File Fide Lnpbsiz007 1 42 PH B teo sr bachound prti 2007 10 15 63 kB Omni Spectral Pikes LO 542007 Love PH PKR Om Spectral Fim LOPES 1 41 PIA L3 backareunds 2007 06 Cy backgnoundk 2007 07 L3 backgrounds 2007 08 L3 backareunds 2007 09 LJ bachgnounds 2007 10 E L2 Cons zm Lj Document ad Secr IL dmirestr ator D Cocke V Dedi Ur Favorites k L7 My Decurengs e Sart Meri H E Programs k LJ WIndows EAS cC rip amp Lap File jary E L3 IFFS C3 IPPs 2007 07 02 j birrat E 3 My Documents amp O Ok Method LO Personal E Ly Propan Fides i Cz RESULT Dh Sy Sipe H C2 Spec Name the copied file BKG Select ImaccMonitor to return to measurement Another way to collect instrument zero spectrum is to use Thermo Modbus Controller In the pull
152. ionship between the position of the moving mirror relative to the fixed mirror and the wavelength of the light Omni FTIR Multi Gas CEMS Instruction Manual 7 7 System Component Description FTIR 1 8 Omni FTIR Multi Gas CEMS Instruction Manual When both mirrors are the same distance from the beamsplitter the two reflected beams pass at exactly the same path length and consequently all wavelengths of light are totally in phase The resulting signal intensity is at its maximum a point called the Zero Path Distance ZPD The modulated beam is reflected from the interferometer s mirrors and lenses to the sample where selective absorption takes place From the sample the beam travels on to the detector which translates the beam into an electrical signal Infrared Source Interferometer Detector Figure 7 6 FTIR Flow Schematic The cosine waves produced by the source and modulated by the interferometer appear to the detector as an interferogram a signature of intensity versus mirror position The interferogram is a summation of all the IR light frequencies and for all practical purposes it cannot be interpreted in its original form The detector sends the interferogram to the analog to digital converter or ADC which converts the interferogram into a form that can be used by a computer where it is transformed by the software into an IR spectrum
153. ir line from the Ejector Air In fitting and the tee on the side of the rack Re connect the inlet of the purge gas generator to its original position Remove the 1 4 inch Swagelok plugs This completes the leak test Place the eductor pump plumbing assembly back into the sample system heater assembly box Using the 5 8 inch wrench tighten the bulkhead nuts to secure the fittings to the box Use a second 5 8 inch wrench to hold the hex part of the fitting in place to keep the fittings from trying to spin during reassembly Follow steps 1 4 in reverse order to complete the procedure Omni FTIR Multi Gas CEMS Instruction Manual 5 81 Preventive Maintenance and Servicing sample System Heater Assembly Components Removing the Heated Block Assembly AN 5 82 Omni FTIR Multi Gas CEMS Instruction Manual Use the following procedure to remove the heated block assembly from the sample system heater assembly box This will be necessary to replace both the check valve and the sample solenoid valve Figure 5 59 Equipment Required Phillips screwdriver Wrench 5 8 inch 2 9 16 inch and 1 2 inch Hex wrench 3 16 inch Wire Cutters Tie Wraps zip ties CAUTION High surface temperatures present Allow sufficient time to cool A 1 Remove the sample system heater assembly and its cover per the previously mentioned procedure Removing the Sample System Heater Assembly and Cover 2 Remove the top bottom left and right side pieces
154. is case this setting is to trigger the sample valve to open and shut down the zero air flow into the gas cell while all other control valves are closed Delay box is the delay time setting in the unit of ms milliseconds e System running status setting The System Running Status is the top setting block inside the main setting frame It is configured to display live system running status such as the date time and current interferometer status It is not adjustable by users e Modbus Sensor setting ModbusMultiSensor setting block is right below the System running Status setting This setting is used to log six monitored parameters into the cons files They are gas cell temperature sample temperature short inlet sample line temperature heated box temperature short outlet sample line Thermo Fisher Scientific Thermo Fisher Scientific IMACC Script Setting CEMS SampleMode temperature and gas cell pressure Move the cursor to the block and double click The subpanel named Modbus Register Setting pops up as shown i Modbusbhrulti amp ensor amp 8 address i loptical path FrontMain comm part 5 settings o6on0 8 None 1 NHons request bytes response t bytes Modbus Register Settings setup serial Optical Path Fronth ain T Measurement Channel Mapping IEEE float CELLTEMP Ona IEEE float sampleline alc IEEE float cellinlet 4az24 IEEE float
155. ittings to their original positions on the solenoid valve and then tighten until snug using the 9 16 inch wrench 12 Turn the gas cylinder back on or reset the house air regulator back to the pressure noted earlier then push the knob down to lock it 13 Re install the left side panel to complete the procedure Replacing the Flow Use the following procedure to replace the flow meter regulators on the Meters X pneumatic panel The procedure is the same to replace any of the 6 flow meters except where otherwise noted The 4 center flow meters have the same part number but the 2 end flow meters have a different part number Be sure to order the correct flow meter Equipment Required Phillips screwdriver 5 94 Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific Thermo Fisher Scientific Preventive Maintenance and Servicing Pneumatic Panel Components Small flat blade screwdriver Wrench 9 16 inch Nut driver 11 32 inch Flow meter regulator Remove the left side panel per procedure Removing the Left Side Panel for better accessibility If the probe spike or probe span flow meter is being replaced turn off the HCI SF6 cylinder or the EPA mix cylinder respectively From the rear of the pneumatic panel the probe spike is the first flow meter on the left and the probe span is next to it If any of the other 4 flow meters are being replaced note the pressure on the house air regulator located on the right side
156. ker 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 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 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 facilitate re connection 6 Per steps 9 10 and 12 of the Removing the FTIR section disconnect the ground wire heater connector temperature sensor connector and heated lines 7 Using the 7 16 inch wrench loosen the nut and slide the temperature sensor out of the fitting to remove it Figure 5 30 8 Using the 7 16 inch wrench loosen the nut and remove the pressure sensor assembly and SS tubing from the gas cell Similar to Figure 5 27 but with the tubing removed with the sensor 9 Using the 5 32 inch hex wrench remove the 4 cap screws that mount the gas cell to the mounting plate Figure 5 32 Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual 5 43 Preventive Maintenance and Servicing Gas Cell Alignment Gas Cell Alignment 5 44 Omni FTIR Multi Gas CEMS Instruction Manual REMOVE SUM P Figure 5 32 FTIR Heated Gas Cell Replacement 10 Using the 7 64 inch hex wr
157. ks Center Taskbar and TRU instal User Accounts Windows Windows rt Menu CardSpace 9 s e Audo Devices wor we c Thermo Fisher Scientific Calogix Setup Finding the Correct COM Port f Automahic Updates Remote Computer Name Hardware Advanced System Microsoft Windows XP Profesional 1 M Version 2002 I3 Service Pack 3 Regatesed to ute Themo T6487 OEM 0027964 35871 Computer leitet PerbunR 4 CPU 340GHz 339 GHz 0 39 GB of RAM Physical Addets Extermon Lx em Syitem Restore i Automate Updates Remote General Computer Name Hardware Advanced Derce Manage The Device Manager ists al the hardware devices wietalied On pour compet Use the Device Manage to change the properties of ang device Devers Driver Signing lets you make sure that installed devert are compatible with Windows Windows Update lets you set up how Windows connect to Windows Update for diwers Hardere Prolles gm Hardware peofiles provide a say bor you to set up and store different hardware configurations Le Cea Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual D 3 Calogix Setup setting the Virtual COM Port 5 Expand Ports COM amp LPT Find USB Serial Port COMn where 7 is the number of the com port here it is 6 O FTR Spectrometer Devices Gy WE ATAJATAPI controllers U Keyboards 73 Mice and other pointing devices Moderns Mont ors Piao Device on High
158. le Probe 630 W 1 8 Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific Introduction opecifications Pneumatics Table 1 5 Pneumatics Pneumatic Swagelok Connector Instrument Air 80 120 PSI 5 SCFM 3 8 inch Zero gas FID not used 1 4 inch Span gas FID not used 1 4 inch Fuel FID not used 1 4 inch Span gas 1 4 inch opike gas 1 4 inch Vent gas 1 2 inch Vent condensate 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 Fowback 6 0 l min Blowback 50 l min Cabinet Table 1 6 Free Standing Cabinet Cabinet Thermo Fisher Scientific 35U Dimensions 22 x 70 x 36 inches whd 558 8 x 1778 x 914 4 mm whd 31 x 70 x 36 inches built system 787 4 x 1778 x 914 4 mm built system Weight 440 Ibs 200 kg without doors Color Thermo Fisher Scientific Blue PMS 646 Ambient temperature 60 to 95 F 15 to 35 C without doors Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual 1 9 Introduction Other Manuals Other Manuals 1 10 Omni FTIR Multi Gas CEMS Instruction Manual The following manuals are currently available for the Omni FTIR Multi Gas CEMS system e Antaris IGS User s Guide e Result Software User s Guide e M amp C Operating Instructions Gas Sample Probe Series SP Version SP2000 SP2000 H SP2300 H SP2400 H e Parker Balson FT IR Purge Gas Generator Models 75
159. lenoid valve operation setting From the top to the bottom the valve operation is sequentially implemented Alternatively the blowback valve is first triggered to open for five seconds and then closed for 10 seconds The same procedure is repeated for two more times before switching back to the normal sample mode setting e Script Setting for Modbus Version Script For the Modbus version script all commands are set or sent by users via PLC or an other GUI The system reads the command and transfers it into the script using Modbus protocol The list of the commands and their description is given in Table B 3 in Appendix B Modbus Protocol The Modbus based script named Modbus control is saved in the script folder of the directory of c scripts Use script edit to open it so that its setting block pops up Thermo Fisher Scientific Thermo Fisher Scientific IMACC Script Setting Modbus Control Version m DG E m OF 2 Wouintpsm Edi eut pa Calc 2 Cale 4 Shs Ores SIONS aa Eee p expres chi Expression container container clear_all datm Calc A Sessions T ALARMSI CELLTEMP 175 10 5 ALARM i SYSTEM CMDI 1 1 0 ALARMES ALARM T ALARM results mmm mmm mm SYSTEM STATUS Calc 4B Express SYSTEM CMD DATA VALID De EE Coletha raters gt Analysis Controls pu tontrals Eg ate E oo ig Fiecara Gil boo Gi Mosbussenso E vate Eg MetDnesxatien Eg Fres
160. liably at temperatures up to 185 C The gas cell is fitted with zinc selenide ZnSe sample windows Figure 7 8 Major System Components Gas Cell Heating The 5 2 meter gas cell is supplied with a heating jacket The heating jacket Jacket can maintain the gas cell at a constant temperature to improve quantitative accuracy and prevent condensation of sample gases The heating jacket is designed to heat the gas cell to a temperature of 185 C Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual 7 11 System Component Description Air Purifier Temperature Sensor The temperature sensor is used to measure the cell gas temperature This is used to control the cell temperature and to compensate the concentration calculations The temperature controller is programmed to ensure that the gas cell is not heated too quickly or to a temperature that could damage it Pressure Sensor The pressure sensor allows monitoring of the gas cell pressure This is used to compensate the concentration calculations and warn in the event of a system pressure issue Gas Cell Interface The FTIR analyzer provides sampling through the gas cell using an upper sample beam path The gas cell interface includes e Astainless steel pin aligned mechanical interface to mount the gas cell to the analyzer e Astainless steel mechanical interface to maintain the gas cell gasket seal on the sample beam path e An optical interface to allow the infrared
161. lues 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 followed in the correct order The ramp program must be saved and the program mode must be set to On before the controllers are set to run If the controllers are set to run with the ramp program not enabled heated line and sample cell temperatures could rise too quickly and damage those components A Thermo Fisher Scientific Calogix Setup Programming the Controllers and Setting Parameters Creating Ramp Programs Use the following procedure to create ramp programs 1 Right click anywhere on the CALogix window Select Edit Programs from the pop up menu F e instrument Alarms Chats View Window Help OSs Baie DD esas Properties b 10 Loge Clone CALOGIx Edt program formation 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 Segment 2 Segment type SOAK Soak time Continuous EOP Status None gt d VEM A CREER EIE CUR E TI LHP TENNANT Ba NEE m 3 Select the Module 2 tab Enter Segment 1 Segment type RAMP Ramp rate 90 Target Setpoint 185 Holdback band 0 EOP Status Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual D 7 Calogix Setup Programming the Controllers and Se
162. lve bank assembly to the flow meter panel Pull the valve bank assembly away from the flow meter panel to access the back side Figure 5 62 Omni FTIR Multi Gas CEMS Instruction Manual 5 93 Preventive Maintenance and Servicing Pneumatic Panel Components 5 Using the Phillips screwdriver loosen and remove the 4 screws that mount the solenoid valve to the valve plate and remove it Figure 5 63 6 Using the Phillips screwdriver remove the screw and connector with cable assembly from the end of the solenoid valve to be used later 7 Using the 3 4 inch wrench remove the 2 fittings and their o rings from the solenoid valve Install the fittings and o rings on the new solenoid valve and tighten until snug Figure 5 62 8 Using the small Phillips screwdriver remove the screw and connector from the new solenoid valve and discard them Install the original connector with cable assembly on the new valve install the screw and tighten until snug Note that one tab is wider than the others so that it can only be installed 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 valves Figure 5 62 10 Re install the valve bank assembly onto the flow meter panel using the 2 nuts removed previously Using the 11 32 inch nut driver tighten until snug 11 Re install the tubing or f
