Omni FTIR - User Manual
Omni FTIR Multi Gas
CEMS
Instruction Manual
Part Number 108004-00
11Apr2013
© 2013 Thermo Fisher Scientific Inc. All rights reserved.
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consult your local sales representative for details.
Thermo Fisher Scientific
Air Quality Instruments
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Franklin, MA 02038
1-508-520-0430
www.thermoscientific.com/aqi
WEEE Compliance
This product is required to comply with the European Union’s Waste
Electrical & 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.
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WEEE Compliance
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WEEE Compliance
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 organized into the following chapters and appendixes to provide direct
access to specific operation and service information.
Thermo Fisher Scientific
●
Chapter 1 “Introduction” provides an overview of the product,
describes the system components, and product specifications.
●
Chapter 2 “System Installation, Start Up and Shut Down” describes
the setup and different instrument configurations, and provides a quick
start procedure.
●
Chapter 3 “Operation” describes the functions of the instrument
keypad, and the enhanced probe display.
●
Chapter 4 “Calibration” provides the calibration process and
procedures for calibrating the instrument.
●
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.
●
Chapter 6 “Troubleshooting” provides guidelines for diagnosing
analyzer problems, isolating faults, and includes recommended actions
for restoring proper operation.
●
Chapter 7 “System Component Description” provides an overview,
theory of operation, and describes the function of the system
components.
●
Appendix A “Warranty” is a copy of the warranty statement.
●
Appendix B “Modbus Protocol” provides a description of the Modbus
Protocol Interface and is supported both over RS-232/485 (RTU
protocol) as well as TCP/IP over Ethernet.
●
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
i
About This Manual
Safety
Safety
Safety and Equipment
Damage Alerts
●
Appendix D “Calogix Setup” provides a description of the Calogix
software.
●
Appendix E “IMACC Script Setting” describes the script setting for
two versions of IMACC scripts.
●
Appendix F “Concentration Data Transfer Using a Web Server”
describes transferring data.
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.
This manual contains important information to alert you to potential safety
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
Alert
Description
DANGER
A hazard is present that will result in death or serious
personal injury if the warning is ignored. ▲
WARNING
A hazard is present or an unsafe practice can result in
serious personal injury if the warning is ignored. ▲
CAUTION
The hazard or unsafe practice could result in minor to
moderate personal injury if the warning is ignored. ▲
Equipment Damage
The hazard or unsafe practice could result in property
damage if the warning is ignored. ▲
Safety and Equipment Damage Alerts in this Manual
Alert
Description
WARNING
If the equipment is operated in a manner not specified by
the manufacturer, the protection provided by the
equipment may be impaired. ▲
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. ▲
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Omni FTIR Multi Gas CEMS Instruction Manual
Thermo Fisher Scientific
About This Manual
Safety and Equipment Damage Alerts
Alert
Description
Aggressive condensate is possible. Wear protective
glasses and proper protective clothing. ▲
High surface temperatures! Wear protective gloves. ▲
Flush probe in the case of toxic gases. ▲
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.
▲
The desiccant is harmful if swallowed. Follow the
manufacturer’s instructions to dispose of desiccant
packets properly. ▲
To avoid shock hazard, always turn off the FTIR circuit
breaker on the breaker panel before replacing any
components inside the FTIR analyzer. ▲
CAUTION
To prevent damage to the interferometer; do not apply
electric power to the analyzer before internal shipping
restraints have been removed ed. ▲
Lift from each side of the analyzer, not from the front and
back. Damage to the unit may occur. ▲
Ethernet and serial Modbus can not be implemented at
the same time. ▲
Sample gas should not be introduced to the cell 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. ▲
The safety instructions specific to the plant and process
are to be consulted prior to any maintenance work. ▲
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. ▲
High surface temperatures present. Allow sufficient time
to cool. ▲
Avoid burn and fire hazards. Do not attempt to
regenerate spent desiccant packets. ▲
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
Thermo Fisher Scientific
Omni FTIR Multi Gas CEMS Instruction Manual
iii
About This Manual
WEEE Symbol
Alert
Description
before removing the source from the analyzer. Handle the
source assembly only by the ceramic base. ▲
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. ▲
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. ▲
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 touching any internal
components. When the PC is unplugged, the chassis is
not at earth ground. ▲
When the temperature controller is unplugged, the
chassis is not at earth ground. ▲
WEEE Symbol
The following symbol and description identify the WEEE marking used on
the instrument and in the associated documentation.
Symbol
Description
Marking of electrical and electronic equipment which applies to electrical and
electronic equipment falling under the Directive 2002/96/EC (WEEE) and the
equipment that has been put on the market after 13 August 2005. ▲
iv
Omni FTIR Multi Gas CEMS Instruction Manual
Thermo Fisher Scientific
About This Manual
Where to Get Help
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/aqilibrary.
Thermo Fisher Scientific
Omni FTIR Multi Gas CEMS Instruction Manual
v
About This Manual
Where to Get Help
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Omni FTIR Multi Gas CEMS Instruction Manual
Thermo Fisher Scientific
Contents
Thermo Fisher Scientific
Chapter 1
Introduction........................................................................................................ 1-1
System Overview................................................................................. 1-3
Sample Probe ................................................................................... 1-4
Sample Line ..................................................................................... 1-4
Temperature Controller ................................................................... 1-4
Sample Conditioning ....................................................................... 1-4
FTIR................................................................................................ 1-4
PC.................................................................................................... 1-5
Data Logger ..................................................................................... 1-5
Data Communications ..................................................................... 1-6
Typical System Flow ........................................................................... 1-6
System Power Distribution ................................................................. 1-6
Specifications ...................................................................................... 1-6
Measuring Components with Minimum Measuring Range and
Required MDL ................................................................................ 1-7
Performance ..................................................................................... 1-7
Connections..................................................................................... 1-8
Power Requirements ........................................................................ 1-8
Pneumatics....................................................................................... 1-9
Cabinet ............................................................................................ 1-9
Other Manuals.................................................................................. 1-10
Chapter 2
System Installation, Start Up and Shut Down............................................. 2-1
Lifting ................................................................................................. 2-1
Unpacking and Inspection .................................................................. 2-1
Site Requirements ............................................................................... 2-2
Ambient Temperature Instrument Air.............................................. 2-2
Power Requirements ........................................................................ 2-2
Rack Dimensions ............................................................................. 2-2
Weight ............................................................................................. 2-2
Flange Requirements........................................................................ 2-2
Remove Shipping Restraint .............................................................. 2-2
Installing the FTIR Analyzer into the Rack ......................................... 2-3
Connect the FTIR Unit ................................................................... 2-5
Connect the Purge Lines to the FTIR .............................................. 2-6
Connect the Power to the FTIR....................................................... 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
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Contents
Connect Sample lines to the Heated Pump/Valve Assembly............. 2-7
Hydrator .......................................................................................... 2-7
External System Connections .............................................................. 2-8
Connect the Sample Line to the FTIR Analyzer Cabinet and Heated
Sample Box ...................................................................................... 2-8
Instrument Air ................................................................................. 2-9
Exhaust Line .................................................................................... 2-9
Calibration Gases ............................................................................. 2-9
Communications ............................................................................. 2-9
Ethernet ........................................................................................ 2-9
Serial ............................................................................................. 2-9
Analog......................................................................................... 2-10
Digital......................................................................................... 2-10
System Startup .................................................................................. 2-10
Turn Power ON ............................................................................ 2-10
Adjust/Confirm Flow and Heat Settings ........................................ 2-11
Air flow ....................................................................................... 2-11
Heat............................................................................................ 2-12
IMACC ......................................................................................... 2-12
Autostart ........................................................................................ 2-12
Maintenance Switch....................................................................... 2-13
System Shut Down ........................................................................... 2-14
Chapter 3
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Omni FTIR Multi Gas CEMS Instruction Manual
Operation.............................................................................................................3-1
Normal Operation .............................................................................. 3-1
Software Description........................................................................... 3-1
Imacc FTIR Software Suite (IFSS) ...................................................... 3-2
Monitor ........................................................................................... 3-2
Concentrations Pane ........................................................................ 3-4
ProcessStatus.................................................................................... 3-5
ConcentrationPlot/Spectrum Plot .................................................... 3-6
Display Tab .................................................................................. 3-6
Timespan Tab............................................................................... 3-7
Datasource Tab............................................................................. 3-8
Data files.......................................................................................... 3-8
Remote Control ............................................................................. 3-10
Server ............................................................................................. 3-10
Script Engine ................................................................................. 3-10
OMNIC ........................................................................................... 3-11
Result................................................................................................ 3-13
NI-DAQ ........................................................................................... 3-13
CALGrafix ........................................................................................ 3-13
CDM-USB Driver ............................................................................ 3-13
Data Server Software ......................................................................... 3-13
ImaccCurrentLoop......................................................................... 3-13
Configure.................................................................................... 3-14
Thermo Fisher Scientific
Contents
Analog Output Board ................................................................. 3-15
ImaccModbus/ImaccModbusTCP ................................................. 3-16
Thermo Fisher Scientific
Chapter 4
Calibration.......................................................................................................... 4-1
Automatic FTIR Instrument Zero Background Collection.................. 4-1
Periodic System Zero Check ............................................................... 4-2
Periodic System Span Check ............................................................... 4-3
System Dynamic Spiking .................................................................... 4-3
External Audit Gas Procedure ............................................................. 4-3
Calibration Gases ................................................................................ 4-4
Manual Background Spectrum Collection Procedure .......................... 4-5
Manual Background Spectrum Collection using Thermo Modbus
Controller ......................................................................................... 4-10
System Calibration Procedure Using IMACC Collect....................... 4-11
System Calibration Procedure Using Calibration Factor Table in
Method ............................................................................................. 4-18
Chapter 5
Preventive Maintenance and Servicing....................................................... 5-1
Replacement Parts List ........................................................................ 5-3
Safety Precautions ............................................................................... 5-6
Cleaning the System............................................................................ 5-6
Maintenance for the Sample Probe...................................................... 5-7
Replacing the Filter Element and Graphite Seals .............................. 5-7
Replacing the Pre-filter................................................................... 5-10
Maintenance and Servicing of the FTIR Analyzer Components ........ 5-11
Checking and Replacing the Desiccant........................................... 5-11
Replacing the Humidity Indicator.................................................. 5-13
Cleaning or Replacing the Fan Filter.............................................. 5-14
Replacing the Source...................................................................... 5-16
Replacing the Laser ........................................................................ 5-19
Replacing the Detector................................................................... 5-22
Replacing the Beamsplitter............................................................. 5-25
Replacing the Air Filters.................................................................... 5-29
Removing the Purge Gas Generator .................................................. 5-31
Removing the Left Side Panel ........................................................... 5-33
Removing the FTIR .......................................................................... 5-34
Replacing the FTIR Power Supply .................................................... 5-38
Replacing the Temperature Sensor .................................................... 5-39
Replacing the Pressure Sensor ........................................................... 5-41
Replacing the Gas Cell ...................................................................... 5-42
Gas Cell Alignment........................................................................... 5-44
Replacing the Gas Cell Heater........................................................... 5-51
Replacing the Heated Lines............................................................... 5-54
Replacing the PC .............................................................................. 5-55
Replacing the PC Console................................................................. 5-57
Omni FTIR Multi Gas CEMS Instruction Manual
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Contents
Replacing the National Instruments Boards ...................................... 5-59
Temperature Control Box Components............................................ 5-62
Replacing External Fuses ................................................................ 5-62
Replacing Internal Components..................................................... 5-64
Removing and Installing the Cover ............................................. 5-64
Replacing the Internal Fuses........................................................ 5-65
Replacing the Temperature Control Board.................................. 5-66
Replacing the Power Relays......................................................... 5-68
Replacing the Temperature Control Modules ............................. 5-69
Replacing the Temperature Control Base Unit............................ 5-70
Electrical Panel Components............................................................. 5-71
Replacing the Ethernet Switch ....................................................... 5-73
Replacing the Solid State Relays ..................................................... 5-73
Replacing the 24V Power Supply ................................................... 5-75
Sample System Heater Assembly Components .................................. 5-76
Removing the Sample System Heater Assembly and Cover ............ 5-76
Replacing the Thermostat .............................................................. 5-78
Replacing the Eductor Pump ......................................................... 5-79
Removing the Heated Block Assembly ........................................... 5-82
Replacing the Check Valve............................................................. 5-83
Replacing the Sample Solenoid Valve............................................. 5-86
Pneumatic Panel Components .......................................................... 5-90
Replacing the Pressure Reducers..................................................... 5-90
Replacing the Pressure Gauges ....................................................... 5-91
Replacing the Solenoid Valves........................................................ 5-92
Replacing the Flow Meters ............................................................. 5-94
Service Locations............................................................................... 5-97
x
Chapter 6
Troubleshooting.................................................................................................6-1
Concentration Errors .......................................................................... 6-3
Boot Up Error/IMACC Software Error............................................... 6-4
Temperature Errors............................................................................. 6-4
Cell Pressure Errors/Sampling System Errors ...................................... 6-5
Communication Errors ....................................................................... 6-6
I/O Errors ........................................................................................... 6-7
Service Locations................................................................................. 6-8
Chapter 7
System Component Description .....................................................................7-1
Sample Probe ...................................................................................... 7-2
Temperature Controller ...................................................................... 7-3
Heated Sample Line ............................................................................ 7-3
Heated Pump/Valve Assembly ............................................................ 7-4
Hydrator ............................................................................................. 7-4
Pneumatic Panel ................................................................................. 7-4
Sample mode ................................................................................... 7-5
Omni FTIR Multi Gas CEMS Instruction Manual
Thermo Fisher Scientific
Contents
Blowback ......................................................................................... 7-5
Instrument Background Scan and Flowback .................................... 7-5
Check Zero ...................................................................................... 7-6
Check Spike ..................................................................................... 7-6
Check Span...................................................................................... 7-6
FTIR................................................................................................... 7-7
Optical Components........................................................................ 7-9
Source .............................................................................................. 7-9
Interferometer ................................................................................ 7-10
Laser .............................................................................................. 7-10
Mirrors........................................................................................... 7-10
Aperture......................................................................................... 7-10
Detector......................................................................................... 7-11
Gas Cell ......................................................................................... 7-11
Gas Cell Heating Jacket ................................................................. 7-11
Temperature Sensor ....................................................................... 7-12
Pressure Sensor............................................................................... 7-12
Gas Cell Interface........................................................................... 7-12
Computer Interface........................................................................ 7-12
Humidity Control.......................................................................... 7-12
Air Purifier ........................................................................................ 7-12
Industrial PC..................................................................................... 7-13
I/O Boards ..................................................................................... 7-14
Console............................................................................................. 7-14
Datalogger......................................................................................... 7-14
Electrical Panel Assembly .................................................................. 7-14
AC Power Input................................................................................ 7-15
Thermo Fisher Scientific
Appendix A
Warranty ............................................................................................................ A-1
Appendix B
Modbus Protocol.............................................................................................. B-1
Serial Communication Parameters ......................................................B-2
TCP Communication Parameters .......................................................B-2
Application Data Unit Definition .......................................................B-2
Slave Address....................................................................................B-2
MBAP Header .................................................................................B-2
Function Code .................................................................................B-3
Data .................................................................................................B-3
Error Check .....................................................................................B-3
Function Codes...................................................................................B-3
(0x03) Read Holding Registers.........................................................B-3
Modbus Parameters Supported ...........................................................B-5
Appendix C
Interfacing a DCS/PLC with the Omni FTIR Multi Gas CEMS...................C-1
Introduction....................................................................................... C-1
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Contents
Connecting a DCS/PLC to the Omni FTIR Multi Gas CEMS ......... C-2
Establishing Communications............................................................ C-3
Analog Outputs............................................................................... C-3
Digital I/O...................................................................................... C-4
Solid-State Relays (SSR).................................................................. C-6
SSR Rail....................................................................................... C-6
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Appendix D
Calogix Setup....................................................................................................D-1
Hardware Description........................................................................ D-1
Finding the Correct COM Port ......................................................... D-2
Setting the Virtual COM Port ........................................................... D-4
Programming the Controllers and Setting Parameters ........................ D-6
Creating Ramp Programs ............................................................. D-7
Inputting Controller Values ......................................................... D-9
Appendix E
IMACC Script Setting....................................................................................... E-1
CEMS_SampleMode ..........................................................................E-1
Modbus Control Version ..................................................................E-10
Appendix F
Concentration Data Transfer Using a Web Server .....................................F-1
Omni FTIR Multi Gas CEMS Instruction Manual
Thermo Fisher Scientific
Figures
Figure 1–1. Omni FTIR Multi Gas CEMS ............................................................ 1-2
Figure 1–2. Omni FTIR Multi Gas 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 ........................................................ 2-5
Figure 2–4. Connecting to the FTIR Unit ............................................................ 2-6
Figure 2–5. Rear Panel Terminal Blocks............................................................. 2-8
Figure 2–6. Pneumatic Panel Rear View .......................................................... 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 ............................................................................... 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................................................................ 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 .......................................... 5-18