163. ly Hydrator Pneumatic Panel 7 4 Omni FTIR Multi Gas CEMS Instruction Manual The sample system heater assembly includes the ejector pump and sample valve This assembly also includes heated copper tubing to pre heat instrument air for the ejector pump FTIR instrument zero and sample line flowback The sample gas is extracted continuously via the sample probe and the heated line by an air driven ejector pump which is mounted inside this assembly The main air stream pressurized air has an adjustable flow which is typically set to 6 l min This creates a slight under pressure which is used to extract the sample gas from the stack The heated sample valve is used to allow sample air into the system from the probe This is a normally closed valve in the closed state zero air is run through a hydrator and a pre heater and then 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 valve is opened air extracted by the probe is delivered to the FTIR for analysis This is the sample mode The hydrator assembly adds moisture to the sample line during flowback mode while the FTIR instrument zero is performed This ensures the sample line to the probe is not stagnant and isn t dried out by the zero air flow This assembly is provided for future use and maintenance but is not currently used
164. ly Push the sensor in as far as it will go with the red dot facing up Tighten the nut until it is finger tight 9 Using the 7 16 inch wrench tighten the nut 1 1 4 turns 10 Re install the sensor connector onto the 3 metal prongs of the sensor with the red dots lining up with each other 11 Follow steps 2 4 in reverse order to complete the procedure 5 40 Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific Preventive Maintenance and Servicing Replacing the Pressure Sensor Replacing the Use the following procedure to replace the FTIR pressure sensor Pressure Sensor Equipment Required Wrench 9 16 inch and 3 4 inch Phillips screwdriver Small Phillips screwdriver Pressure sensor cool A N CAUTION High surface temperatures present Allow sufficient time to 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 put the system in fail safe mode so that it will not be sampling stack gas 2 Using the Phillips screwdriver remove the FTIR cover panel in the front of the system and the blank panel above it 3 Slide the FTIR drawer out of the system to access the right rear side of the unit 4 Using the small Phillips screwdriver loosen the captive screw that holds the pressure sensor cable in place then pull the cable assembly off of the sensor Figure 5 31 Thermo Fisher Scientific Omni FTIR Multi Gas CEMS
165. mo Fisher Scientific Preventive Maintenance and Servicing Maintenance and Servicing of the FTIR Analyzer Components 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 Allow the source element to cool for at least 15 minutes before proceeding 3 Using the 3 32 inch hex wrench remove 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 analyzer when all of the screws are removed Figure 5 6 V 393135 yy VV NV Y 9 f m5 99 333313 333 5993 9 yay j ZO 1333 Figure 5 6 Removing the Right Side Panel 4 Locate the source assembly inside the analyzer and then unplug the source power supply cable from the power distribution cable 5 Loosen the thumbscrew that secures the source assembly to the analyzer Rotate the clamp bar that holds the source in place 90 degrees counterclockwise Figure 5 7 Figure 5 7 Removing the Source Assembly Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual 5 17 Preventive Maintenance and Servicing Maintenance and Servicing of the FTIR Analyzer Components 5 18 Omni FTIR Multi Gas CEMS Instruction Manual 6 Grasp the source assembly by the ceramic base Lift it straight up until it clears the al
166. mo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual 4 7 Calibration Manual Background Spectrum Collection Procedure 4 8 Omni FTIR Multi Gas CEMS Instruction Manual Select tab Process and select Reprocess IM l lum x Bbeorbanca Corba m E Trai ChbisT CH Detrimer Inter organ fiavelne Correct Boinne Baseline Connect Adah ATH Cornsebon B Lini Blank Strand une Verify or set the following Resolution 0 5 Apodization Happ Genzel Phase correction Mertz Zero filling None Final format SingleBeam Correction None Saved spectral range 4500 400 Press OK Thermo Fisher Scientific Calibration Manual Background Spectrum Collection Procedure Select tab File and select Save As Go to directory BKGS and press Set Filename to Title i med imace capture j i 3 n E a Save As zero alr background xyz amp 7 2007 10 15 i 4 FA smen c2 8r55 emm C baduundszUU 43 Ghar Oo Cobachgounds 2007 404 Cybaekg nuns 2007 10 baci grounds zu EaD a background spear 2001 Ca background 2007 06 e Cjbachgnounds 2007 07 CObachgnaunde ZUUT UE Ei E Fiemme e ar background ga 2007 1015 co FEET o oe new Single Beam Wiavenumha rs exe Go to tab My Documents If not opened yet then open it with Explorer Move previous background file to monthly archive and dele
167. n on the FTIR analyzer ensures that the electronics are not damaged by high temperatures The filter prevents dust and particulates from entering the electronics compartment The fan filter can be cleaned but it can also be replaced as part of the FTIR maintenance kit Use the following procedure to periodically clean or replace the fan filter which is located on the left side panel of the analyzer Important Note Do not remove the screws that secure the fan filter housing to the panel A Equipment Required Phillips screwdriver Flat blade screwdriver Fan filter optional Using the Phillips screwdriver remove the FTIR cover panel in the front of the system rack Slide the FTIR drawer out of the rack to gain access to the analyzer Using the flat blade screwdriver carefully pry the fan cover grill off of the fan filter housing Remove the dirty filter Figure 5 5 Thermo Fisher Scientific Thermo Fisher Scientific Preventive Maintenance and Servicing Maintenance and Servicing of the FTIR Analyzer Components Figure 5 5 Removing the Fan Filter 3 To clean the filter either use compressed air to blow it clean or rinse it thoroughly with warm water and let it dry Compressed air can be used to speed up the drying process 4 Place the cleaned filter or a new filter into the filter housing Replace the grill on the filter housing by pressing it firmly until it snaps into place 5 Slide the FTIR drawer back into
168. n procedure is in accordance with EPA method 320 321 P515 FTIR instrument zero system zero check system span and system dynamic spiking are described in this chapter The user can also perform manual instrument background collection and manual system calibration System zero check span check and dynamic spiking are set to be controlled by the operator via Thermo Modbus Controller or a data logger and PLC The user interface for the PLC is currently under development For details see the following topics e Automatic FTIR Instrument Zero Background Collection on page 4 l e Periodic System Zero Check on page 4 2 e Periodic System Span Check on page 4 3 e System Dynamic Spiking on page 4 3 e External Audit Gas Procedure on page 4 3 e Calibration Gases on page 4 4 e Manual Background Spectrum Collection Procedure on page 4 5 e Manual Background Spectrum Collection using Thermo Modbus Controller on page 4 10 e System Calibration Procedure Using IMACC Collect on page 4 11 e System Calibration Procedure Using Calibration Factor Table in Method on page 4 18 In normal operation mode FTIR instrument zero is part of the system auto operation procedure It is scheduled to be performed once every day Instrument zero spectrum collection begins at 3 15 am The sample control valve is first shut off followed by triggering the instrument zero valve to flow zero air into the optical gas cell After purg
169. nalog output board running under Windows XP The program opens in a minimized state so it is necessary to click on the taskbar to open it for observation or for changing the configuration The top section of the ICL window allows the user to assign the data channels The Valid Data Settings section transmits a TTL signal that describes the status of the instrument on any of the digital output lines The Configure section allows Omni FTIR Multi Gas CEMS Instruction Manual 3 13 Operation Data Server Software Configure 3 14 Omni FTIR Multi Gas CEMS Instruction Manual the user to enter basic configuration data In order to make changes it is necessary that the program be in the Stopped mode 5 ImaccCurrentLoop compound S02 AVG MO ANG NOZ AYG Neo AYG MH3 ANG HEI AvG HF ANG File type con con con con con con con channel 16 17 18 19 el el ez miri cutoff 6 575000 13 075000 6 100000 12 725000 1 650000 2 3000060 2 600000 max cutoff 6 300000 22 400000 24 300000 50 900000 6 600000 9 200000 11 200000 scale 1 000000 1 000000 1 000000 1 000000 1 000000 1 000000 1 000000 value 0 000831 0 122510 0 000432 0 240756 0 166957 0 036732 0 030003 output mA 3 399494 4 037479 4 000253 4 075680 3 095256 3 336119 3 957139 x Valid Data Settings Vmas Mmin 7 228000 OOo ddaa z Good Scans Valid Data Channel Earl Stop Configure
170. nd Servicing Sample System Heater Assembly Components Using the 9 16 inch wrench and the 1 2 inch wrench remove the copper tubing segment and union fitting from the old eductor pump and install it on the new eductor pump in the same orientation tightening the nut until snug Using the 9 16 inch wrench and the 1 2 inch wrench remove the union fitting on the opposite side of the old eductor pump and install it on the new eductor pump in the same location tightening the nut until snug Using the 9 16 inch wrench and the 1 2 inch wrench remove the stainless steel tubing segment and fittings from the old eductor pump and install it on the new eductor pump in the same orientation tightening the nut until snug It is important to leak test the rebuilt assembly Using the wrenches install the 1 4 inch Swagelok plugs onto the fittings for the FTIR Out and the Ejector 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 long air line Connect that air line to the Ejector Air In fitting Turn the air regulator that is next to the filters up to 25 PSI Using the liquid leak detector wet each connection to see if there are leaks which will produce air bubbles If any are present tighten the fittings until the leaking stops Turn the air regulator back down to zero PSI Using the wrenches disconnect the a
171. nd Shut Down Installing the FTIR Analyzer into the Rack Connect the FTIR The following connections need to be made to the FTIR unit Purge Unit Power Computer Pressure Cell heater and Sample lines Figure 2 3 4 aN A o gt NS c M dE LIE A WL S va y g 1 C Accessor 1 Power KL C b b Ne 1 i PURGE INPU Figure 2 3 Purge and Power Connections Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual 2 5 System Installation Start Up and Shut Down Installing the FTIR Analyzer into the Rack Connect the Purge Lines to the FTIR Connect one 1 4 inch PTFE line marked Purge Input to the corresponding quick release fitting on the lower edge of the FTIR chassis Figure 2 4 ATED SAMPLE ASSEMBLY HEATED SAMPLE LINE 1 p A FTIR IN HEATED SAMPLE LINE 2 Ae JAN FTIR N Ext Acces Signals ELECTRICAL HDUK UP NOTES CONNECT CABLES PER TABLE ABOVE ROUTE CABLES ALONG CABLE CARRIERS AN Connect the Power 2 6 Omni FTIR Multi Gas CEMS Instruction Manual ASSEMBLY ELECTRICAL HOOK UPS JESCRIPTION 10 HEATED SAMPLE LINE 1
172. nect y 7 Unplua all pl tta C a CO to ear panel as A SAA ot E S x1 7 sd MT rit I e P vo ea T a ANO i ye a M N di Se Detach purge tubing je Figure 5 14 FTIR Wiring and Tubing Connections 5 26 Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific Thermo Fisher Scientific Preventive Maintenance and Servicing Maintenance and Servicing of the FTIR Analyzer Components Using the Phillips screwdriver remove the ground wire from the rear plate of the gas cell assembly Disconnect the 2 blue connectors for the heaters at the rear of the unit by carefully pulling them apart Disconnect the temperature sensor connector from the sensor by pulling it off exposing the 3 metal prongs Note that the red dot on the connector lines up with the red dot on the sensor Using the 9 16 inch wrench disconnect the two 3 foot heated lines from the elbow fittings at the rear of the unit Note or mark their position to facilitate re connection Using the Phillips screwdriver remove the 20 screws that mount the cover on the coupling optics and then remove the cover Do not remove the 2 screws on the front that are further away from the edge than the other screws Using the 5 32 inch hex wrench remove the 4 corner screws that mount the gas cell and coupling optics plate to the top of the analyzer Using 2 people carefully lift the plate up over the 2 alignment pins in the front corners of
173. nents Use the following procedure to replace the laser in the FTIR analyzer The laser is located behind the rear panel of the analyzer The laser indicator light on the analyzer front panel will be off if the laser has failed WARNING To avoid shock hazard always turn off the FTIR circuit breaker on the breaker panel before replacing any components inside the FTIR analyzer A CAUTION High surface temperatures present Allow sufficient time to cool A 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 components A Important Note A system 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 analyzer compartment is open there is a potential for damage to sensitive components which will affect the performance of the system A Equipment Required Phillips screwdriver Hex wrench 3 32 inch Laser assembly 1 Shut down the FTIR analyzer and heaters by turning off the FTIR 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 The laser is located behind the rear panel of the analyzer which can be accessed from the rear of
174. ni FTIR Multi Gas CEMS Modbus Protocol specification see the following topics e Serial Communication Parameters on page B 2 e TCP Communication Parameters on page B 2 e Application Data Unit Definition on page B 2 e Function Codes on page B 3 e Modbus Parameters Supported on page B 5 Additional information on the Modbus protocol can be obtained at http www modbus org References are from Modbus Application Protocol Specification V1 1a Modbus IDA June 4 2004 Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual B 1 Modbus Protocol serial Communication Parameters Serial Communication Parameters TCP Communication Parameters Application Data Unit Definition The Modbus RTU protocol is supported using the zmaccModbus server The following are the communication parameters that are used to configure the serial port of the system to support Modbus RTU protocol Number of Data bits 5 6 7 or 8 8 is default Number of Stop bits 1 1 5 or 2 1 is default Parity Even Mark None Odd Space None is default Data rate 110 to 115200 Baud 9600 is default Flow Control None Xon Xoff Cts Rts Cts Dtr None is default Device address to 255 70 is default In addition the poll 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 inte
175. nternal components A Important Note A system 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 Thermo Fisher Scientific Preventive Maintenance and Servicing Maintenance and Servicing of the FTIR Analyzer Components Whenever the analyzer compartment is open there is a potential for damage to sensitive components which will affect the performance of the system A Equipment Required Phillips screwdriver Short flat blade screwdriver optional Flat blade screwdriver DTGS Detector assembly 1 Using the Phillips screwdriver remove the FTIR cover panel in the front of the system rack Slide the FTIR drawer out of the rack to gain access to the analyzer 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 6 front panel mounting screws Be sure to support the panel when it is removed as it drops free of the analyzer when all of the screws are removed Be careful not to unplug or damage any cables connected to the panel 4 The detector is located on the center right hand side Loosen the 2 thumbscrews on the base plate that secure the detector assembly to the analyzer A short flat blade screwdriver can be used to loosen the thumbscrews if they are too tigh