Figure 5–9. Locating the Laser Assembly ........................................................ 5-20
Figure 5–10. Unlocking the Laser Spring Clamps ............................................ 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 Panel .................................. 5-28
Figure 5–17. Removing the Beamsplitter......................................................... 5-28
Figure 5–18. Turning Off House Air.................................................................. 5-29
Figure 5–19. Removing Filter Cap..................................................................... 5-30
Figure 5–20. Unscrewing Filter Element .......................................................... 5-30
Figure 5–21. Installing Filter Element .............................................................. 5-31
Figure 5–22. Removing the Purge Gas Generator............................................ 5-32
Figure 5–23. Lock and Hand Grips.................................................................... 5-33
Figure 5–24. Posts and Keyhole Slots.............................................................. 5-34
Figure 5–25. Remove Screws and Two Lowest Panels ................................... 5-35
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Omni FTIR Multi Gas CEMS Instruction Manual
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Figures
Figure 5–26. FTIR Shelf Out ..............................................................................5-35
Figure 5–27. FTIR Wiring and Tubing Connections ..........................................5-37
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 Cell.....................................5-47
Figure 5–37. Beam Image on the First Objective Mirror in the Multi-pass Gas
Cell ......................................................................................................................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 .....................................................5-50
Figure 5–41. Typical Interferometer of Omni FTIR CEMS ................................5-50
Figure 5–42. Cutting Insulation Paper at the Seam .........................................5-52
Figure 5–43. Insulation Removal ......................................................................5-53
Figure 5–44. Hose Clamp Removal...................................................................5-53
Figure 5–45. Heated Line Replacement............................................................5-55
Figure 5–46. PC Removal ..................................................................................5-56
Figure 5–47. PC Console Removal ....................................................................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 ...........................................................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 .........................................................5-63
Figure 5–55. Temperature Control Box Internal Component Replacements ...5-66
Figure 5–56. Electrical Panel Component Location (Front Side) ......................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 Block Removal........................................................................................5-80
Figure 5–60. Check Valve Replacement ...........................................................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
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Figures
Figure 7–1. FTIR Multi Gas CEMS System Component Layout ......................... 7-2
Figure 7–2. Sample Probe................................................................................... 7-3
Figure 7–3. Pneumatic Panel .............................................................................. 7-5
Figure 7–4. Sample and Calibration Gas Flow Diagram.................................... 7-6
Figure 7–5. FTIR Analyzer ................................................................................... 7-7
Figure 7–6. FTIR Flow Schematic ....................................................................... 7-8
Figure 7–7. Spectrometer Compartment............................................................ 7-9
Figure 7–8. Major System Components........................................................... 7-11
Figure 7–9. FTIR Purge Gas Generator ............................................................. 7-13
Figure 7–10. FTIR PC......................................................................................... 7-13
Figure 7–11. Electrical Panel ............................................................................ 7-15
Figure 7–12. AC Mains ..................................................................................... 7-15
Figure C–1. Rear Panel Terminal Connectors .................................................... C-2
Figure C–2. Analog Outputs ............................................................................... C-4
Figure C–3. Digital I/O - Rear Panel Terminals.................................................. C-5
Figure C–4. SSR Rail........................................................................................... C-6
Figure C–5. SSR Indicator Light Configurations................................................. C-6
Figure D–1. Base Unit and Four Controllers.......................................................D-1
Figure D–2. Temperature Controller Connection ...............................................D-2
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Figures
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Tables
Table 1–1. FTIR Compounds ............................................................................... 1-7
Table 1–2. FTIR Performance Specifications...................................................... 1-7
Table 1–3. Electrical Connections ...................................................................... 1-8
Table 1–4. Power ................................................................................................ 1-8
Table 1–5. Pneumatics........................................................................................ 1-9
Table 1–6. Free-Standing Cabinet ...................................................................... 1-9
Table 3–1. Analog Current Channel Assignments ........................................... 3-15
Table 4–1. Calibration Factors.......................................................................... 4-20
Table 5–1. Replacement Parts List ..................................................................... 5-3
Table B–1. Modbus Read Registers................................................................... B-5
Table B–2. Modbus Write Registers.................................................................. B-6
Table B–3. System Command Values ................................................................ B-6
Table B–4. System Flag Bits............................................................................... B-7
Table C–1. Analog Output Connections ............................................................. C-3
Table C–2. Digital I/O Connections.................................................................... C-5
Table D–1. Controller Values............................................................................D-10
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Tables
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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 highspeed 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 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.
Thermo Fisher Scientific
Omni FTIR Multi Gas CEMS Instruction Manual
1-1
Introduction
System Overview
For details, see the following topics:
●
“System Overview” on page 1-3
●
“Typical System Flow” on page 1-6
●
“System Power Distribution” on page 1-6
●
“Specifications” on page 1-6
●
“Other Manuals” on page 1-10
Figure 1–1. Omni FTIR Multi Gas CEMS
1-2
Omni FTIR Multi Gas CEMS Instruction Manual
Thermo Fisher Scientific
Introduction
System Overview
System
Overview
The Omni FTIR Multi Gas CEMS is a complete continuous emissions
monitoring system (CEMS) designed to extract a sample from a source and
deliver a hot/wet sample to the measurement instruments to determine
concentrations of various gases. This system utilizes a Fourier Transform
Infrared (FTIR) spectrometer to measure most gases. Figure 1–2 shows the
major system components of a complete system.
Note This manual is for use with the Omni FTIR Multi Gas CEMS
integrated by Thermo Fisher Scientific. Systems integrated by others will
vary from the information provided in this document. ▲
Figure 1–2. Omni FTIR Multi Gas CEMS System Overview
Thermo Fisher Scientific
Omni FTIR Multi Gas CEMS Instruction Manual
1-3
Introduction
System Overview
Sample Probe
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.
Sample Line
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).
Temperature
Controller
The system includes a temperature control module which is used to control
the temperatures in the following components:
●
FTIR cell
●
Sample conditioning assembly
●
Heated lines to FTIR
●
Sample line
In addition, the FTIR cell pressure is measured with this controller.
Sample
Conditioning
FTIR
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Omni FTIR Multi Gas CEMS Instruction Manual
The sample conditioning subsystem consists of multiple components that
are used to control and condition the sample and calibration gases:
●
Sample system heater assembly (pump, sample valve, check valve, preheaters)
●
Hydrator
●
Pneumatic panel
●
FTIR purge gas generator
●
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
Introduction
System Overview
meter heated gas cell and a TE cooled DTGS detector, with a resolution of
0.5 cm-1.
PC
The PC is a 2U Rackmount industrial PC with the following components:
●
Black ATX 2U heavy duty steel case
●
Intel® Pentium® 4 Processor 2.4 GHz
●
1GB DDR2 800mHz RAM
●
250GB SATA2 hard drive
●
24X DVD RW drive
●
1.44 MB floppy drive
●
3 RS-232 serial ports
●
2 Ethernet ports
●
2 front-facing USB ports, 4 rear-facing USB ports
●
32-channel analog output board
●
96-channel digital output board
●
300W power supply
●
Windows XP Pro
The 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.
Data Logger
Thermo Fisher Scientific
A data logger is required to:
●
Capture measurement data in real-time
●
Allow the operator to trigger a calibration check sequence
●
Manually control calibration gases
●
Mark data taken during any calibration purge or activity
●
Generate reports
Omni FTIR Multi Gas CEMS Instruction Manual
1-5
Introduction
Typical System Flow
Data
Communications
The system provides several methods for establishing data communication
with a DCS/PLC including:
●
Modbus protocol (Ethernet or serial)
●
Analog output connections
●
Digital I/O connections
Typical communications functions provided by the FTIR Multi-Gas
CEMS include:
Concentration readings
●
System status or alarms (calibration checks, blowback, etc.)
Typical System
Flow
There are six gas flow modes: sample mode, blowback, instrument
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”.
System Power
Distribution
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:
Specifications
1-6
●
Omni FTIR Multi Gas CEMS Instruction Manual
●
FTIR
●
PC with console
●
FTIR purge gas generator
●
24 VDC power supply
●
Probe
●
Temperature controller
This section provides technical data on:
●
Compounds
●
Performance
●
Electrical, data, and pneumatic connections
●
Power and instrument air
●
Dimensions and weight
Thermo Fisher Scientific
Introduction
Specifications
Measuring Components
with Minimum Measuring
Range and Required MDL
Performance
Thermo Fisher Scientific
Table 1–1. FTIR Compounds
Compound
Compound
(ppm)
MDL
1σ 1 min. avg
(ppm)
Carbon monoxide CO
0–750
0.15
Nitric oxide NO (gas turbine)
0–1200
0.40
Sulfur dioxide SO2
0– 350
0.40
Hydrogen chloride HCl
0–150
0.10
Ammonia NH3
0–100
0.10
Water H2O
0–40.0 vol%
0.10 vol%
Nitrogen dioxide NO2
0–50.0
0.10
Nitrous oxide N2O
0–50.0
0.10
Hydrogen fluoride HF
0–15.0
0.15
Carbon dioxide CO2
0–30.0 vol%
0.10 vol%
Sulfur hexafluoride SF6
0–10.0
0.003
Table 1–2. FTIR Performance Specifications
Parameter
Specification
Linearity
<2% of minimum measuring range
Zero drift (during period of
unattended operation
<3% of minimum measuring range
Span drift (during period of
unattended operation
<2% of minimum measuring range
Influence of ambient temperature
<5% of minimum measuring range for zero and span
with 20 °C as reference
Influence of sample gas pressure
None (pressure compensation)
Flow
~5 l/min
Response time T95
<3 minutes for all non-reactive gases
<5 minutes for NH3, HCl and HF spiking
<10 minutes for NH3, HCl and HF dry
Availability
>98%
Ambient temperature
+60 to +95 °F/+15 to +35 °C
Omni FTIR Multi Gas CEMS Instruction Manual
1-7
Introduction
Specifications
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
Gas mode inputs and outputs: check span, check
spike, check zero, background and flowback,
blowback, and sample
Power
Requirements
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Omni FTIR Multi Gas CEMS Instruction Manual
Table 1–4. Power
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
<6000 W
Sample Probe
630 W
Thermo Fisher Scientific
Introduction
Specifications
Pneumatics
Cabinet
Thermo Fisher Scientific
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
Spike 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
Flowback
6.0 l/min
Blowback
~50 l/min
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 lbs/200 kg (without doors)
Color
Thermo Fisher Scientific Blue PMS 646
Ambient temperature
+60 to +95 °F/+15 to +35 °C (without doors)
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:
●
Antaris IGS User’s Guide
●
Result Software User’s Guide
●
M&C Operating Instructions—Gas Sample Probe Series SP®
Version SP2000, SP2000-H, SP2300-H, SP2400-H
●
Parker Balson® FT-IR Purge Gas Generator
Models 75-45, 75-52, and 75-62
Thermo Fisher Scientific
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:
Lifting
●
“Lifting” on page 2-1
●
“Unpacking and Inspection” on page 2-1
●
“Site Requirements” on page 2-2
●
“Installing the FTIR Analyzer into the Rack” on page 2-3
●
“External System Connections” on page 2-8
●
“System Startup” on page 2-10
●
“System Shut Down” on page 2-14
When lifting the analyzer, use a procedure appropriate to lifting a large
heavy object, such as bending at the knees 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.
Unpacking and
Inspection
Thermo Fisher Scientific
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
still securely fastened to the side of the rack.
Omni FTIR Multi Gas CEMS Instruction Manual
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System Installation, Start Up and Shut Down
Site Requirements
Site
Requirements
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.
Ambient Temperature
Instrument Air
Power
Requirements
Rack Dimensions
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)
Weight
Flange
Requirements
Remove Shipping
Restraint
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Omni FTIR Multi Gas CEMS Instruction Manual
Approximately 450 lbs.
The Omni FTIR Mulit Gas CEMS is provided with an M&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.
Figure 2–1. Removing the shipping Screws
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
FTIR Analyzer
into the Rack
Lift the analyzer from the pallet. The analyzer weighs about 130 lbs. (60
kg), so at least two people will be needed to lift it.
CAUTION To prevent damage to the interferometer; do not apply electric
power to the analyzer before internal shipping restraints have been
removed. ▲
CAUTION Lift from each side of the analyzer, not from the front and back.
Damage to the unit may occur. ▲
Position the analyzer on the rack slide per Figure 2–2.
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Omni FTIR Multi Gas CEMS Instruction Manual
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System Installation, Start Up and Shut Down
Installing the FTIR Analyzer into the Rack
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 & 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.
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Omni FTIR Multi Gas CEMS Instruction Manual
Thermo Fisher Scientific
System Installation, Start Up and Shut Down
Installing the FTIR Analyzer into the Rack
Connect the FTIR
Unit
The following connections need to be made to the FTIR unit: Purge,
Power, Computer, Pressure, Cell heater and Sample lines (Figure 2–3).
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).
Figure 2–4. Connecting to the FTIR Unit
Connect the Power
to the FTIR
2-6
Omni FTIR Multi Gas CEMS Instruction Manual
The FTIR power supply is located inside the rear of the FTIR shelf.
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
System Installation, Start Up and Shut Down
Installing the FTIR Analyzer into the Rack
Connecting the
Computer Cable to
the FTIR
Connect the Pressure
Transducer Cable to
the FTIR
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, 4-contact, female DIN connector.
One end is hardwired to the electronics in the rack. Attach the connector
to the pressure transducer plumbed to the FTIR.
Connect the Cell
Heater Cable 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 Sample
lines to the Heated
Pump/Valve
Assembly
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.
Hydrator
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.
Thermo Fisher Scientific
Omni FTIR Multi Gas CEMS Instruction Manual
2-7
System Installation, Start Up and Shut Down
External System Connections
External System
Connections
Connect the Sample
Line to the FTIR
Analyzer Cabinet and
Heated Sample Box
See the following external system connections.
The sample line from the M&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
1 = 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)
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Omni FTIR Multi Gas CEMS Instruction Manual
Thermo Fisher Scientific
System Installation, Start Up and Shut Down
External System Connections
Instrument Air
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.
Exhaust Line
The rack is provided with connections for two 1/2-inch OD exhaust lines.
The top exhaust marked ‘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.
Calibration Gases
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&C SP2000-H probe via the heated
calibration line.
Adjust calibration gas regulators to an output pressure of 40 psi.
Communications
Refer to Appendix B, “Modbus Protocol” for detailed Modbus instructions.
Ethernet
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.
Serial
The system may be connected serially for MODBUS communications via
the computer’s RS-232 serial port 1 using IMACC server software
ImaccModbus.exe.
CAUTION Ethernet and serial Modbus can not be implemented at the
same time. ▲
Thermo Fisher Scientific
Omni FTIR Multi Gas CEMS Instruction Manual
2-9
System Installation, Start Up and Shut Down
System 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 & 22 of terminal block X2. The terminals have an identical
output. ‘High’ indicates a low-temperature alarm (Figure 2–5).
System Startup
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. ▲
CAUTION Sample gas should not be introduced to the cell until the cell has
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. ▲
Turn Power ON
Switch the Measurement/Maintenance switch on the front of the system
rack to the Maintenance position.
Use the 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 FSS software is running; the other lights should be steady.
2-10
Omni FTIR Multi Gas CEMS Instruction Manual
Thermo Fisher Scientific
System Installation, Start Up and Shut Down
System Startup
Adjust/Confirm Flow
and Heat Settings
Air flow
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:
CO2 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 l/min
System 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).
Figure 2–6. Pneumatic Panel Rear View
Thermo Fisher Scientific
Omni FTIR Multi Gas CEMS Instruction Manual
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System Installation, Start Up and Shut Down
System Startup
Heat
IMACC
Autostart
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
The IMACC FSS software is preconfigured and starts automatically on
computer power up. Refer to Chapter 3, “Operation” for details on
software operation.
For automatic 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
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
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Omni FTIR Multi Gas CEMS Instruction Manual
Thermo Fisher Scientific
System Installation, Start Up and Shut Down
System Startup
Drag the shortcuts into the Startup folder.
Close the folder.
Maintenance
Switch
Thermo Fisher Scientific
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
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. ▲
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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:
Normal
Operation
Software
Description
●
“Normal Operation” on page 3-1
●
“Software Description” on page 3-1
●
“Imacc FTIR Software Suite (IFSS)” on page 3-2
●
“OMNIC” on page 3-11
●
“Result” on page 3-13
●
“NI-DAQ” on page 3-13
●
“CALGrafix” on page 3-13
●
“CDM-USB Driver” on page 3-13
●
“Data Server Software” on page 3-13
In normal operation, all software components of the Omni FTIR Multigas
CEMS will be loaded in the Windows ‘Startup’ menu. 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:
●
Thermo Fisher Scientific
IFSS – Imacc FTIR Software Suite:
●
Monitor – User Interface
●
Server – Data Collection & Analysis
●
Script Engine
●
Data Server Software
●
ImaccCurrentloop
●
ImaccModbus
●
ImaccModbusTCP
Omni FTIR Multi Gas CEMS Instruction Manual
3-1
Operation
Imacc FTIR Software Suite (IFSS)
Imacc FTIR
Software Suite
(IFSS)
●
OMNIC – Spectrometer Driver and Diagnostic software
●
Result – Spectrometer Driver software
●
CALGrafix – Heater Configuration and Diagnostic software
●
CDM – USB Driver software
●
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).
Figure 3–1. Component Relational Diagram
Monitor
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Omni FTIR Multi Gas CEMS Instruction Manual
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.
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” (►) and “stop” (■) 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 the CALogix controllers in the Temperature
Control Box (TCB) will display temperature data.
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.
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Omni FTIR Multi Gas CEMS Instruction Manual
3-3
Operation
Imacc FTIR Software Suite (IFSS)
Concentrations
Pane
The concentrations pane displays the analyzed compound names,
concentration, numerical 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.
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.
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Thermo Fisher Scientific
Operation
Imacc FTIR Software Suite (IFSS)
ProcessStatus
ProcessStatus is used to display various process parameters, such as board
temperature, FTIR status, percentage complete, numbers of scans
completed, and pressure.
Settings:
Select Parameters – Check the parameters to be displayed.
Order Parameters – Use arrows to reorder the selected parameters.
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Operation
Imacc FTIR Software Suite (IFSS)
ConcentrationPlot/
Spectrum Plot
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.
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.
Display Tab
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
colors (*.desc file).
Save Configuration – Saves a configuration of data limits and colors.
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Operation
Imacc FTIR Software Suite (IFSS)
Timespan Tab
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 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.
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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.
Data files
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Omni FTIR Multi Gas CEMS Instruction Manual
See the following:
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 are 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 CO2
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:\Scripts
.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.
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Operation
Imacc FTIR Software Suite (IFSS)
Remote Control
Server
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.