176. nting screws to complete the procedure Use the following procedure to replace the humidity indicator which is located on the left side panel of the FTIR analyzer If the indicator is pink the desiccant and the humidity indicator need to be replaced Equipment Required Phillips screwdriver Humidity indicator 1 Using the Phillips screwdriver remove the FTIR cover panel in the front of the system rack Slide the FTIR drawer out of the rack to gain access to the analyzer Omni FTIR Multi Gas CEMS Instruction Manual 5 13 Preventive Maintenance and Servicing Maintenance and Servicing of the FTIR Analyzer Components Cleaning or Replacing the Fan Filter 5 14 Omni FTIR Multi Gas CEMS Instruction Manual 2 Locate the humidity indicator on the analyzer left side panel If the indicator is pink the desiccant and the humidity indicator need to be replaced Figure 5 3 For more information see Checking and Replacing the Desiccant Lift the tab on the indicator cover and remove the indicator Insert the new indicator it should be blue into the indicator cover Secure the indicator cover to the panel making sure the indicator cover completely covers the indicator Press the edges of the cover against the analyzer panel to create a firm seal Slide the FTIR drawer back into the rack then use the Phillips screwdriver to re install the FTIR cover panel and its mounting screws to complete the procedure The cooling fa
177. ntrol version in which all scheduled events are triggered by users via PLC All scripts are saved in the same directory of c scrips CEM SS amp leMode Script setting for CEMS SampleMode Users can open the script CEMS samplemode either using the script editor or IMACC monitor On the IMACC monitor display just click che file or click load script button to open the script File Edit Settings View Help Con gt oe F n Conditional Structures C container I gensmensmsmemme O while Q do if Ai if else E script 5 for each break loop TI stop script FTIR Controls CollectBkg CollectEZ CollectParameters Analysis Controls IO Controls AIO DIO FileData LoadFile ModbusSensor SQL SerialCommand Valve MetOneStation ModbusMultiSensor PressureDP40 PressurePAXD TemperatureCn System Runnning Status iteration o ModbusMultiSensor_8 address 1 optical path FrontMain com port 5 settings 9600 8 None 1 None request o bytes response o bytes Data Collection Collect Settings pathName FrontMain pathLength 5 209 scanTime 0 58 elapsedTime Bench Settings TemperatureCN85 Miscellaneous Controls AZELSequencer Cale Counter Dataltems Delay GasPlume highCutoff 4500 Analysis methods C method Rate method_Mitsubishi_tentative method background C Background bkg spa As indicated in the fig
178. o Fisher Scientific Line System Component Description Temperature Controller y STINGER TEMP CONTR ASH DEFLECTOR Figure 7 2 Sample Probe The probe is designed so that changing the filter element does not involve the use of tools In this operation neither the sample probe tube nor sample line need to be removed thus avoiding contamination of the clean gas path and maintaining the integrity of the system The system includes a temperature control module which is used to control the temperatures of the following system components e FTIR cell e Heated pump valve assembly e 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 heated sample line may be from 33 feet to 100 feet in length depending on manufacturer It includes two 1 4 inch lines for sample and calibration and one 3 8 inch line for blowback The lines may be PTFE or PFA depending on manufacturer All lines are heated to 185 C and the maximum current necessary to heat these lines is 15 Amps at 220 240VAC 50 60 Hz The sample line temperature is monitored using a 2 wire 100 ohm RTD Additional electrical lines are included to hook up the probe temperature alarm and blowback valve Omni FTIR Multi Gas CEMS Instruction Manual 7 3 System Component Description Heated Pump Valve Assembly Heated Pump Valve Assemb
179. odbus exe CAUTION Ethernet and serial Modbus can not be implemented at the same time A Omni FTIR Multi Gas CEMS Instruction Manual 2 9 System Installation Start Up and Shut Down oystem Startup Analog The system has the option to output up to eleven analog 4 20 ma output signals The corresponding terminals on the X1 analog output terminal block are listed in Appendix C Interfacing a DCS PLC with the Omni FTIR Multi Gas CEMS Output ranges must be manually set up at each installation to match the facility s analog data system Digital The system has a pre configured Temperature Alarm output located on terminals 21 amp 22 of terminal block X2 The terminals have an identical output High indicates a low temperature alarm Figure 2 5 System Sta rtup See the following for system startup Note The initial startup of the FTIR Multi Gas CEMS should be performed by the service department of Thermo Fisher Scientific A reached 185 C Before air pressure 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 fail safe mode with sample valve closed and system zero valve open A N CAUTION Sample gas should not be introduced to the cell until the cell has Turn Power ON Switch the Measurement Maintenance switch on the front of the system rack to the Maintenance position Use t
180. of the system so that it can be reset later Pull up on the knob to unlock it and turn the pressure down to zero Figure 5 18 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 their locations to facilitate re connection Figure 5 62 Using the 11 32 inch nut driver loosen and remove the 6 nuts that mount the flow meter panel to the pneumatic panel Pull the flow meter panel away from the pneumatic panel for better access Figure 5 62 Using the Phillips screwdriver loosen and remove the 2 screws that mount the flow meter to the flow meter panel then remove the flow meter from the front of the panel Figure 5 62 To prepare the new flow meter regulator make sure the valve is closed by turning the knob all the way counterclockwise Remove the nuts and ferrules from the 2 fittings and discard them Insert the new flow meter into position on the flow meter panel making sure the orientation is correct Insert the 2 mounting screws and tighten using the Phillips screwdriver until snug Omni FTIR Multi Gas CEMS Instruction Manual 5 95 Preventive Maintenance and Servicing Pneumatic Panel Components 8 Place the flow meter panel back into position over the studs then thread on the 6 nuts that were previously removed Using the 11 32 inch nut driver tighten them until snug Figure 5
181. ollection script 2 Double click on the CollectEZ window 3 Click on the options tab 4 In the entry box Copy CON file to directory browse for the data transfer folder created earlier IFSS will save a copy of the current concentration file to the file current con in that folder 5 Click OK and save the script Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual F 3 Concentration Data Transfer Using a Web Server Modbus Control Version Communications Security FTIR Computer The preceding installation process allows anonymous access to the concentration data by anyone who knows the computer name or IP address The FTIR Data web site can be made password protected by the following series of steps 1 In the IIS management window right click on F77R Data and click Properties 2 Click the Directory Security tab and the Edit button 3 Uncheck Anonymous access and check Integrated Windows Authentication Click OK twice to save the change and exit the configuration window Access to the data will now be restricted to users who possess valid usernames and passwords for the FTIR computer In this case the software written to use IIS access will also have to provide this additional information F 4 Omni FIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific
182. om 2 up to 6 The subsequent calculation block is used to send the value of system cmd to the variable of system status The second script setting is used to assign the digital I O output channels P g g g P for each system mode using the system status variable E 12 Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific IMACC Script Setting Modbus Control Version For each system mode the corresponding system control is configured by the third script setting The description for each system mode is summarized in Table B 3 in Appendix B Modbus 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 blowback valve to open just double click its setting block and set the correct DIO channel dev2 port1 line0 7 pattern 0x050 and time delay setting 0 Output Settings x Channel Description ex dev1 port0 line0 7 dev2 portl line0 7 Pattern hex poo test Delay ms D Wait this many ms after writting port Cancel ttern OX050 EndBlowback e dev2 portt lineD ipattern 0x090 e Script setting for ModbusMultiSensor Next to the script setting for system command and status is the container for ModbusMultiSensor setting as shown container container ModbushktultiSensor_ido add
183. omplete the procedure Use the following procedure to replace the PC Console monitor and keyboard Equipment Required l 2 Phillips screwdriver PC Console Slide the Lock lever on the front of the PC console to the Release position Shut the PC down through Windows and then shut off the PC Console circuit breaker on the breaker box Using the Phillips screwdriver remove the blank panel in the front of the system directly above the PC console Figure 5 46 At the rear of the system unplug the PC console power connector as well as the connectors for the console mouse and keyboard Figure 5 47 Omni FTIR Multi Gas CEMS Instruction Manual 5 57 Preventive Maintenance and Servicing Replacing the PC Console 5 58 Omni FTIR Multi Gas CEMS Instruction Manual P Cmm Geary Sy tm toe foe e m m m m m CO CO I2 Cn Qe
184. on Manual 2 3 System Installation Start Up and Shut Down Installing the FTIR Analyzer into the Rack 2 4 Omni FTIR Multi Gas CEMS Instruction Manual aay J JEEP I u Y X uy CHOY A Y Sot 2j SE X G Figure 2 2 Analyzer Installation Remove screws and front FTIR rack panel and set aside for reassembly later It may be helpful to remove unpopulated side panel not shown Remove rubber feet inserts from bottom of the calibrated FTIR power supply that is to be used with this assembly Cut 2 lengths of 4 5 of 112596 00 Velcro with hook amp loop 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 shelf out all the way Remove backing of Velcro and position power supply up against the inside of the back lip and against the right side bend of the shelf assembly Figure 2 2 Once in position apply even pressure and push down to secure the Velcro Run cable to shelf assembly alongside the power supply Reinstall FTIR shelf cover Use 2 people to install FTIR to shelf Carefully place FTIR on top of shelf while lining up shock mount feet holes to the 8 studs on the FTIR shelf Secure with 8 nuts Thermo Fisher Scientific System Installation Start Up a
185. on box In this example 0 3 ppm is the zero offset Type in the new zero 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 e Schedule setting for auto zero background collection By default the zero background collection is executed daily starting at 3 15 am If a change is needed get access to the script block labeled Background Spectrum Collection if TimeCondition equal to MextTime 03115100 iackground amp Pectrum collection Click the green shadow block if l imeCondition equal to and the subpanel time setup pops up Thermo Fisher Scientific Thermo Fisher Scientific IMACC Script Setting CEMS SampleMode Time Setup settings Condition Current Time equal to Time HH HEI8 SS 03 75 00 add remove Time Window HH MAIS 5 5 00 cancel To make a change highlight the time 03 15 00 and click the remove button to delete the existing time stamp Then clickthe add button so the current 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 same procedure to type in the start time In general one daily background collection is adequate e Script setting for background spectrum collection Double cl
186. on to complete the gas cell alignment Re install the cover on the coupling optics compartment Use the Phillips screwdriver to install the 20 mounting screws to complete the procedure Replacing the Use the following procedure to replace the FTIR gas cell heater Gas Cell Heater Thermo Fisher Scientific Equipment Required Wrench 9 16 inch 7 16 inch and 3 4 inch Hex wrench 5 32 inch and 7 64 inch Phillips screwdriver Razor blade utility knife Omni FTIR Multi Gas CEMS Instruction Manual 5 51 Preventive Maintenance and Servicing Replacing the Gas Cell Heater Gloves Flat blade screwdriver High temperature tape Gas cell heater cool A N CAUTION High surface temperatures present Allow sufficient time to 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 put the system in fail safe mode so that it will not be sampling stack gas 2 Remove the gas cell by following procedure Replacing the Gas Cell 3 Using the utility knife carefully cut the paper of the insulation at the seam Figure 5 42 T D Figure 5 42 Cutting Insulation Paper at the Seam 4 Remove the insulation from the gas cell Wearing gloves is suggested when handling the insulation Figure 5 43 5 52 Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific Thermo Fisher Scientific Preventive Maintenance and Servicin
187. ons Paicen Compite TOCL 000i Number Di Scans 14 Lact Wire 2 828000 Lait Vinx 5561000 Last Tempershune 2 3 000000 Last Pressure TEX ODODOU Last Number OF Good Scans 14 Last Mumbes Of Bad Scans Display Parameters Mepis 5 kit Select Paeameteis Mist d P a e a l coleciSistuz dastPrervure I bencnStatuio detector codec Sahat T empag benchstangso emos ana colectStatus slam C benichStatuss tuse voltage colecitLalut atium I benchstatur sa S curceCurerd ColectStalut o number ES cans O bench tar iS ourceVotage tine me NI elie aol see h Settings Select Parameters Check the parameters to be displayed Order Parameters Use arrows to reorder the selected parameters Omni FTIR Multi Gas CEMS Instruction Manual 3 5 Operation Imacc FTIR Software Suite IFSS ConcentrationPlot Spectrum Plot Display Tab 3 6 Omni FTIR Multi Gas CEMS Instruction Manual The SpectrumPlot is used to display both real time spectral data from the ImaccServer or saved spectrum files The configuration popup menu appears when right clicking at any point of the grey area of the plot Different plots can be added or removed by the add and remove control When right clicking over the white area of the plot a menu appears to add saved spectral files to the plot The toolbar on the right can be used to adjust the SpectrumPlot display settings Pilot Too bar Fix Auto Ecroli X scrolls all plots to