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.
Double clicking on the icon in the notify tray will display the Imacc Server.
The main client for the Imacc Server’s data is the Imacc Monitor.
Script Engine
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Omni FTIR Multi Gas CEMS Instruction Manual
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.
Thermo Fisher Scientific
Operation
OMNIC
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.
OMNIC
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).
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 Chapter 5, “Preventive Maintenance and
Servicing”).
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Operation
OMNIC
When there is no fault in communication between the spectrometer and
the computer, there is a green ‘Bench Status’ checkmark in the upper righthand 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”.
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Operation
Result
Result
Result is an additional FTIR spectrometer driver that must be loaded with
OMNIC. No user-accessible functions are available with Result.
NI-DAQ
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
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.
CDM-USB Driver
Data Server
Software
ImaccCurrentLoop
Thermo Fisher Scientific
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.
●
ImaccCurrentLoop provides analog data output in 4-20ma format.
●
ImaccModbus allows for data output and control input via serial
Modbus.
●
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
analog 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
the user to enter basic configuration data. In order to make changes, it is
necessary that the program be in the Stopped mode.
Configure
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.
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Operation
Data Server Software
Analog Output Board
The PCI-7604 analog output board has eight digital channels (DIO0 –
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
Thermo Fisher Scientific
Channel
Sulphur dioxide
SO2
16
Nitric oxide
NO
17
Nitrogen dioxide
NO2
18
Nitrous oxide
N2O
19
Ammonia
NH3
20
Hydrogen chloride
HCl
21
Hydrogen fluoride
HF
22
Carbon monoxide
CO
23
Carbon dioxide
CO2
24
Water
H2O
25
Omni FTIR Multi Gas CEMS Instruction Manual
3-15
Operation
Data Server Software
ImaccModbus/
ImaccModbus
TCP
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.
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 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. ▲
Note For additional information on how to read registers and interpret the
data, refer to Appendix B, “Modbus Protocol”. ▲
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Operation
Data Server Software
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 configuration 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.
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Omni FTIR Multi Gas CEMS Instruction Manual
3-17
Operation
Data Server Software
The three Modbus network parameters are:
●
Device Address: Modbus slave address of the FTIR gas analyzer
●
Poll Delay: Interval at which the Modbus COM port is scanned for
instructions
●
Response Delay: Delay in sending the response (used in case of timing
problems).
The AutoStart checkbox needs to be selected to cause Modbus 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.
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Thermo Fisher Scientific
Chapter 4
Calibration
The Calibration procedure is in accordance with EPA method 320, 321,
PS15. 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:
Automatic FTIR
Instrument Zero
Background
Collection
Thermo Fisher Scientific
●
“Automatic FTIR Instrument Zero Background Collection” on page 41
●
“Periodic System Zero Check” on page 4-2
●
“Periodic System Span Check” on page 4-3
●
“System Dynamic Spiking” on page 4-3
●
“External Audit Gas Procedure” on page 4-3
●
“Calibration Gases” on page 4-4
●
“Manual Background Spectrum Collection Procedure” on page 4-5
●
“Manual Background Spectrum Collection using Thermo Modbus
Controller” on page 4-10
●
“System Calibration Procedure Using IMACC Collect” on page 4-11
●
“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 purging 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
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.
Periodic System
Zero Check
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 (>6
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, 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
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Omni FTIR Multi Gas CEMS Instruction Manual
Thermo Fisher Scientific
Calibration
Periodic System Span Check
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 (>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. Adjustments 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 (>6 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.
System Dynamic
Spiking
External Audit
Gas Procedure
Thermo Fisher Scientific
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 is 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
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 HCl 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 HCl long term stability.
A similar requirement for the NH3 cylinder gas is suggested. Relatively,
NH3 has a faster response time than HCl, so a shorter duration for the
NH3 daily calibration check can be chosen. In this case, the NH3 gas
cylinder will last much longer than the HCl 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, NH3 and H20 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 HCl 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.
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Thermo Fisher Scientific
Calibration
Manual Background Spectrum Collection Procedure
Manual Background
Spectrum Collection
Procedure
When running IMACC Monitor, press Stop Script and press OK go to tab
OMNIC.
In OMNIC, select Exp Set, tab Collect, and set the following. No. of
scans: 30, Resolution: 0.5, Final Format: Interferogram, Correction: None.
Thermo Fisher Scientific
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.
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.
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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.
The system will now collect 30 scans when prompted with “Add to
IMACC capture?” press Yes.
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Omni FTIR Multi Gas CEMS Instruction Manual
4-7
Calibration
Manual Background Spectrum Collection Procedure
Select tab Process and select Reprocess….
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.
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Calibration
Manual Background Spectrum Collection Procedure
Select tab File and select Save As. Go to directory BKGS and press Set
Filename to Title.
Go to tab My Documents (If not opened yet then open it with Explorer).
Move previous background file to monthly archive and delete BKG.
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4-9
Calibration
Manual Background Spectrum Collection using Thermo Modbus Controller
Copy just collected zero air background and rename.
Name the copied file BKG. Select ImaccMonitor to return to
measurement.
Manual Background
Spectrum Collection
using Thermo
Modbus Controller
4-10
Omni FTIR Multi Gas CEMS Instruction Manual
Another way to collect instrument zero spectrum is to use Thermo Modbus
Controller. In the pull 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
System Calibration Procedure Using IMACC Collect
System Calibration
Procedure Using
IMACC Collect
Doubleclick on icon “ImaccCollect” and answer Yes when prompted
“Would you like to load “ftir_calibrate.collect?”.
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 factors.
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
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Omni FTIR Multi Gas CEMS Instruction Manual
4-11
Calibration
System Calibration Procedure Using IMACC Collect
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.
4-12
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Thermo Fisher Scientific
Calibration
System 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: CellTemp,
Register:0x0a20,
COM Port: 6, Parity: None, Baud: 9600, Stopbits: 1, Databits: 8, Flow
Control: None
Press OK to close ModbusMultiSensor Settings box.
Click on the “...” button of Pressure 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, Databits: 8, Flow
Control: None
Press OK to close ModbusMultiSensor Settings box.
Thermo Fisher Scientific
Omni FTIR Multi Gas CEMS Instruction Manual
4-13
Calibration
System Calibration Procedure Using IMACC Collect
Click on Single Collect button to verify that the system is operating
properly.
Switch to calibration tab.
Click on the open tab to open Method: C:\Methods\omni
Press map to check that all compounds are listed. If not, enter the required
compound and click the add button. Check that the corresponding
compounds in the method are selected for the highlighted compound.
4-14
Omni FTIR Multi Gas CEMS Instruction Manual
Thermo Fisher Scientific
Calibration
System Calibration Procedure Using IMACC Collect
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.
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.
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Omni FTIR Multi Gas CEMS Instruction Manual
4-15
Calibration
System Calibration Procedure Using IMACC Collect
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).
When you return to ImaccMonitor, the reading should equal the value of
the calibration gas.
4-16
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Thermo Fisher Scientific
Calibration
System Calibration Procedure Using IMACC Collect
When pressing Start Script, the new zero air background will now be used.
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Omni FTIR Multi Gas CEMS Instruction Manual
4-17
Calibration
System Calibration Procedure Using Calibration Factor Table in Method
System Calibration
Procedure Using
Calibration Factor
Table in Method
Other than using IMACC Collect to perform a system calibration, an
alternative way is to manually input the correct calibration factors for each
gas.
Click “All Programs” on Windows and locate the IMACC FTIR software
suite. Move the cursor to “Tools” and open “IMACCquantify”. Click the
“Open” tab to locate the method in the directory of
c:\methods\Omni.method, and open the method as shown below.
Click the “linearity” tab and you will see the tab button “Calibration
Factors”. Click the button and open the table as shown below.
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Calibration
System 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 calibration 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 % CO2 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.
There are 28 calibration factors listed in the Table 4–1 Calibration Factors.
For each calibration factor, the appropriate concentration range and H2O
content are listed. Gases with no H2O 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.
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4-19
Calibration
System Calibration Procedure Using Calibration Factor Table in Method
Table 4–1. Calibration Factors
Gases
Range
H20
CO2
0 to 30%
NH3_Hi
16 to 105 ppm
NH3_lo
0 to 70 ppm
CO2_HI
0 to 30%
SO2_LO
0 to 50 ppm
SO2_dry
0 to 350 ppm
<13%
NO2_wet
0 to 60 ppm
1%
NO_wet
10 500 ppm
1%
CO_HI
57 to 766 ppm
N2O
0 to 50 ppm
SO2_Hi
0 to 350 ppm
HCl_Lo
0 to 13 ppm
HCl_Hi
15 to 100 ppm
H2O_LO
5% to 40%
<2%
HF_dry
0 to 14 ppm
<0.5 %
H2O_HI
3% to 35%
>2%
CH4
0 to 1000 ppm
CO_LO
10 to 100 ppm
NO_dry_LO
1 to 103 ppm
<1%
HF_wet
0 to 15 ppm
>0.5 %
HCl_dry
0 to 13 ppm
<0.5%
HCl_wet
13 to 100 ppm
>0.5%
NH3_wet
0 to 106 ppm
>0.5%
NH3_dry
0 to 106 ppm
<0.5%
NO_dry_Hi
60 to 1253 ppm
<1%
NO2_dry
1 to 50 ppm
<1%
SF6
0 to 6 ppm
H2O
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Omni FTIR Multi Gas CEMS Instruction Manual
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.