188. ont on top and 1 is on each side Figure 5 49 Removing the PC Cover 4 Using the Phillips screwdriver remove the 5 screws holding the card cage in place Figure 5 50 Note that 4 of the screws are on the back of the PC and 1 is inside Figure 5 50 Removing the Card Cage Mounting Screws 5 60 Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific Preventive Maintenance and Servicing Replacing the National Instruments Boards 5 Remove the card cage from its mount in 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 of the NI board to be replaced and then gently remove the board from the edge connector See Figure 5 52 and Figure 5 53 that show the Digital Figure 5 52 Removing NI Board Mounting Screw Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual 5 61 Preventive Maintenance and Servicing Temperature Control Box Components Figure 5 53 Removing NI Board from Card Cage 7 Install the new board in the edge connector and re install the mounting screw using the Phillips screwdriver 8 Re install the card cage and install the 5 mounting screws using the Phillips screwdriver 9 Re install the PC cover and install the 5 mounting screws using the Phillips screwdriver 10 Re install the PC back in
189. ounts of static electricity A properly grounded antistatic wrist strap must be worn while handling any internal components A Remove the temperature control box cover per the previously mentioned procedure Removing and Installing the Cover Thermo Fisher Scientific Preventive Maintenance and Servicing Electrical Panel Components 2 Using the 3 8 inch nut driver remove the 2 nuts that mount the control module and base unit assembly to the temperature control box Note the orientation of the assembly 3 Note or mark the position of each temperature control module to ensure that they are re installed in the correct locations 4 To remove one of the temperature control modules lift the assembly so you can access the bottom of it Squeeze the two mounting tabs of the module inward while lifting the module off of the base unit to release it taking care not to disconnect the wiring Repeat to remove the other 3 modules 5 Pull 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 the din rail into the slots on the bottom of the new base unit until it is centered 8 Re install each temperature control module into its appropriate slot in the base unit by inserting the tabs into the slots and snapping them into place 9 Place the control module and base unit assembly onto the threa
190. ove the 2 screws that mount the thermostat to the plate and remove it Figure 5 59 Install the new thermostat by mounting it to the plate with the mounting screws using the Phillips screwdriver Re install the sample system heater assembly cover by referring to procedure Removing the Sample System Heater Assembly and Cover Use the following procedure to replace the eductor pump inside of the sample system heater assembly Equipment Required Phillips screwdriver Wrench 5 8 inch 2 9 16 inch and 1 2 inch Hex wrench 9 64 inch Plugs for 1 4 inch Swagelok tube fittings Liquid leak detector such as Snoop 6 foot section of PTFE or PFA tubing with 1 4 inch nuts and ferrules attached Eductor pump CAUTION High surface temperatures present Allow sufficient time to cool A Remove the sample system heater assembly cover per the previously mentioned procedure Removing the Sample System Heater Assembly and Cover skipping steps 6 and 7 sample system heater assembly doesn t need to be removed from the rack for this procedure Omni FTIR Multi Gas CEMS Instruction Manual 5 79 Preventive Maintenance and Servicing sample System Heater Assembly Components 2 Remove the top bottom and left 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 9 64 inch hex wrench remove the eductor pump cover by removing the 5 mounting screw
191. own to zero PSI 10 Leak test the other side of the check valve by disconnecting the air line with union from the Sample In line and connecting that to the Flowback line using the wrenches Install the 1 4 inch Swagelok plug onto the other 1 4 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 tubing to see if there are leaks which will produce air bubbles If any are present tighten the fitting until the leaking stops 11 Using the 9 16 inch wrench slightly loosen the 1 4 inch plug on the Sample In line Air should be flowing out of it if the check valve is installed in the proper direction Turn the air regulator back down to zero PSI Remove the 1 4 inch plug and 1 4 inch Swagelok union fitting from the Sample In line and disconnect the air line with union fitting from the Flowback line Remove the union fitting from the end of the air line Disconnect the air line from the tee on the side of the rack Re connect the inlet of the purge gas generator to its original position This completes the leak test 12 Using the 9 64 inch hex wrench tighten the 5 mounting screws that were loosened that attach the double coil clamp plate to the heated block until snug 13 Follow the procedures referenced in step 2 Removing the Heated Block Assembly and in step 1 Removing the Sample System Heater
192. perature Control circuit breaker on the breaker box to complete the procedure Replacing the Internal Use the following procedure to replace any of the internal fuses in the Fuses temperature control box Equipment Required Phillips screwdriver Small Phillips screwdriver Replacement Fuses 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 components A 1 Remove the temperature control box cover per the previously mentioned procedure Removing and Installing the Cover 2 There are 16 fuses located on the PC Board inside the temperature control box plus 4 spare fuses To remove any one of them simply grasp the fuse with your fingers and pull it up and out of the connector Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual 5 65 Preventive Maintenance and Servicing Temperature Control Box Components 5 66 UC LE Omin MAN rir LLLI E fo L LL L Ai Lr a 9X FUSE hA PAN R k D FIN Neu SED Mess FMP CONTROL BOARD M 2 p S oA N
193. ppendix A Table B 1 Modbus Read Registers Register Number 1 amp 2 3 amp 4 5 amp 6 7 amp 8 9 amp 10 118 amp 12 13 amp 14 15 amp 16 17 amp 18 19 amp 20 21 amp 22 101 amp 102 103 amp 104 105 amp 106 107 amp 108 109 amp 110 111 amp 112 113 amp 114 115 amp 116 Variable 502 CONC NO CONC N02 CONC N20 CONC NH3 CONC HCI CONC HF CONC CO CONC C02 CONC H20 CONC SF6 CONC SYSTEM STATUS SYSTEM FLAGS SAMPLE TEMP PUMP TEMP INLET TEMP OUTLET TEMP CELL TEMP CELL PRES Omni FTIR Multi Gas CEMS Instruction Manual B 5 Modbus Protocol Modbus Parameters Supported B 6 Omni FTIR Multi Gas CEMS Instruction Manual Table B 2 Modbus Write Registers Register Number 201 Variable SYSTEM COMMAND Table B 3 System Command Values Value 0 1 Description N A SAMPLE MODE BLOWBACK MODE BACKGROUND MODE SAVE BACKGROUND BACKGROUND MODE amp SAVE BACKGROUND CHECK ZERO MODE CHECK SPIKE MODE CHECK SPAN MODE CHECK SPAN2 MODE N A CHECK SPAN3 MODE N A System Status Description sample solenoid valve is triggered only sample flow Is pumped into the gas cell oystem auto blowback is triggered At the end of three pulsed blowbacks the system is switched back to sample mode sample valve is closed and instrument zero and flowback flows are triggered This mode is independent of spectrum collection he FITR is commanded to collect the spectrum In gen
194. pply Note Due to the effect of humidity on certain components inside the FTIR it is important to minimize the amount of time that the purge air is disconnected 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 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 A Replacing the Use the following procedure to replace the FTIR power supply FTIR Power Equipment Required Supply Wrench 9 16 inch 7 16 inch and 3 4 inch Phillips screwdriver FTIR Power Supply 1 Remove the FTIR from the system per procedure Removing the FTIR 2 Using the Phillips screwdriver remove the 8 mounting screws and lift the panel off of the base Figure 5 29 Figure 5 29 FTIR Power Supply Replacement 3 Disconnect the power cord from the back of the power supply 5 38 Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific Preventive Maintenance and Servicing Replacing the Temperature Sensor 4 Lift the power supply off of the base disengaging it from the Velcro underneath 5 Install the new power supply and re install the cover panel by following the previous steps in reverse order Replacing the Use the following procedure to replace the FTIR RTD temperature sensor
195. pter 5 Preventive Maintenance and Servicing Omni FTIR Multi Gas CEMS Instruction Manual 3 11 Operation OMNIC 3 12 Omni FTIR Multi Gas CEMS Instruction Manual Collect View Process Ansym Report Window Hep Gas Process EF x xperiment Expermert Setup Cue ND Bench Status we E caeco oms eed Collect Background Cues Cuplsy Spectral Quality Reference Advanced Diagnostics start When there is no fault in communication between the spectrometer and the computer there is a green Bench Status checkmark in the upper right hand corner of the main OMNIC screen System 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 Diagnostic and Configure Selecting the Diagnostic tab brings up a menu with the Align button and a readout of the detector maximum and minimum voltage The align button performs an automatic optimization of the mirror position See Chapter 6 Troubleshooting Concentration Errors Experiment Setup C my documents omnic ParamWefault exp free Cee ESTE EET Diagnostic Confiqu ma Oboe Max 401 Min 2 324 Loo 1018 FF view reference detector t 1000 Data points Thermo Fisher Scientific Result NI DAQ CALGrafix CDM USB Driver Data Server Software ImaccCurrentLoop Thermo
196. pts script files which call the method file to run on the server control the timed operation of sample and data collection and are saved in C Scripts The system will have a pre set OMNI script file C Spec There is the option to collect a time and date stamped spectrum file for each minute s data point in C Spec This allows for post processing of the data at any time in the future There is also the capability to not save these files Omni FTIR Multi Gas CEMS Instruction Manual 3 9 Operation Imacc FTIR Software Suite IFSS Remote Control Windows Remote desktop or other third party software can be used to access these files and control the system computer remotely by interacting with the Monitor layout Automatic folder sharing may also be used for remote access to these files Server The Imacc FTIR Server controls the OMNIC spectrometer driver and performs an analysis of the retrieved data The server then makes that data available to other components in the system The server also writes the results of the analysis to the hard drive The Imacc Server ImaccServer exe is a simple executable 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 diagram when it is running L1 50 PH DEAE lrnaccServe Double clicking on the icon in the notify tray will display the Imacc
197. put Connections Analog No Signal 1 902 NO NO2 N20 NH3 HCI HF CO C02 H20 SF6 cO CO wN I oy A Aa C2 rn Omni FTIR Multi Gas CEMS Instruction Manual C 3 Interfacing a DCS PLC with the Omni FTIR Multi Gas CEMS Establishing Communications C 4 Omni FTIR Multi Gas CEMS Instruction Manual Digital 1 0 Bo 29690888088 i i NNNM aug NM MUME z ostii Rt RU CER M ER D UR Figure C 2 Analog Outputs The FTIR allows the user to access system status conditions via the digital I O connections The digital I O signals are labelled DIGITAL OUTPUT X2 on the electrical panel assembly which is accessible from the rear of the rack The terminals are labelled 1 28 Pins 1 6 support digital input functionality A common ground is provided on pin 1 and the digital 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 The digital outputs are provided by solid state relays with an operating voltage of 0 24 VDC maximum load current of 3 5A minimum load current of 1 mA The positive side of the SSRs are the odd numbers and the negative side are the even numbers The maintenance status is a physical key switch not an SSR Refer to Table C 2 for the digital output assignments and associated rear panel terminal signal pin outs methods for accessin
198. r Boot U D System does not start automatically Error IMACC Verify the following programs are in the setup Software Error Omni layout ImaccCurrentLoop ImaccModbus ImaccModbusTCP e See System Startup in Chapter 2 Temperatu Bad temperature readings Either in Status or in Modbus block in Errors IMACC script See Appendix E IMACC Script Setting e Last Temperature reading in Status on ImaccMonitor software main screen reads 185 000000 e Check virtual com port number See Appendix D Calogix Setup e Check USB connection between PC and temperature controller e Stop and re start script in ImaccMonitor e Pump sampling box temperature reading is low but other temperatures are OK e Check thermostat inside pump box See Chapter 5 Preventive Maintenance and Servicing e ERROR QUANT TEMPRESSCON in ImaccMonitor e Check temp control breaker and AC wiring connections 6 4 Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific Cell Pressure Errors Sampling System Errors Thermo Fisher Scientific Troubleshooting Cell Pressure Errors Sampling System Errors Check power and communications connecting between temperature control board and controller base assembly inside temperature control box e Low temperature Main power supply insufficient power for heaters check circuit breaker 230 VAC power supply Calogix controller error see Appendix D
199. re information see Replacing the Humidity Indicator Figure 5 3 Locating the humidity Indicator 3 4 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 The desiccant packet is located in a cage on the inside of the front panel of the analyzer Using the 3 32 inch hex wrench remove the 6 front panel mounting screws Be sure to support the panel when it is removed as it drops free of the analyzer when all of the screws are removed Be careful not to unplug or damage any cables connected to the panel Figure 5 4 Thermo Fisher Scientific Replacing the Humidity Indicator Thermo Fisher Scientific Preventive Maintenance and Servicing Maintenance and Servicing of the FTIR Analyzer Components Figure 5 4 Replacing the Desiccant 5 Remove the desiccant packet from the desiccant cage and discard it Place the new desiccant packet into the desiccant cage 6 Using the 3 32 inch hex wrench re install the front panel with the mounting screws taking care to support the panel until the screws are in place Be careful to place all wiring and cables completely inside the analyzer 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 install the FTIR cover panel and its mou
200. re saved in C Background The file being currently used by the system is automatically named BKG spa The system will automatically collect a new zero spectrum file at a pre set interval controlled by the script file This directory can be observed to verify that the system is automatically collecting background files on schedule as well as be used for post processing of concentration data and trouble shooting sample system operation The BKG spa file is a spectrum taken by the system on a reference sample of zero air Zero air is ordinary room air that has been scrubbed of CO and H2O as well as any of the other analytes that the Omni is detecting The purpose of taking the BKG spa file is 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 suffix con These files are Comma Separated Variable csv files that record a time stamped record of analyte concentration as well as system parameters such as sample system temperatures cell pressure and detector voltage C Layouts layout files which set the configuration of the Monitor screen GUI are saved in C Layouts The system will have a pre set OMNI layout file C Methods method files which control the analysis functions of the ImaccServer are saved in C Methods The system will have a pre set OMNI method file C Scri