Thermo Fisher Scientific
●
“Replacement Parts List” on page 5-3
●
“Safety Precautions” on page 5-6
●
“Cleaning the System” on page 5-6
●
“Maintenance for the Sample Probe” on page 5-7
●
“Maintenance and Servicing of the FTIR Analyzer Components” on
page 5-11
●
“Replacing the Air Filters” on page 5-29
●
“Removing the Purge Gas Generator” on page 5-31
●
“Removing the Left Side Panel” on page 5-33
●
“Removing the FTIR” on page 5-34
●
“Replacing the FTIR Power Supply” on page 5-38
●
“Replacing the Temperature Sensor” on page 5-39
●
“Replacing the Pressure Sensor” on page 5-41
●
“Replacing the Gas Cell” on page 5-42
●
“Gas Cell Alignment” on page 5-44
●
“Replacing the Gas Cell Heater” on page 5-51
●
“Replacing the Heated Lines” on page 5-54
●
“Replacing the PC” on page 5-55
●
“Replacing the PC Console” on page 5-57
Omni FTIR Multi Gas CEMS Instruction Manual
5-1
Preventive Maintenance and Servicing
System Calibration Procedure Using Calibration Factor Table in Method
5-2
Omni FTIR Multi Gas CEMS Instruction Manual
●
“Replacing the National Instruments Boards” on page 5-59
●
“Temperature Control Box Components” on page 5-62
●
“Electrical Panel Components” on page 5-71
●
“Sample System Heater Assembly Components” on page 5-76
●
“Pneumatic Panel Components” on page 5-90
●
“Service Locations” on page 5-97
Thermo Fisher Scientific
Preventive Maintenance and Servicing
Replacement Parts List
Replacement
Parts List
Thermo Fisher Scientific
Table 5–1 lists the replacement parts for the Omni FTIR Multi Gas
CEMS.
Table 5–1. Replacement Parts List
Sample Probe
Part Number
Replacement
Period
Sample Probe Assembly, SP2000-H, 4" Flange, 1.0M
Stinger
113200-00
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
Sample Probe Blowback Valve
113317-00
Sample Probe Graphite Gasket (69) Lid Seal
113318-00
Sample Probe Stinger PID Controller
113319-00
Sample Probe Pre-Filter Element, 25 micron, Coated SS,
ext screw
113321-00
Sample Probe Heated Stinger Assembly, 1.0M
113335-00
Sample Probe Filter Housing Lid Assy 320 C
113336-00
Sample Probe Lid Seal Retaining Washer
113337-00
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
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
one BX instrument air filter)
113309-00
1 year
DX Instrument Air Filter (box of 10)
9810
9-12 months
BX Instrument Air Filter (box of 10)
9811
9-12 months
1 year
3-6 months
1 year
3-6 months
Replacement
Period
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
CI Instrument Air Filter
9812
9-12 months
Hydrator Assembly
105490-00
Sample System
Part Number
Sample System Heater Assembly
112462-00
Assembly, Replacement, Eductor Pump
113289-00
Assembly, Replacement, Sample Solenoid Valve
113288-00
Check Valve
101246-00
Thermostat, 400 Degrees F
04-011901
FTIR Instrument
Part Number
FTIR Instrument Assembly
109765-00
FTIR Maintenance Kit (Laser, Fan Filter, Source,
Desiccant, Humidity Indicator)
113316-00
FTIR Desiccant packages and humidity label
113312-00
FTIR Desiccant package
106975-00
1 year
FTIR Humidity Indicator
113313-00
2 years
FTIR IGS HeNe Laser Assembly
106963-00
FTIR IGS Source Assembly
106976-00
FTIR IGS DTGS Detector Assembly
113440-00
FTIR KBr Beamsplitter Assembly
106954-00
FTIR Pressure Sensor
113267-00
FTIR Pressure Sensor Cable 12' (Sensor to temp
controller)
110300-00
FTIR Temperature Sensor
113383-00
FTIR Heater Control Cable 12' (Sensor/Heater to temp
controller)
108009-00
FTIR Power Supply
109948-00
FTIR Sample Cell
113268-00
FTIR Cell Heater
113320-00
Assembly, Replacement, Heated Line (FTIR to Sample
System)
113390-00
USB Cable, 10' (FTIR to PC)
112796-00
Temperature Controller
Part Number
Temperature Controller Assembly
112701-00
Relay, SSR, Crydom 2425
103344-00
Replacement
Period
Replacement
Period
2 years
2 years
Replacement
Period
Thermo Fisher Scientific
Preventive Maintenance and Servicing
Replacement Parts List
Thermo Fisher Scientific
Fuse, 5.0 Amp, 250 VAC, TR5
108403-00
CALOGIX Temperature Controller Base
109713-00
CALOGIX Dual Temperature Module
109714-00
CALOGIX 4-20mA Module
109715-00
Temperature Controller PCBA
109933-00
Fuse, Cartridge, Slo-Blo, 25 Amp
112608-00
USB Cable, 10' (Temp Controller or FTIR to PC)
112796-00
PC
Part Number
PC (with NI boards)
112813-00
Console, 1U
112700-00
PCI Board, NI 32-Channel Analog
107260-00
PCI Board, NI 96-Channel Digital
112792-00
Cable, Ethernet
109996-00
Cable, NI Analog I/O 68 Conductor, 2M
110039-00
Cable, NI Digital I/O 100 Conductor, 2M
112496-00
Pneumatic Panel
Part Number
Pneumatic Panel Assembly (2 Gauge)
112689-02
Assembly, Replacement, Pressure Reducer
113310-00
Assembly, Replacement, Pressure Gauge, 0 to 100 PSI
113311-00
Solenoid Valve, NO, 24V
112569-00
Solenoid Valve, NC, 24V
107259-00
Flow meter/Regulator, 10 LPM
112969-00
Flow meter/Regulator, 1.5 LPM
112970-00
Electrical Panel
Part Number
Electrical Panel Assembly
112790-01
Switch, Ethernet, 5-Port, Industrial
103530-00
Power Supply, 24VDC, 120W
112227-00
Solid State Relay, DIN Rail, 24VDC
112498-00
Solid State Relay, DIN Rail, 5VDC
112224-00
Digital I/O 100 Pin to 32 Terminal Breakout PCBA
112165-00
Analog I/O 68 Terminal Breakout PCBA
109665-00
Cable, Temperature Alarm, 10' (Temp Controller to
Electrical Panel)
110252-00
Replacement
Period
Replacement
Period
Replacement
Period
Omni FTIR Multi Gas CEMS Instruction Manual
5-5
Preventive Maintenance and Servicing
Safety Precautions
Safety
Precautions
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. ▲
CAUTION The safety instructions specific to the plant and process are to be
consulted prior to any maintenance work. ▲
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. ▲
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. ▲
Cleaning the
System
During normal operation, the system may become dirty over time,
depending on the environment in which it is installed. The system may be
cleaned, keeping in mind the following warning and important 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. ▲
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. ▲
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. ▲
5-6
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Thermo Fisher Scientific
Preventive Maintenance and Servicing
Maintenance for the Sample Probe
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. ▲
WARNING High surface temperatures! Wear protective gloves. ▲
WARNING Flush probe in the case of toxic gases. ▲
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. ▲
Important Note For any sample probe service procedures that are not
covered in this manual, please consult the M&C operator’s manual. See the
“Other Manuals” on page 1-10. ▲
Replacing the Filter
Element and
Graphite Seals
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 surface temperatures present. Allow sufficient time to
cool. ▲
1. Flush the probe with inert gas or air to clear any toxic gases.
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Omni FTIR Multi Gas CEMS Instruction Manual
5-7
Preventive Maintenance and Servicing
Maintenance for the Sample Probe
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.).
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).
5-8
Omni FTIR Multi Gas CEMS Instruction Manual
Thermo Fisher Scientific
Preventive Maintenance and Servicing
Maintenance for the Sample Probe
Figure 5–2. Filter Housing Lid Assembly
6. 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.
7. Inspect the 3 graphite gasket filter element seals and replace if
necessary.
8. 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.
9. Before re-installing the filter housing lid assembly, the filter housing
itself can be cleaned using a clean cloth dampened only with clean
water.
10. 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.
11. Re-install the probe protection shield onto the probe. Close the two
pressure clamps to secure the shield to the probe assembly.
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Omni FTIR Multi Gas CEMS Instruction Manual
5-9
Preventive Maintenance and Servicing
Maintenance for the Sample Probe
12. Power up the probe by turning on the Probe circuit breaker on the
breaker box to complete the procedure.
Replacing the
Pre-filter
Use the following procedure to replace the pre-filter 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. ▲
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 prefilter.
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 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.
5-10
Omni FTIR Multi Gas CEMS Instruction Manual
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 the
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.
Maintenance and
Servicing of the
FTIR Analyzer
Components
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 problems with the analyzer, contact technical
support. Also refer to the Antaris IGS manual in the “Other Manuals” on
page 1-10. ▲
Checking and
Replacing the
Desiccant
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. ▲
CAUTION Avoid burn and fire hazards. Do not attempt to regenerate spent
desiccant packets. ▲
Thermo Fisher Scientific
Omni FTIR Multi Gas CEMS Instruction Manual
5-11
Preventive Maintenance and Servicing
Maintenance and Servicing of the FTIR Analyzer Components
Equipment Required:
Phillips screwdriver
Hex wrench, 3/32-inch
Desiccant packet
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. 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 “Replacing the
Humidity Indicator”.
Figure 5–3. Locating the humidity Indicator
3. 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.
4. 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).
5-12
Omni FTIR Multi Gas CEMS Instruction Manual
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 mounting screws
to complete the procedure.
Replacing the
Humidity Indicator
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.
Thermo Fisher Scientific
Omni FTIR Multi Gas CEMS Instruction Manual
5-13
Preventive Maintenance and Servicing
Maintenance and Servicing of the FTIR Analyzer Components
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”.
3. Lift the tab on the indicator cover and remove the indicator.
4. Insert the new indicator (it should be blue) into the indicator cover.
5. 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.
6. 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.
Cleaning or
Replacing the Fan
Filter
The cooling fan 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. ▲
Equipment Required:
Phillips screwdriver
Flat blade screwdriver
Fan filter (optional)
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. Using the flat blade screwdriver, carefully pry the fan cover grill off of
the fan filter housing. Remove the dirty filter (Figure 5–5).
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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 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. ▲
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
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Maintenance and Servicing of the FTIR Analyzer Components
for damage to sensitive components. Damage to components inside the
analyzer will affect the performance of the system. ▲
Replacing the
Source
Use the following procedure to replace the source in the FTIR analyzer.
The source is located behind the right side 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. ▲
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. ▲
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. ▲
Important Note The FTIR analyzer source is pinned in place and prealigned. 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 onsite maintenance personnel who have been trained by us replace the
source. ▲
Important Note Never touch the new source element with your bare
fingers. Skin oils or other deposits on the element will shorten its life. ▲
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.
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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).
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
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6. Grasp the source assembly by the ceramic base. Lift it straight up until
it clears the alignment pin and remove it from the analyzer.
7. 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
8. 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.
9. Connect the source power supply cable to the power distribution cable.
10. 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.
11. Power up the FTIR by turning on the FTIR circuit breaker on the
breaker box.
12. Slide the FTIR drawer back into the rack, then use the Phillips
screwdriver to re-install the FTIR cover panel and its mounting screws.
13. 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.)
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Maintenance and Servicing of the FTIR Analyzer Components
Replacing the Laser
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. ▲
CAUTION High surface temperatures present. Allow sufficient time to
cool. ▲
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. ▲
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. ▲
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 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
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Maintenance and Servicing of the FTIR Analyzer Components
analyzer. Be sure to note or mark their locations to facilitate reconnection if needed.
3. 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”.
4. 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.
5. Locate the laser assembly inside the analyzer and then unplug the laser
power supply cable from the power distribution cable (Figure 5–9).
Figure 5–9. Locating the Laser Assembly
6. 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 the clamp release hooks near the
bottom of the analyzer compartment (Figure 5–10).
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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. ▲
9. Place the springs over the laser tube and re-attach the clamp release
hooks.
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Maintenance and Servicing of the FTIR Analyzer Components
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, and then line
up the mounting holes. Install the mounting screws using the 3/32inch 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 reconnect 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.)
Replacing the
Detector
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. ▲
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. ▲
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.
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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. ▲
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 tight.) 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).
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Maintenance and Servicing of the FTIR Analyzer Components
Figure 5–12. Locating the Detector Assembly
5. Before installing the new DTGS 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
pins, taking care to engage the connector. Tighten the thumbscrews on
the base plate until snug.
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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 cables 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.
Replacing the
Beamsplitter
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. ▲
CAUTION High surface temperatures present. Allow sufficient time to
cool. ▲
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. ▲
Important Note 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. ▲
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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).
Figure 5–14. FTIR Wiring and Tubing Connections
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Maintenance and Servicing of the FTIR Analyzer Components
4. 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.
5. 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.
6. 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.
7. 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.
8. 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 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).
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Maintenance and Servicing of the FTIR Analyzer Components
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).
Figure 5–17. Removing the Beamsplitter
11. Grasp the new beamsplitter by the handle with the label facing you.
Again, use the flat blade screwdriver to pry 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.
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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
Air Filters
Use the following procedure to replace the filters in the filter bracket
assembly.
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).
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Replacing the Air Filters
Figure 5–19. Removing 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).
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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. ▲
Removing the
Purge Gas
Generator
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
servicing information. See the “Other Manuals” section at the end of
Chapter 1. ▲
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).
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Removing the Purge Gas Generator
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).
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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. ▲
Removing the
Left Side Panel
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.
1. 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).
Figure 5–23. Lock and Hand Grips
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Removing the FTIR
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.
Removing the
FTIR
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. ▲
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).
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Removing the FTIR
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
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Removing the FTIR
5. Note or mark the position of wiring and fittings to facilitate reconnection.
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 (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.
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Removing the FTIR
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.
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Replacing the FTIR Power Supply
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”. ▲
Replacing the
FTIR Power
Supply
Use the following procedure to replace the FTIR power supply.
Equipment Required:
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.
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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
Temperature
Sensor
Use the following procedure to replace the FTIR RTD temperature sensor.
Equipment Required:
Wrench, 7/16-inch
Phillips screwdriver
Temperature sensor
CAUTION High surface temperatures present. Allow sufficient time to
cool. ▲
1. Shut down the FTIR heaters by turning off the Temperature Control
circuit breaker on the breaker box and allow it to cool for 1 hour. This
will also put the 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).
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Replacing the Temperature Sensor
Loosen fitting to remove
Temperature Sensor
Figure 5–30. FTIR Cell RTD 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 loosely. 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.
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Replacing the Pressure Sensor
Replacing the
Pressure Sensor
Use the following procedure to replace the FTIR pressure sensor.
Equipment Required:
Wrench, 9/16-inch and 3/4-inch
Phillips screwdriver
Small Phillips screwdriver
Pressure sensor
CAUTION High surface temperatures present. Allow sufficient time to
cool. ▲
1. Shut down the FTIR heaters by turning off the Temperature Control
circuit breaker on the breaker box and allow it to cool for 1 hour. This
will 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).
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Replacing the Gas Cell
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.
Replacing the
Gas Cell
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
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Replacing the Gas Cell
CAUTION High surface temperatures present. Allow sufficient time to
cool. ▲
1. Shut down the FTIR heaters by turning off the Temperature Control
circuit breaker on the breaker box and allow it to cool for 1 hour. This
will 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 reconnection.
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).
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Figure 5–32. FTIR Heated Gas Cell Replacement
10. Using the 7/64-inch hex wrench, remove the 4 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.
Gas Cell
Alignment
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
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Gas Cell Alignment
Figure 5–33. Gas Cell Mirror Configuration
CAUTION High surface temperatures present. Allow sufficient time to
cool. ▲
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. ▲
Important Note It is recommended that only our certified service engineers
align the mirrors in the gas cell. There is a potential for damage to sensitive
components or improper alignment, which will affect the performance of
the system. ▲
1. Be sure that the FTIR heaters are still off from the “Replacing the Gas
Cell” procedure, that is, the Temperature Control circuit 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).
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Gas Cell Alignment
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 gas 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
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Gas Cell Alignment
1
2
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,
and mirror #3 is used to position the beam image on the objective
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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.
input
output
8
1
6
3
4
5
2
7
9
Figure 5–38. Typical Image Pattern on the Field Mirror
Figure 5–39. Location of Components on Back Plate of Gas Cell
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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. ▲
9. Adjust the field mirror to get the image centered on the 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.
10. 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.
11. 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 exiting beam properly positioned in
the output field mirror cutout. For the 5.2 meter gas cell, the
maximum number of passes should be 20, with the number of 5 images
on the bottom row as shown in Figure 5–40.
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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.
Figure 5–41. Typical Interferometer of Omni FTIR CEMS
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Replacing the Gas Cell Heater
Note that the gas cell is aligned by the manufacturer before being delivered
to customers. 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. Reinstall 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.
CAUTION High surface temperatures present. Allow sufficient time to
cool. ▲
14. For the fine alignment adjustment, only the input vertical and
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” button to complete the gas cell
alignment.
15. 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
Gas Cell Heater
Use the following procedure to replace the FTIR gas cell heater.
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
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Replacing the Gas Cell Heater
Gloves
Flat blade screwdriver
High temperature tape
Gas cell heater
CAUTION High surface temperatures present. Allow sufficient time to
cool. ▲
1. Shut down the FTIR heaters by turning off the Temperature Control
circuit breaker on the breaker box and allow it to cool for 1 hour. This
will 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).