201. reak loop elapsed o 07 22 05 s pois dn ModbusMultiSensor 8 M cha address i CollectBkg optical path FrontMain CollectEZ com port 5 CollectParameters settings 9600 8 None 1 None Analysis Controls IO Controls don oxa2o IEEE float CELLTEMP 185 018 EZ oxa1c IEEE float sampleline 189 963 FileData oxa24 IEEE float cellinlet 184 864 LoadFile oxa1e IEEE float heatedbox 184 752 ModbusSensor oxa26 IEEE float celloutlet 184 771 SQL oxa2a IEEE float CELLPRES 628 938 SerialCommand Valve request 8 bytes 01030a2ao002 e61b Meere response 9 bytes 010304441d 3c10 6e09 ModbusMultisensor Data collacion PressureDP40 s Collect Settings PressurePAXD pathName FrontMain TemperatureCN 77 pathLength 5 209 TemperatureCN85 scanTime 0 58 Miscellaneous Controls elapsedTime 00 11 AZELS PHODIEEE Bench Settings Calc lightSource IR ii aperture i5 Dataltems gain 8 Delay Ready 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 or by double clicking the OMNIC icon on the desktop See diagram MMIC OMNIC ordinarily runs in the background under the control of the Imacc server It can also be used for diagnostic purposes and when re aligning the spectrometer after changing the beamsplitter IR source laser or detector on the optical bench See Cha
202. rear of the PC console 11 Using the Phillips screwdriver re install 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 breaker box and re start the PC to complete the procedure Use the following procedure to replace the National Instruments NI Boards in the PC Equipment Required Phillips screwdriver Flat blade screwdriver NI Digital Board or NI Analog Board 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 component If an antistatic wrist strap is not available be sure to touch the instrument chassis before Omni FTIR Multi Gas CEMS Instruction Manual 5 59 Preventive Maintenance and Servicing Replacing the National Instruments Boards touching any internal components When the PC is unplugged the chassis is not at earth ground A 1 Shut the PC down through Windows and then shut off the PC Console circuit breaker on the breaker box 2 Remove the 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 cover on and remove the cover Figure 5 49 Note that 3 of the screws are in fr
203. ress 1i optical path FrontMain cam port settings 9000 5 None i1 one request o bytes response o bytes eYorEM STATUS Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual E 13 IMACC Script Setting Modbus Control Version E 14 Omni FTIR Multi Gas CEMS Instruction Manual Move the cursor to the block and double click it The detailed setting for each monitored parameter is listed as indicated Modbus Register Settings setup serial Optical Path Front aln T Measurement Channel Mapping measur code register al IEEE float SampleT alc IEEE float InlaetT Ones IEEE float PumpT ale IEEE float CELLTEMP nx azt IEEE float CELLPRES xaza IEEE float OutletT OxUazb Add Remove E dit Default teen As shown there are six 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 temperature On the top of the panel there are two buttons named setup and serial Under the setup configuration the setting panel is similar to the figure below Highlight the target parameter such as SampleT in the list Double click it so its subpanel pops up as shown container Au ww ww ww ww ww wen gy container for each DataCollection Conce ModbusMultiSensor 180 i address 1
204. rface TCP connection port for Modbus 502 user configurable Here are the Modbus ADU Application Data Unit formats over serial and TCP IP Slave Address MBAP Header B 2 Omni FTIR Multi Gas CEMS Instruction Manual The Modbus slave address is a single byte in length This value can be between 1 and 255 decimal i e 0x01 hex to OxFF hex The default value is 70 In Modbus over TCP IP a Modbus Application Protocol Header MBAP is used to identify the message This header consists of the following components Thermo Fisher Scientific Function Code Data Error Check Function Codes 0x03 Read Holding Thermo Fisher Scientific Registers Modbus Protocol Function Codes Transaction Identifier 2 Bytes 0x0000 to OxFFFF Passed back in response Protocol Identifier 2 Bytes 0x00 Modbus protocol Length 2 Bytes 0x0000 to OxFFFF Number of following bytes Unit Identifier 1 Byte 0x00 to OxFF Passed back in response The function code is a single byte in length The following function codes are supported by the system Read Holding Registers 0x03 Write Single Register 0x06 If a function code is received that is not in this list an invalid function exception is returned The data field varies depending on the function For more description of these data fields see Function Codes below In Modbus over serial an error check is included in the message This is not necessary in Modbus over TCP
205. rn the electrical panel around to access the rear components being careful not to pull any of the wires out or damage any of the components To remove a relay use your finger or the flat blade screwdriver to press down the locking tab and then slide the relay out of the DIN mount Carefully move any wires out of the way if they block the selected relay Similarly remove the new relay from its DIN mount by pressing down on the locking tab and sliding the relay out Discard the new DIN mount as it will not be used Slide the new relay into its position and press in firmly until the locking tab pops up into its original position Be sure that the voltage of the new relay matches the one being replaced Re install the electrical panel by following steps 1 4 in reverse order Thermo Fisher Scientific Replacing the 24V Power Supply Thermo Fisher Scientific AN Preventive Maintenance and Servicing Electrical Panel Components Use the following procedure to replace the 24V power supply on the electrical panel in the rear of the system Figure 5 57 Equipment Required Phillips screwdriver Small Phillips screwdriver Flat blade screwdriver 24V Power Supply 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 components A 1 Shut off the 24VDC circuit breaker on the breaker box 2 Using
206. roblems with the analyzer contact technical support Also refer to the Antaris IGS manual in the Other Manuals on page 1 10 A Use the following procedure to periodically check and or replace the desiccant packet in the FTIR analyzer which is located behind the front panel These packets keep the analyzer optics free of excess moisture They should be checked even if the analyzer is in storage Replace spent desiccant packets as they cannot be dried or regenerated safely Keep all covers closed tightly unless a maintenance and servicing procedure is being performed to minimize the exposure to humidity WARNING The desiccant is harmful if swallowed Follow the manufacturer s instructions to dispose of desiccant packets properly A CAUTION Avoid burn and fire hazards Do not attempt to regenerate spent desiccant packets A Omni FTIR Multi Gas CEMS Instruction Manual 5 11 Preventive Maintenance and Servicing Maintenance and Servicing of the FTIR Analyzer Components 5 12 Omni FTIR Multi Gas CEMS Instruction Manual Equipment Required Phillips screwdriver Hex wrench 3 32 inch Desiccant packet Using the Phillips screwdriver remove the FTIR cover panel in the front of the system rack Slide the FTIR drawer out of the rack to gain access to the analyzer Locate the humidity indicator on the analyzer left side panel If the indicator is pink the desiccant and the humidity indicator need to be replaced Figure 5 3 For mo
207. rument background scan and flowback check zero check 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 Component Description The system is powered by a single phase 220 240 VAC 50 60 Hz 60 Amp service This is fed to a rack mounted circuit breaker assembly with a main breaker plus breakers for the following system components e FTIR e PC with console e FTIR purge gas generator e 24 VDC power supply e Probe e Temperature controller This section provides technical data on e Compounds e Performance e Electrical data and pneumatic connections e Power and instrument air e Dimensions and weight Thermo Fisher Scientific Measuring Components with Minimum Measuring Range and Required MDL Performance Thermo Fisher Scientific Table 1 1 FTIR Compounds Compound Carbon monoxide CO Nitric oxide NO gas turbine Sulfur dioxide S0 Hydrogen chloride HCI Ammonia NH3 Water H20 Nitrogen dioxide NO Nitrous oxide N20 Hydrogen fluoride HF Carbon dioxide CO Sulfur hexafluoride SFe Compound ppm 0 750 0 1200 0 350 0 150 0 100 0 40 0 vol 0 50 0 0 50 0 0 15 0 0 30 0 vol 0 10 0 Table 1 2 FTIR Performance Specifications Parameter Linearity Zero drift during period of unattended operation Span drift during period of unattended operation
208. s desc file Save Configuration Saves a configuration of data limits and colors Thermo Fisher Scientific Thermo Fisher Scientific Timespan Tab Settings display timespan datasource Cade Harme o be HI Lirit Eco 18H3HI remove 15H30 1212443 bad c02HI LOs Lini e I clear al HIHI Limt _ LOW LOW Limit _ Show as percentage Settings display timespan datasource Timespan D amp YS HH MM 55 0 24 00 00 Autoscroll Timespan DAT S HH MM S5 Dr ad 20 n0 0 000000 ti oroi amp 0g porogi 0 000000 Torii Dd diw D000000 312124430 eed HODES 113 1355 D pomas 000037 poira 0 007063 DO 363 Operation Imacc FTIR Software Suite IFSS O 000000 0 000000 D 000000 O 000000 O 000000 6 000000 D 000000 0 000000 C 000000 g adii 0 000000 0 000000 0 000000 0 000000 D 000000 o 000000 0 000000 6 000000 000MM 0 000000 Lead Canig star f Save Conligurahor The timespan tab is used to set the current displayed range When the control is running the control automatically scrolls the data to show the proper 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 automatically deleted from the control Leaving the Timespan box blank will display all of the data Autoscroll
209. s that secure it to the heater block Figure 5 59 TING m c c ptm gu 9 Figure 5 59 Sample System Heater Assembly Component Replacement and Heated Block Removal 4 Using the 9 64 inch hex wrench remove the eductor tube clamp plate by removing the 12 mounting screws that secure it to the heater block Figure 5 59 5 Using the 5 8 inch wrench loosen the nuts that secure the bulkhead fittings to the box for the Ejector Air In and the FTIR Out Figure 5 59 6 Pull the entire eductor pump plumbing assembly out of the sample system heater assembly box 5 80 Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific Thermo Fisher Scientific ie 10 11 12 13 Preventive Maintenance a
210. s used for the testing SF6 concentration is monitored and saved in con file C cons along with all other gases The user can choose to output the SF6 concentration to the data logger via the system analog output 4 20 mA terminal The external audit gas procedure is similar to the regular system zero span and spiking procedures as described above The only difference is that the system operator needs to swap the span gas cylinder with the audit gas source dry gas cylinder or wet hot HovaCal output Omni FTIR Multi Gas CEMS Instruction Manual 4 3 Calibration Calibration Gases 4 4 Omni FTIR Multi Gas CEMS Instruction Manual Calibration Gases To perform a daily calibration check a sufficient calibration gas flow is necessary Relative to the sampling flow rate of 5 LPM a 6 LPM cal gas flow rate is recommended If the cal gas line is directly connected to a gas cylinder an HCl concentration of 50 ppm is strongly recommended in terms of HCI long term stability Such a gas cylinder can be purchased from Air Liquide For an A size cylinder with a pressure of 2300 psi a newly purchased gas cylinder is estimated to last for two months If the cal gas is diluted from a high concentration gas cylinder for instance 1000 ppm one gas cylinder would last much longer and may be also beneficial for HCI long term stability A similar requirement for the NH cylinder gas is suggested Relatively NH has a faster response time than
211. sample System Heater Assembly Components 5 88 Omni FTIR Multi Gas CEMS Instruction Manual 11 12 13 14 15 16 Using the 9 16 inch wrench and the 1 2 inch wrench loosen the nut and remove the tee fitting and check valve assembly from the old solenoid valve Install it on the new sample solenoid valve in the same orientation then tighten the nut until snug Figure 5 61 Using the 9 16 inch wrench and the 1 2 inch wrench loosen the nut and remove the fitting and tubing assembly from the other side of the old solenoid valve Install it on the new sample solenoid valve in the same orientation then tighten the nut until snug Figure 5 61 It is important to leak test the rebuilt assembly before installing it into the heated block 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 long air line Attach the 1 4 inch Swagelok union fitting to it and connect that to the Sample In line Turn the air regulator that is next to the filters up to 25 PSI If air flows out of the check valve it is installed backwards Using the liquid leak detector wet 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 regulator back down to zero PSI Use th
212. sample probe umbilical wiring and temperature control box See Chapter 7 System Component Description and Appendix D Calogix Setup Check Calogix software for correct software setup for alarm states see Appendix D Calogix Setup e Last Pressure reading in Status on ImaccMonitor 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 C Ommunication External communications errors Erro rs e Ethernet not communicating e Check IMACC Modbus TCP server running on PC e Check power LED on ADAM hub Chapter 7 System Component Description If off check 24 VDC breaker and wiring to and from power supply e Check Ethernet cable between computer and ADAM hub see Chapter 7 System Component Description e Serial e Check IMACC Modbus TCP server running on PC e Check serial cable connection e Check Hardware setup in Windows system menu Internal communications errors e No temperature readings or heating of system components See Temperature errors in this chapter e Nocommunications with FTIR 6 6 Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific Thermo Fisher Scientific Troubleshooting I O Errors Check FTIR LED activity light Chapter 7 System Component Description If no LEDs on check
213. sen but do not remove the two mounting screws securing the Ethernet switch to the panel Slide the switch to the right and pull it off of the panel 3 Disconnect the green voltage terminal block and the Port 4 Ethernet connector from the left side of the switch 4 Using the Phillips screwdriver remove the ground wire on the bottom of the Ethernet switch 5 Using the Phillips screwdriver attach the ground wire to the bottom of the new switch 6 Follow steps 1 3 in reverse order to complete the procedure Use the following procedure to replace the solid state relays on the electrical panel in the rear of the system There are 3 24VDC relays and 15 5VDC relays Figure 5 57 Omni FTIR Multi Gas CEMS Instruction Manual 5 73 Preventive Maintenance and Servicing Electrical Panel Components 5 74 Omni FTIR Multi Gas CEMS Instruction Manual Equipment Required Phillips screwdriver Flat blade screwdriver Relays Shut the PC down through Windows and then shut off the PC Console circuit breaker on the breaker box Shut off the 24VDC circuit breaker on the breaker box Using the Phillips screwdriver remove the 2 grounding wires from the grounding strip on the right rear side of the rack near the electrical panel 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 the left to free it Carefully tu
214. servicing information See the Other Manuals section at the end of Chapter 1 A Equipment Required Wrench 9 16 inch Large Phillips screwdriver 1 Note the pressure on the house air regulator then pull up on the knob to unlock it and turn the pressure down to zero Figure 5 22 Omni FTIR Multi Gas CEMS Instruction Manual 5 31 Preventive Maintenance and Servicing Removing the Purge Gas Generator 5 32 Omni FTIR Multi Gas CEMS Instruction Manual S z c amp BB e a o H AIR SUPPLY REGULATUR UNPLUG POWER J SCUNNEC TUBING BUTH SIDES SEN MOUNTING Figure 5 22 Removing the Purge Gas Generator 2 Turn off the air purifier circuit breaker on the breaker box Turn off the power switch 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 inch wrench loosen the nut and remove the outlet tubing from the purge gas generator Figure 5 22 5 Using the large Phillips screwdriver loosen but do not remove the 4 mounting screws Figure 5 22 6 Lift the purge gas generator up and off of the 4 mounting screws Figure 5 22 Thermo Fisher Scientific Preventive Maintenan
215. slide plate screws on either side of the heater assembly box just enough to slide the box to the right to disengage it from the tubing 6 Disconnect the sample system heaters from the rear of the temperature control box by removing the twist lock connector from the position labeled Pump Turn the connector nut counterclockwise and pull it out of its socket Remove the cable assembly tie wraps using the wire cutters Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual 5 77 Preventive Maintenance and Servicing sample System Heater Assembly Components Replacing the Thermostat AN 5 78 Omni FTIR Multi Gas CEMS Instruction Manual 10 11 12 Using the Phillips screwdriver loosen the 4 screws that mount the sample system heater assembly to the rack Support the bottom of the assembly box remove the 2 mounting screws on the right hand side then slide the whole assembly a little to the right and remove it Lay it down on a flat surface Loosen the 2 captive thumb screws on each side of the sample system heater assembly by hand and remove the cover A Phillips screwdriver can be used if the screws are too tight Disconnect the flag lugs from both sides of the thermostat to be able to move the wiring out of the way 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 To re install the cover carefully plac
216. sor Cable 12 Sensor to temp controller FIIR Temperature Sensor FTIR Heater Control Cable 12 Sensor Heater to temp controller FTIR Power Supply FTIR Sample Cell FTIR Cell Heater Assembly Replacement Heated Line FTIR to Sample System USB Cable 10 FTIR to PC Temperature Controller Temperature Controller Assembly Relay SSR Crydom 2425 9812 105490 00 Part Number 112462 00 113289 00 113288 00 101246 00 04 011901 Part Number 109765 00 113316 00 113312 00 106975 00 113313 00 106963 00 106976 00 113440 00 106954 00 113267 00 110300 00 113383 00 108009 00 109948 00 113268 00 113320 00 113390 00 112796 00 Part Number 112701 00 103344 00 9 12 months Replacement Period Replacement Period 2 years 1 year 2 years 2 years Replacement Period Thermo Fisher Scientific Thermo Fisher Scientific Fuse 5 0 Amp 250 VAC TR5 CALOGIX Temperature Controller Base CALOGIX Dual Temperature Module CALOGIX 4 20mA Module Temperature Controller PCBA Fuse Cartridge Slo Blo 25 Amp USB Cable 10 Temp Controller or FTIR to PC PC PC with NI boards Console 1U PCI Board NI 32 Channel Analog PCI Board NI 96 Channel Digital Cable Ethernet Cable NI Analog 1 0 68 Conductor 2M Cable NI Digital 1 0 100 Conductor 2M Pneumatic Panel Pneumatic Panel Assembly 2 Gauge Assembly Replacement Pressure Reducer Assembly Replacement Pressur
217. ssure reducers on the Pressure Reducers 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 opening Pressure reducer 1 Remove the left side panel per procedure Removing the Left Side Panel for better accessibility 2 Note the pressure on the gauge above the pressure reducer to be replaced so that it can be reset later 5 90 Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific Preventive Maintenance and Servicing Pneumatic Panel Components 3 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 down to zero Figure 5 18 4 Atthe rear of the pneumatic panel use the 9 16 inch wrench to loosen the nut and disconnect the short Teflon line on the pressure reducer that goes to the pressure gauge Loosen the nut and disconnect the inlet and outlet lines on the pressure reducer Note or mark their locations to facilitate re connection Figure 5 62 5 Atthe front of the pneumatic panel use the adjustable wrench to loosen the panel nut of the pressure reducer Completely unthread the nut and remove the pressure reducer from 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 t
218. st strap must be worn while handling any internal component If an antistatic wrist strap is not available be sure to touch the instrument chassis before touching any internal components When the temperature controller is unplugged the chassis is not at earth ground A Use the following procedure to remove and install the cover of the temperature control box Equipment Required Phillips screwdriver Small Phillips screwdriver 1 Shut off the Temperature Control circuit breaker on the breaker box 2 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 fully extended Figure 5 54 3 To remove the cover use the small Phillips screwdriver to remove the 8 screws that mount the cover to the temperature control box and lift the cover off Thermo Fisher Scientific Preventive Maintenance and Servicing Temperature Control Box Components 4 After replacing the internal components install the cover Place the cover on the temperature control box with the lip closest to the front panel Line up the mounting holes and use the small Phillips screwdriver to install the 8 mounting screws 5 Slide the temperature control box back in the rack Using the Phillips screwdriver re install che 4 front panel screws that secure the temperature control box to the rack to complete the procedure 6 Turn on the Tem
219. stopbits 9600 1 Databits Flow Control B T Mone Ad tae This setting is the same for all six parameters e Collect EZ setting for running FTIR interferometer The spectrum collection setting is included in the stand alone container next to the ModbusMultiSensor container As shown it is the same as described in the CEMS Samplemode section x container collect bench directories omnic options spectral math CollectEZ 182 Scan Time MM 55 Low Cutoff High Cutoff Collect Settings 0 48 400 4500 pathName FrontMain jpathLength 5 208 V Use Method Shift Settings scanTime 0 48 on Shift File Bench Settings bow lightSource IR Shift Start Shift Stop aperture 15 fo S 0 gain 4 Shift Max Delay Shift Interpolate Shift Count velocity 0 6329 L p resolution 0 5 a E ds pulis 00 Background spa PointsFile pts g C SBackgroundibkg spa 0 browse Analysis Method s method s C methodDTGS Holcim SFB calibrated new 1 method C method DTGS_Holcim_SF6_calibrated_new_ lt lt add lt lt background C Background bkg spa gt E gt gt remove gt gt v Use Dyanamic References v Use Bias Correction IV Forget Analysis State Cancel Note that all the settings should be the same as the one included in the background spectrum collection Omni FTIR Multi Gas CEMS Instruction Manual E 15 IMACC Script Set
220. sus BA mam AG ns LEES Wages UN T miri urbi aet x E E ine ner hi zv ny c Si ji Haii Kah Collect Ez Sebup ux B oie Bench Pibe Cipli juath ff roni m Finito c Simon IA xr iR Apatura 100 15 000000 T n queso r Gan Dalina Piiriin PEAT o mail start a P A orac rnac capture p imacrCaleet cere m Microsoft Ceed moka TAGO 34088 sm Thermo Fisher Scientific Thermo Fisher Scientific Calibration oystem Calibration Procedure Using IMACC Collect Click on the button of Temperature Control and select ModbusmultiSensor Control Click on config button to display settings of the Temperature Sensor Verify or set the following Optical Path FrontMain Type of data IEEE float Code Cell Temp Register 0x0a20 COM Port 6 Parity None Baud 9600 Stopbits 1 Databits 8 Flow Control None Press OK to close ModbusMultiSensor Settings box ImaccCollect C IFSS FTIR_calibrate collect Optical Path FrontM ain v Measurement Channel Mapping IEEE float CELLTEMP Ox0a20 1 Single Collect Continuous Collect Click on the button of Pressure Control and select ModbusMultiSensor Control Click on config button to display settings of the Pressure Sensor Verify or set the following Optical Path FrontMain Type of data IEEE float Code CellPressure Register 0x0a2a COM Port 1 Parity None Baud 9600 Stopbits 1
221. t Lift the detector straight up to disengage it from the connector and to clear the 2 alignment pins Remove it from the analyzer Figure 5 12 Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual 5 23 Preventive Maintenance and Servicing Maintenance and Servicing of the FTIR Analyzer Components Figure 5 12 Locating the Detector Assembly 5 Before installing the new D TGS detector assembly make sure the switches are set correctly Using the flat 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 Switch 2 ON Switch 3 OFF Switch 4 ON Using the flat blade screwdriver re install the detector access plate Figure 5 13 Removing the Detector Access Plate 6 Install the new detector assembly in the analyzer over the 2 alignment y y g pins taking care to engage the connector Tighten the thumbscrews on the base plate until snug 5 24 Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific Thermo Fisher Scientific Replacing the Beamsplitter gt gt gt Preventive Maintenance and Servicing Maintenance and Servicing of the FTIR Analyzer Components 7 Using the 3 32 inch hex wrench re install the front panel with the mounting screws taking care to support the panel until the screws are in place Be careful to place all wiring and c
222. t 0 5 NH3_wet 0 to 106 ppm gt 0 5 NH3_dry 0 to 106 ppm lt 0 5 NO_dry_Hi 60 to 1253 ppm lt 1 H20 NO2_dry 1 to 50 ppm lt 1 SF6 0 to 6 ppm Thermo Fisher Scientific Thermo Fisher Scientific Chapter 5 Preventive Maintenance and Servicing This chapter includes the following maintenance information and replacement procedures that should be performed on the Omni FTIR Multi Gas CEMS to ensure proper operation Replacement periods for expendable items are indicated in Table 5 1 For additional service assistance see Service Locations at the end of this chapter e Replacement Parts List on page 5 3 e Safety Precautions on page 5 6 e Cleaning the System on page 5 6 e Maintenance for the Sample Probe on page 5 7 e Maintenance and Servicing of the FTIR Analyzer Components on page 5 11 e Replacing the Air Filters on page 5 29 e Removing the Purge Gas Generator on page 5 31 e Removing the Left Side Panel on page 5 33 e Removing the FTIR on page 5 34 e Replacing the FTIR Power Supply on page 5 38 e Replacing the Temperature Sensor on page 5 39 e Replacing the Pressure Sensor on page 5 41 e Replacing the Gas Cell on page 5 42 e Gas Cell Alignment on page 5 44 e Replacing the Gas Cell Heater on page 5 51 e Replacing the Heated Lines on page 5 54 e Replacing the PC on page 5 55 e Replacing the PC Console on page 5 57 Omni FTIR Multi Gas CEMS Instruction Manual 5 1
223. t ae ioter t o n cte ex Ere 7 11 Temperature o cN O ea di tp S oud udo eee 7 12 Pressure Sens Obha naaa n ra ar Le ei 7 12 Gas Cell Inter iCenter T a e aaa a aT 7 12 Computer Interfaces odes at di oec ditas ess 7 12 Euros bubo Conto eseu tuo ipa D botupE mus tease rtu uqde 7 12 ZU DN ete aaron EEA EET E we N anise M EAD Eee 7 12 dustrial Poe due Am ME EI UM A T E rere 7 13 FIGNA SI IUe RR RR NE REEL PON FRE ae 7 14 Grey rival Co eee eaten ase ema ene E EN M AU UNE LM MD LI 7 14 NE AA ers asa scents va tno d dapes iia mca d aea dud pa 7 14 Electrical Panel Assembly disent om eub te tan quee ii enc uus 7 14 AC Power DIIDUL sedie ri eene Riese tu died reta rct etse teen reine 7 15 Appendix A Waan o inne eddie meos etd tuerit E Nd EET A 1 Appendix B VIQG DUS PEotoc l 5 ied ndo cde Cui ceo RR use EO EI B 1 Serial Communication Parameters ccssecccssecccessccecsscceceeceensccens B 2 TCP Communication Parameters ucoi oeste eee etnies etiv e eoi e eH v eor vss B 2 Application Data Unit Definition ssena R B 2 Slave GUESS done rette an a a teu mie eiu eta LE D B 2 MBAP Headers cse intERERUS D a T B 2 Funcion C Odesoicctoemds ite ete ete CeLs e M iSc LC LO E e RE Lec doce OEC B 3 E T E EPEA T B 3 a E Deos EE T E E AE EAEE E E ETE AE A A UE B 3 Func om C odessa e E ERN B 3 0x03 Read Holding Reis ters coseseecites ptos a better t B 3 Modbus Parameters SUDDOPGU soe aas oS pe Ree a REN preise B 5 Appendix C Interfacing a DCS
224. ta communications For details on interfacing a DCS PLC with the Omni FTIR Multi Gas CEMS see the following topics e Introduction on page C 1 e Connecting a DCS PLC to the Omni FTIR Multi Gas CEMS on page C 2 e Establishing Communications on page C 3 Introduction Typical communications functions provided by the Omni FTIR Multi Gas CEMS include Checking data values Reading system and alarm status Triggering events such as calibration checks and probe blowbacks The Omni FTIR Multi Gas CEMS provides several methods for establishing data communication with a DCS PLC including Analog output connections 4 20mA Digital I O connections 5V TTL logic Modbus protocol over RS 232 or Ethernet Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual C 1 Interfacing a DCS PLC with the Omni FTIR Multi Gas CEMS Connecting a DCS PLC to the Omni FTIR Multi Gas CEMS Connecting a DCS PLC to the Omni FTIR Multi Gas CEMS C 2 Omni FTIR Multi Gas CEMS Instruction Manual You can connect to the FTIR via Serial or Ethernet communications Refer to 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 the instrument Note Consult with a network engineer or system administrator for information about making the appropriate Ethernet connection for your applica
225. te BKG x Fle Edt Wew Favorites Took Help T Qa O B Erh i r ae o X MD E Addens p cons E Ee Foklor x Meme 5e Ty Dake Modified EI reutin backgrounds 2007 03 Fie Folder Ale MEQUE 12 10 PH iL Py Documents SY bachanounds 2007 404 File Folder Sifar wot AH C abii Data Cbarkgreuncs 2007 05 Fir Fr tee BDO 9 21 AM 2 Hy docks Cobsckgrounds 2007 06 Pis Folder Tao 1 52 PI i My Max backache 2007 07 Fils Fisker 8 13 7007 10 20 AM Ep pau Iibackaneonds 2007 08 File Folder SOO 10 03 AM M ry Coger backgrounds 200799 Pile l alder LO wa se AM E d rs Popoy A backgrounds 2007 10 Fie Fiiter LO 4J2007 9 17 AM isi fuii Loc al Disk 0 E ireo or background sys 2 2007 1044 DAKE Omne Spedra Pies L i4 2007 3 17 AM so Etimo m badhuround syd Z007 10 15 GP kl Om Spectral Files VOrS 2007 bon prd CD backgrounds 2007 02 bacira BOKE Cirie Spectral ies 10 4 2007 9 17 AM backarcureds 2007 04 E beckgrounds 2007 05 beachgoers 2007 06 gt bactogrsunets 2007 07 C backgrounds 2007 08 3 buckgrournes 2007 08 E backgrounds 2007 10 8 C3 Cons i QD Documenbs anal Saitis B j Administrator I cooker L3 Desiton iE CUR Faveribes E 2 My Deut 5 D Start Menu Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual 4 9 Calibration Manual Background Spectrum Collection using Thermo Modbus Controller Manual Background Spectrum Collection using Thermo Modbus Controller 4 10 Omni FTIR Multi Gas CEMS Instruct
226. the CALogix controllers in the Temperature Control Box TCB will display temperature data EI i be ae E L mmia a P ae gm 4 fils eel i Peen LS GL i MEE mr uas A rms X ee i n Nt qpe er gs 21 em ceti eh M nt Pre PR au ete s Pte 7 fe a e m i rn aua eet qf a mer mum PP DE ENS 1 Tau 2 a AMET IH urn ris ur Pata i rT a 3 a zm a E nmm Vea finm ais p Pu euh ua n ume e rmn i ens Ps Pii Imre Pr p mg a ER ol B F 4 we a m Bes E CAEL EIE I LL BITS Pie NIIT LITE LI mem ui mci a nius E IET i TEETH LIT ELT Abhay Taig iab _ z 3H inks mm MM M M M l EEG me Tl 1i Diu cH xw IL LE tii ie nig LIE URL E WTURG NLIS MES 3e FEAR TES GT VEG T WU Biik The top section of the screen is divided into two panes Concentrations which displays a list of current compounds and their concentrations and Process Status which displays various FTIR status parameters The lower half of the screen consists of four tabbed displays Spectrum Plot that displays spectral plots of single beam intensities and absorbance and three Concentration Plot tabs that display plots of concentrations versus time Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual 3 3 Operation Imacc FTIR Software Suite IFSS Concentrations The concentrations pane displays the analyzed compound names Pane concentration numerical
227. the Phillips screwdriver remove the 2 grounding wires from the grounding strip on the right rear side of the rack 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 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 components 5 Using the small Phillips screwdriver remove the wires from the connector on the top and bottom of the power supply Note or mark the location of each wire to facilitate re connection 6 Using the flat blade screwdriver pull down the tab on the bottom of the power supply to unlock it while lifting the power supply off of the din rail 7 To install the new power supply hook the upper tabs of the rear of the power supply onto the din rail and then firmly push the bottom of the supply toward the panel until it locks into place Omni FTIR Multi Gas CEMS Instruction Manual 5 75 Preventive Maintenance and Servicing sample System Heater Assembly Components Sample System Heater Assembly Components Removing the Sample System Heater Assembly and Cover AN 5 76 Omni FTIR Multi Gas CEMS Instruction Manual 8 Using the small Phillips screwdriver re attach the wiring to the power supply in the proper locations 9 Re install the electri
228. the analyzer and then remove the plate and put it in a safe place Figure 5 15 Figure 5 15 Corner Screws on Coupling Optics Plate 9 Locate the rectangular top access panel toward the rear of the analyzer Using the 5 32 inch hex wrench remove the 4 corner mounting screws and remove the top access panel Figure 5 16 Omni FTIR Multi Gas CEMS Instruction Manual 5 27 Preventive Maintenance and Servicing Maintenance and Servicing of the FTIR Analyzer Components Port Figure 5 16 Removing the Beamsplitter Access Panel 10 Using the 5 32 inch hex wrench remove the beamsplitter clamping bolt Using the flat blade screwdriver pry the beamsplitter holding bar away from the casting Grasp the beamsplitter by the handle and lift it out of the analyzer Figure 5 17 YN Figure 5 17 Removing the Beamsplitter y Ae S F ah 1 dee 11 Grasp the new beamsplitter by the handle with the label facing you Again use the flat blade screwdriver to pry the beamsplitter holding bar away from the casting Insert the new beamsplitter into position Using the 5 32 inch hex wrench re install the beamsplitter clamping bolt and tighten until snug 12 Place the rectangular top access panel back into position Using the 5 32 inch hex wrench re install the 4 corner mounting screws and tighten until snug 13 Follow steps 2 8 in reverse to complete the installation procedure 5 28 Omni FTIR Multi Gas CEMS Instr
229. the rack then use the Phillips screwdriver to re install the FTIR cover panel and its mounting screws to 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 laser both of which have a limited lifespan and replacing the detector and beamsplitter both of which only need to be replaced if exposed to high levels of humidity for an extended period of time 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 components A Important Note Although the system operator can perform these service procedures it is recommended that only our certified service engineers or on site maintenance personnel who have been trained by us perform these operations Whenever these procedures are performed there is a potential Omni FTIR Multi Gas CEMS Instruction Manual 5 15 Preventive Maintenance and Servicing Maintenance and Servicing of the FTIR Analyzer Components Replacing the Source 5 16 Omni FTIR Multi Gas CEMS Instruction Manual for damage to sensitive components Damage to components inside the analyzer will affect the performance of the system A Use the following procedure to replace the source in the FTTR analyzer The source is located behind the right side panel
230. the system rack To create space to work move the two short heated lines out of the way If more room is needed use the 9 16 inch wrench to loosen the nuts to disconnect the heated lines from the sample system heater assembly and or the FTIR Omni FTIR Multi Gas CEMS Instruction Manual 5 19 Preventive Maintenance and Servicing Maintenance and Servicing of the FTIR Analyzer Components 5 20 Omni FTIR Multi Gas CEMS Instruction Manual Figure 5 9 Locating the Laser Assembly analyzer Be sure to note or mark their locations to facilitate re connection if needed Disconnect the purge air line from the bottom rear of the analyzer by pressing the quick disconnect latch on top of the fitting until you hear a click and pulling it out The purge air line is connected to the right side fitting labeled Purge In Using 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 not to unplug or damage any cables connected to the inside or outside of the panel Locate the laser assembly inside the analyzer and then unplug the laser power supply cable from the power distribution cable Figure 5 9 nu gui lt lt Unhook the spring clamps that secure the laser tube The laser tube is held in position with 2 springs and an alignment pin Release the spring clamps by pushing down on
231. till securely fastened to the side of the rack Omni FTIR Multi Gas CEMS Instruction Manual 2 1 System Installation Start Up and Shut Down site Requirements Site Requirements Ambient Temperature Instrument Air Power Requirements Rack Dimensions Weight Flange Requirements Remove Shipping Restraint 2 2 Omni FTIR Multi Gas CEMS Instruction Manual The layout of your equipment rack is an extremely important consideration for proper operation Equipment placed too close together inadequate ventilation and inaccessible panels can cause malfunctions and shutdowns and can make maintenance difficult Plan to access both front and rear panels of the rack The following precautions will help you plan an acceptable operating environment for your system and will help you avoid environmentally caused equipment failures Ensure that the shelter enclosed space where the Omni FTIR CEMS is located is not exposed to the external 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 temperature may not cool equipment to acceptable operating temperatures 60 to 95 F 15 to 35 C 5 SCFM 80 120 psig oil free AC 220V 240V 50 60 Hz 60 Amps WxDxH 31 x 70 x 36 built system 22 x 70 X 36 rack only Approximately 450 lbs The Omni FTIR Mulit Gas CEMS is provid
232. ting Modbus Control Version e Data saving script setting This is the last setting 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 blocks cantalner tar each DataCollection Concentrations WWriteCanFile 156 OpticalPath FrantMain CON FilePath CACONS statistics 100 Iteration 0 time elapsed The first setting block is used to define the file directory for all saved data The second setting block is used to display real time system status on the monitor E 16 Omni FIIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific Thermo Fisher Scientific Appendix F Concentration Data Transfer Using a Web Server Data have sometimes been lost or analyzers have sometimes stopped data acquisition due to conflicts between the IMACC FTIR Software Suite IFSS and customer software attempting to retrieve data over TCP IP networks The IFSS web server feature allows the user to write a copy of the current concentration file to a folder with access mediated by the Windows Internet Information Services IIS component This feature is intended to avoid conflicts with the original concentration file that can cause data acquisition problems The web server technique allows the user to run Internet Explorer IE or a user generated software on a remote computer and
233. tion A z y P T i 5 T titi I ey iy Oy Oy 4 3 82 5 ee ee a ee Bd ed ah w www www Jl i ini eis jets a m i d o e ena nm n 2022522022292 2222242221271 TI TII q 94 hc NEA lt N Figure C 1 Rear Panel Terminal Connectors Thermo Fisher Scientific Establishing Communications Analog Outputs Thermo Fisher Scientific Interfacing a DCS PLC with the Omni FTIR Multi Gas CEMS Establishing Communications This section provides information on the methods available for retrieving system data accessing system status conditions initiating system events and checking system calibration The 4 20mA analog output signals are labeled ANALOG OUTPUT X1 on the electrical panel assembly which is accessible from the rear of the rack Two sets of terminals are labeled 1 11 for the individual 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 from the current loop for local testing and diagnostics The 4 20mA analog outputs are each capable of driving a loop resistance down to 500 Ohms Refer to Table C 1 for the analog output terminal assignments Refer to Modbus Protocol Table B 1 Read Register for Modbus methods for retrieving data Refer to Figure C 2 to locate the pins on the rear panel terminal connector Table C 1 Analog Out
234. tion factors Change the calibration factor to 1 000 before running the certified gas into the gas cell When performing 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 cell input Run the system normally by opening IMACC monitor and watch the measurement data until it has stabilized as shown below In this case 20 96 CO is connected to the system At least three data points should be averaged In this example the new calibration factor should be the ratio of 20 over 19 77 That is 1 0116 You can also open the con file from the directory C cons with Microsoft Excel to calculate the average data E ImaceMonitor C V ayouls ayoul GOC Layout 20 13 1214 Collect spectrum E 50 000000 151550 nn Hel 202 oo Lait T mperstuie 184 355871 an n Lait Fraemum FER ECT H 008 not NH 152 047 HF 002 0000 NO Oa D GER oo 4371 415 ad Speta Gas Concentrator Das Concentrabon 2 fam Concentiatin 3 pot tithe TT y dERS dis 1 3 m H2 a A700 2557 nd 7 i ATH eee z i ATE 4d a a Oa 032013 130356 03 20 13 131215 0320 13 121434 0222 13 121623 02 20 13 131212 032013 1821324 113 F 2044211072 coz LE oi a 201983 4555 pn s 35285 aa SI i ms prc F n 195 18 1653 ee uM a OT aS E eT LLLLLLLLLLLUE AI L
235. to the rack by following the procedure Replacing the PC 11 Turn on the PC Console circuit breaker on the breaker box and re start the PC to complete the procedure Temperatu re Control Use the following procedures to replace the temperature control box Box Comp onents internal and external components Replacing External Use the following procedure to replace the 2 external fuses on the FTIR Fuses temperature control box Equipment Required Phillips screwdriver Flat blade screwdriver Replacement Fuses 5 62 Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific Thermo Fisher Scientific Preventive Maintenance and Servicing Temperature Control Box Components 1 Shut off the Temperature Control circuit breaker on the breaker box 2 Using the Phillips screwdriver remove the blank panel in the front of the system directly below the temperature control box Figure 5 54 Alternately the rack left side panel could be removed per procedure Removing the Left Side Panel for better accessibility 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 fully extended Figure 5 54 EPLACI N Oreo TEIV YT AT N N JV vt AW USES FRUM REAR L Ly a L BELOW TEMP CONTROL BOX m Ann la N F1 Fi
236. tomers For field service an alignment check is needed if there is any uncertainty of the pass length setting Once shining the visible laser into the gas cell through the input window the pattern shown in Figure 5 40 is a clear indication of the correct pass setting 13 Following the gas cell alignment check it is necessary to perform gas cell fine alignment at the system operation temperature 185 C Re install the gas cell casing and back plate fitting plate by following steps 4 and 2 in reverse order Re connect the pressure sensor temperature sensor heated lines ground wire and heater connections that were left disconnected earlier Refer to replacing the gas cell earlier in this chapter for more information Turn the Temperature Control circuit breaker on and allow the system to come up to temperature cool A N CAUTION High surface temperatures present Allow sufficient time to 14 For the fine alignment adjustment only the input vertical and 15 horizontal screws in Figure 5 39 need to be adjusted to maximize the IR light intensity Max in Figure 5 41 Use the 9 16 inch wrench to remove the fitting caps to access the adjustment screws The final step of the gas cell alignment is to run Omnic software click Collect tab to open experiment setup windows Click tab Diagnostic shown in Figure 5 41 and then click button align After the software alignment is finished click cancel butt
237. tral line shape resolution by defining the number and direction of the infrared rays reaching the sample Using an aperture has these advantages it improves wave number accuracy by acting as a point source of infrared radiation and it helps prevent infrared energy saturation so the response of the detector is more linear The proper setting of the fixed aperture has been selected based on the type of detector installed and the resolution setting In general you will find that the larger the aperture the better the signal to noise ratio of the collected data The DTGS detector can accommodate most of the energy from the source which means the software selects a large aperture size 1 10 Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific System Component Description FTIR Detector The FTIR analyzer is configured with a TE cooled DTGS detector with Potassium bromide KBr window which provides usable data in the range between 12 500 cm 1 and 350 cm 1 Note The KBr window material is hygroscopic or absorbs water from the air so the FTIR instrument must be continuously purged to remove water A Gas Cell The FTIR analyzer is using a gas cell with a 5 2 meter optical path length 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 elevated temperature conditions operating re
238. trument Zero the system needs to be in failsafe mode This is accomplished by disconnecting the wire from pin 1 of the Probe I O X3 terminal block on the electrical panel at the rear of the system using a small flat blade screwdriver Once activated turn the knob on the flow meter clockwise until the proper setting is achieved Once the flow rate is set on the new flow meter regulator de activate the solenoid valves by re connecting the wire to the connector on the electrical panel 12 Re install the left side panel to complete the procedure 5 96 Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific Preventive Maintenance and Servicing oervice Locations Service For additional assistance Thermo Fisher Scientific has service available L from exclusive distributors worldwide Contact one of the phone numbers ocations ue A below for product support and technical information or visit us on the web at www thermoscientific com aqi 1 866 282 0430 Toll Free 1 508 520 0430 International Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual 5 97 Chapter 6 Troubleshooting This chapter provides the following troubleshooting and service support information for the Omni FTIR Multi Gas CEMS e Concentration Errors on page 6 3 e Boot Up Error IMACC Software Error on page 6 4 e Temperature Errors on page 6 4 e Cell Pressure Errors Sampling System Errors on page 6 5 e Communication
239. ts of the system span value by the operator or maintenance of the measuring system e g by the supplier may be necessary due to the results of the evaluation The duration of the system span check is determined by the operator Before performing a system span check make sure that the gas cylinder is already connected to the labeled tubing line following the installation procedure Similar to the system zero check procedure make the necessary flow rate adjustments to ensure sufficient flow rate 26 LPM The corresponding rotameter for span gas flow rate is right 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 solenoid valve Check Spike using Thermo Modbus Controller To perform the system dynamic spiking sampling flow rate should first be measured using a flow meter at the inlet of the heated sample line Sample flow rate can be set by adjusting the eductor pump pressure The pressure gauge and adjusting knob of the eductor pump are located on the pneumatic panel Figure 4 1 Spiking flow rate is set by adjusting the rotameter for a recommended 10 to 1 dilution ratio For instance a flow rate of 500 sccm is set for spiking gas with respect to the sampling flow rate of 5000 sccm Alternatively a dilution factor can be determined by monitoring tracer SF6 concentration if a tracer mixed gas cylinder i
240. ttaches 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 and remove the check valve from the stainless steel tubing noting its orientation before doing so 7 Using the wrenches connect the new check valve to the stainless steel tubing and nut with the flow arrow pointing toward the tubing Tighten until snug 8 Using the wrenches connect the other end of the check valve to the brass nut with copper tubing and tighten until snug Some movement of the copper tubing will be required to get it into the check valve 5 84 Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific Preventive Maintenance and Servicing sample System Heater Assembly Components 9 Itis important to leak test the rebuilt assembly 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 long air line Attach the 1 4 inch Swagelok union fitting to it and connect that to the Sample In line Turn the air regulator that is next to the filters up to 25 PSI Using the liquid leak detector wet the connection between the check valve and the stainless steel tubing segment to see if there are leaks which will produce air bubbles If any are present tighten the fitting until the leaking stops Turn the air regulator back d
241. tting Parameters None Enter Segment 2 Segment type SOAK Soak time Continuous EOP Status None ra vee o c E m CALOGIx uL MEC Select the Module 3 tab Enter Segment 1 Segment type RAMP Ramp rate 90 Target Setpoint 185 Holdback band 0 EOP Status None Enter Segment 2 Segment type SOAK Soak time Continuous EOP Status None Sm a2s8RS3 t Eero ft i l OO DIRE pY Sa pE py Sa pE py SG pE BY F pE et ey E y Sa pE EY S E Y S pE y S E E E E E S E Y S E EY oa E Y wa E BY a Ot ey oa 5 Close the program menu The changes will be automatically written to the controllers D 8 Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific Calogix Setup Programming the Controllers and Setting Parameters Inputting Controller Use the following procedure to input controller values 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 F e instrument Asno Chats View Window Help a Hd h l 5 Fan ewao CALOGix 2 Once a module is selected enter the correct values according to Table D 1 Values are grouped according to subheadings CALGrafix dd CIRIBUOOGEMSSUCNDO S Device 001 en COM4 Inatument settings Securiy Property BE Modde 1 Dusi Module settings Module 1 Input settings nie ira ap EB
242. tware main screen see Temperature Errors e Improper cell pressure reading e Check Last Pressure screen readout in Status on Imacc monitor software main screen see Cell Pressure Errors Sampling System Errors e Instrument air issues e Check that instrument air regulator on side of rack reads at least 75 PSI e Check that CO Free Air Gauge on pneumatic panel reads at least 22 PSI e Check that indicating filter on FTIR purge gas generator on side of rack is green If yellow service purge gas generator and filters e Bad background file e Go to C Backgrounds in Windows Explorer and verify that file C Backgrounds BKG spa has been updated in the last 24 hours Refer to Appendix E IIMACC Script Setting for proper script configuration Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual 6 3 Troubleshooting Boot Up Error IMACC Software Error e Dad spectrometer detector or source e Check Last Vmax and Last Vmin in Status Nominally Last Vmax gt 4 0 Volts Last Vmin 1 0 Volts Readings of lt 0 5 Volts indicate detector or source failure Marginal readings may require more detailed analysis by Thermo Fisher Scientific Technical Support Department e Concentration not updating in IMACC e See Communications Errors No Communications with FTIR e H2O concentrations 2000 ppm during zero checks e Make sure hydrator is not filled with wate
243. uction Manual Thermo Fisher Scientific Preventive Maintenance and Servicing Replacing the Air Filters 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 Wait 15 minutes for the new components to stabilize thermally and then align the analyzer by following the instructions in Chapter 3 See OMNIC software on page 3 11 Verify that the new beamsplitter is working properly by switching the system to zero air and looking at the maximum peak voltage Vmax in IMACC monitor refer to Chapter 3 Operation Vmax should be greater than 4 volts Replacing the Use the following procedure to replace the filters in the filter bracket m m l Air Filters 7 All three types of filters are replaced using the same procedure Equipment Required Replacement Filters DX BX and CI from left to right 1 Note the pressure on the house air regulator then pull up on the knob to unlock it and turn the pressure down to zero Figure 5 18 Figure 5 18 Turning Off House Air 2 Grasp the bottom of the filter assembly then with a slight upward pressure turn it to the left until it stops the word Lock should be directly facing you and pull it straight down Figure 5 19 Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual 5 29 Preventive Maintenance and Servicing Replacing the Air Filters Figure 5 19 Remo
244. ueecran m Tere eur m INT SYSTEM STIATUSZSYTSIEN SYSTEM STATUS amp Boe Lg Pa Bad san i CJ Q IMACC Quantify cte C Molin tmaecseriptt ditor E Si Documenti Herrat amp neevcclmma 4UZRM The script execution sequence is from left to right and top to bottom The main operation settings are included in the while statement loop Initial variable definitions are stated in the first two setting blocks on the left and are named Calc 2 and Calc A4 e System Alarm Setting This setting is included in the first container block inside the while statement loop The calc 8 setting is the definition of the system temperature alarm B ImaccScriptEditor E Holcim Pilot12 script stopped File Edit Settings View Help DGdg migFj f7 C centaine while O do f if f if else 1 script 1 3 For each EA break loc T stop scri FTIR Contr CollectBk CollectEz CollectPe Analysis Cc IO Controls AIO DIO FileData LoadFile Modbus Valve MetOnes Pressure Tempera Tempera Miscellane AZELSeq Cale Counter Datalten Delay EE GasPlum while Script stopped container Calc 8 expressions p a Front Define Initial Codes Expressions T_ALARM if CELLTEMP lt 175 1 0 S ALARM if SYSTEM CMDI 1 1 0 JALARM S_ALARM T_ALARM S_ALARM if SYSTEM_CMD 1 1 0 ALARM S_ALARM T_ALARM
245. up e Internal Heated Lines if installed 180 Deg C LED indicators on FTIR e Power should be on continuously if not check circuit breaker and power supply e Laser should be on continuously if not check laser assembly e Source should be on continuously if not check source e Scan should be flashing during normal operation if not check if IMACC software is running Readings in IMACC software e FTIR Vmax gt 0 9 e FTIR Vmin 0 0 e If voltages are too small check source beamsplitter detector cell windows and cell mirrors e Cell Pressure 40 mmHg less than ambient pressure during sample mode The following outline addresses possible instrument and alarm problems and proposes checks and possible troubleshooting solutions Thermo Fisher Scientific Troubleshooting Concentration Errors Concentration Low Concentration Errors e System fail safe e If any of the system components are not at their operating temperature then the temperature alarm is activated and the system automatically switches to instrument zero mode Check temperature alarm or component temperatures e Leaks e Check Probe tubing for melted or cut sections e Check for loose fittings e Check for cold spots ensure proper insulation at both ends of the heated umbilical Low or High Concentration e Improper cell temperature reading e Check Last Temperature screen readout in Status on IMACC monitor sof
246. uration frame Refresh Interval ms sets the time period at which the program will update the Modbus registers from the concentration file data The nominal value is 10000 ms The Settings button can be used to configure the COM port associated with the Modbus network for serial Modbus Omni FTIR Multi Gas CEMS Instruction Manual 3 17 Operation Data Server Software a Imecchodbus CP iT not connected tdle con v 40003 40005 Y 40007 _ 40009 40011 40013 Configuration Drectones con Hle diectones Retesh when mothed by scapt Refresh interval rs fron TCP Port 2000 Modbus Address m0 Auto Start v Accept writes Optical Path FroraMain The three Modbus network parameters are e Device Address Modbus slave address of the FTIR gas analyzer e Poll Delay Interval at which the Modbus COM port is scanned for instructions e Response Delay Delay in sending the response used in case of timing problems The AutoStart checkbox needs to be selected to cause Modbus to be automatically started when the program is opened by Windows If IMACC Modbus is added to the Windows Startup folder and the AutoStart capability is enabled the program will automatically open and start upon bootup 3 18 Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific Automatic FTIR Instrument Zero Background Thermo Fisher Scientific Collection Chapter 4 Calibration The Calibratio
247. ure there is one small setting block on the left Sample Mode and one main setting block on the right System Running Status The vertically aligned sub setting blocks contained in the main script setting body are constructed in a sequential loop Thermo Fisher Scientific Omni FTIR Multi Gas CEMS Instruction Manual E 1 IMACC Script Setting CEMS SampleMode E 2 Omni FTIR Multi Gas CEMS Instruction Manual e System default valve control setting The small setting block outside the main setting frame in the previous figure is used to set the default system status for sampling mode Double click the setting block The subpanel pops up for the valve control setting Digital Output Settings for the sample mode as shown Users can set or adjust the context in each of the boxes to ensure the correct function of the solenoid valves Be cautious that the proper setting is already checked and tested by manufacturer An incorrect change would give rise to a system malfunction Digital Output Settings Mode output Channel Description es dev1 part linet r ev part fine r Pattern hex EM test Delay ms n Wait this many ms after writting port TN Mode output is chosen to define the digital I O channel as output Channel Description assigns the corresponding National Instrument Board channels to control the solenoid valve operation Pattern takes hex number to trigger all related channels In th
248. ving Filter 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 Take the replacement filter and screw it onto the threaded rod Once some resistance is felt turn it approximately another 1 2 turn until it is snug Figure 5 21 5 30 Omni FTIR Multi Gas CEMS Instruction Manual Thermo Fisher Scientific Removing the Thermo Fisher Scientific Purge Gas Generator Preventive Maintenance and Servicing Removing the Purge Gas Generator Figure 5 21 Installing Filter Element 5 With the word Lock centered push the bottom of the filter assembly upward and turn to the right 1 3 turn until it locks into place 6 Reset the regulator to its original pressure and lock it by pushing down on the knob Note Due to the effect of humidity on certain components inside the FTIR it is important to minimize the amount of time that the purge air 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 A Use the following procedure to remove the purge gas generator Note This procedure is for removing the purge gas generator from the FTIR rack only Servicing can be done without removing the purge gas generator from the rack Consult the purge gas generator manual for
249. yhee 1 5 IData IO SI ecce toi tse Dade ose e nc omen nmol nE 1 5 Dir C Om ICAL ONS isses orit aea Drrese iem aa 1 6 Typical Syste tii Flow cucine eto ORE OIN Pel etn iude bet u ads 1 6 System Power DIStEIDIOD iet E iste t Oh ea tetvetaes 1 6 SCTE C AE ONS c eeateeee 1 6 Measuring Components with Minimum Measuring Range and Regained IDE ss test ois esate ss ved isti dupes SS Ut n pent toan ds 1 7 Performancearen s tet b OR ER ACcar titre Ent be eas tuss 1 7 COBBECEIIOS Ee rosae ose smnaa ded dessus teseusta esu ode eds Mese ELee ipu en 1 8 POweE ROGUE EYES Sedet eot cosa ot eds Be die a edit bae 1 8 Paena Se o cam eccL etu aid uA CC CL etaed E Lp E 1 9 M E UU UU T 1 9 Other Manuali sessione timi iced e acit tereti ecd ie tudin tiia aes 1 10 System Installation Start Up and Shut Down 2 1 Brio HR 2 1 Unpackine and Inspection scc On RD O ilv ar d nade 2 1 DiCed Ne quiEe HEIC DIS oeste ette Bono OD RED ve O LP tee SE EiUE 2 2 Ambient Lemperature Instrument ATE iens eere ves tenias 2 2 lMevsrsidiusutiionncc E 2 2 Rack Dimensions se cae aaa recta estt i isset Lcd ut n 2 2 DD 2 2 Hanpge Reguitetmeteso e eda a ks Bodice Rd Haider asp Rub iuga 2 2 Remove Shipping ReSGaIDU sedens its t au ade iens tod ta 2 2 Installing the FTIR Analyzer into the Rack 2 3 Connect the PIIR UMT s eese beet eet este oom aie ieee 2

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