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).
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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.
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Replacing the Heated Lines
Replacing the
Heated Lines
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. ▲
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 “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.
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Replacing the PC
Figure 5–45. Heated Line Replacement
8. Using the 9/16-inch wrench, 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 reconnection.
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
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Replacing the PC
1. Shut the PC down through Windows, and then shut off the
PC/Console circuit breaker on the breaker box.
2. Using the Phillips screwdriver, remove the blank panel in the front of
the system directly above the PC and console.
3. 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.
4. 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 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).
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6. 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).
7. Remove the PC from the rack by depressing the button on each slide
rail and pulling the PC out (Figure 5–46).
8. Using the Phillips screwdriver, remove the slide rails from each side of
the PC, noting the orientation (Figure 5–46).
9. Using the Phillips screwdriver, re-install the slide rails onto the new
PC.
10. 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).
11. Re-attach the cable routing arm to the bracket on the rear of the PC by
lining up the holes and inserting the pin that was removed earlier.
12. Re-connect all of the cables to the rear of the PC in the proper
locations. Follow steps 1–3 in reverse order to complete the procedure.
Replacing the PC
Console
Use the following procedure to replace the PC Console (monitor and
keyboard).
Equipment Required:
Phillips screwdriver
PC Console
1. 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.
2. Using the Phillips screwdriver, remove the blank panel in the front of
the system directly above the PC console (Figure 5–46).
3. 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).
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Replacing the PC Console
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).
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Replacing the National Instruments Boards
Figure 5–48. Connecting PC Console Rack Sliders
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 4 cables to the 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.
Replacing the
National
Instruments
Boards
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
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Replacing the National Instruments Boards
touching any internal components. When the PC is unplugged, the chassis
is not at earth ground. ▲
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 front 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
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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
Board.)
Figure 5–52. Removing NI Board Mounting Screw
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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 into 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.
Temperature Control
Box Components
Replacing External
Fuses
Use the following procedures to replace the temperature control box
internal and external components.
Use the following procedure to replace the 2 external fuses on the FTIR
temperature control box.
Equipment Required:
Phillips screwdriver
Flat blade screwdriver
Replacement Fuses
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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).
Figure 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).
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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.
Replacing Internal
Components
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 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
touching any internal components. When the temperature controller is
unplugged, the chassis is not at earth ground. ▲
Removing and Installing
the Cover
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.
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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 the 4 front panel screws that secure the
temperature control box to the rack to complete the procedure.
6. Turn on the Temperature Control circuit breaker on the breaker box to
complete the procedure.
Replacing the Internal
Fuses
Use the following procedure to replace any of the internal fuses in the
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. ▲
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.
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Temperature Control Box Components
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
Temperature Control
Board
Use the following procedure to replace the temperature control board
inside of the temperature control box.
Equipment Required:
Phillips screwdriver
Small Phillips screwdriver
Temperature Control Board
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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. ▲
1. Remove the temperature control box cover per the previously
mentioned procedure “Removing and Installing the Cover”.
2. It is 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.
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”.
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Replacing the Power
Relays
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. ▲
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 access 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 reconnection.
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.
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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
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 the temperature control box cover per the above procedure
“Removing and Installing the Cover”.
Replacing the
Temperature Control
Modules
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. ▲
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.
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3. 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.
4. To remove the wires from the control module, pull the terminal block
connectors off of the front and rear of the module.
5. 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.
6. 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.
7. 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.
8. Re-install the temperature control box cover per the above procedure
“Removing and Installing the Cover”.
Replacing the
Temperature Control
Base Unit
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
amounts of static electricity. A properly grounded antistatic wrist strap
must be worn while handling any internal components. ▲
1. Remove the temperature control box cover per the previously
mentioned procedure “Removing and Installing the Cover”.
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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 threaded
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 the temperature control box cover per the above procedure,
“Removing and Installing the Cover”.
Electrical Panel
Components
Thermo Fisher Scientific
Use the following procedures to replace the electrical panel components
(Figure 5–56 and Figure 5–57).
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Figure 5–56. Electrical Panel Component Location (Front Side)
Figure 5–57. Electrical Panel Component Location (Rear Side)
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Replacing the
Ethernet Switch
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. ▲
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, loosen 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.
Replacing the Solid
State Relays
Thermo Fisher Scientific
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).
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Equipment Required:
Phillips screwdriver
Flat blade screwdriver
Relays
1. 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.
2. 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.
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. 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.)
6. 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.
7. 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.
8. Re-install the electrical panel by following steps 1–4 in reverse order.
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Replacing the 24V
Power Supply
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. ▲
1. Shut off the 24VDC circuit breaker on the breaker box.
2. 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.
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.
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8. Using the small Phillips screwdriver, re-attach the wiring to the power
supply in the proper locations.
9. Re-install the electrical panel by following steps 1–4 in reverse order.
Sample System
Heater Assembly
Components
Use the following procedures to replace the sample system heater assembly
components.
Removing the
Sample System
Heater Assembly
and Cover
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. ▲
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.
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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 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.
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7. 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.
8. 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.)
9. Disconnect the flag lugs from both sides of the thermostat to be able to
move the wiring out of the way.
10. Pull the pieces of insulation off to gain access to the internal hardware.
Note the placement of the insulation and wiring to facilitate reassembly.
11. To re-install the cover, carefully place 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.
12. Follow steps 1–8 in reverse order to complete the procedure.
Replacing the
Thermostat
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. ▲
1. 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).
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2. 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.
3. If the thermostat is bad, again remove the sample system heater
assembly cover. Use the Phillips screwdriver to remove the 2 screws that
mount the thermostat to the plate and remove it (Figure 5–59).
4. Install the new thermostat by mounting it to the plate with the
mounting screws, using the Phillips screwdriver.
5. Re-install the sample system heater assembly cover by referring to
procedure “Removing the Sample System Heater Assembly and Cover”.
Replacing the
Eductor Pump
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. ▲
1. 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).
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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 screws that secure it to the heater block
(Figure 5–59).
Figure 5–59. Sample System Heater Assembly Component Replacement and
Heated Block Removal
4. Using the 9/64-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.
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7. 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.
8. 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.
9. 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.
10. 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.
11. Turn the air regulator back down to zero PSI. Using the wrenches,
disconnect the air 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.
12. 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.
13. Follow steps 1–4 in reverse order to complete the procedure.
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Removing the
Heated Block
Assembly
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. ▲
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 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.
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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.
Replacing the Check
Valve
Use the following procedure to replace the check 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
Check valve
CAUTION High surface temperatures present. Allow sufficient time to
cool. ▲
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.
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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).
Figure 5–60. Check Valve Replacement
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.
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.
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9. It is 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 down 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
Assembly and Cover”, in reverse order to complete the procedure.
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Preventive Maintenance and Servicing
Sample System Heater Assembly Components
Replacing the
Sample Solenoid
Valve
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. ▲
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
(Figure 5–60).
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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.
Figure 5–61. Solenoid Valve Replacement
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Sample System Heater Assembly Components
11. 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).
12. 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).
13. 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.
14. Use the wrenches to install the 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.
15. 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).
16. 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).
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Sample System Heater Assembly Components
17. Using the 9/64-inch hex wrench, re-install the top and bottom valve
clamp blocks into their original positions, tightening the mounting
screws until snug.
18. 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.
19. 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.
20. To leak test the other side of the union fitting that connects to the
copper tubing, disconnect the air line with the 1/4-inch Swagelok
union fitting from the Flowback line using the wrenches. Connect the
air line with the union fitting to the Instrument Zero line, and then
install the 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 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. Reconnect the inlet of the purge gas generator to its original position.
This completes the leak test.
21. 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.
22. 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.
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Preventive Maintenance and Servicing
Pneumatic Panel Components
Pneumatic Panel
Components
Use the following procedures to replace the pneumatic panel components.
Figure 5–62. Pneumatic Panel Components Replacement
Replacing the
Pressure Reducers
Use the following procedure to replace the pressure reducers on the
pneumatic panel. The procedure is the same for either pressure reducer.
Equipment Required:
Wrench, 9/16-inch
Adjustable wrench with a 1 1/8-inch minimum 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.
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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. At the 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. At the 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 the 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. Set the 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
Pressure Gauges
Use the following procedure to replace the pressure gauges on the
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.
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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 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
Solenoid Valves
Use the following procedure to replace the solenoid valves on the
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
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Pneumatic Panel Components
Nut driver, 11/32-inch
Solenoid valve
1. Remove the left side panel per procedure “Removing the Left Side
Panel” for better accessibility.
2. If the probe spike or probe span solenoid valve is being replaced, turn
off the HCl/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).
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).
4. Using the 11/32-inch nut driver, loosen and remove the 2 nuts that
mount the valve 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).
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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 fittings) 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
Meters
Use the following procedure to replace the flow meter/regulators on the
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
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Pneumatic Panel Components
Small flat blade screwdriver
Wrench, 9/16-inch
Nut driver, 11/32-inch
Flow meter/regulator
1. Remove the left side panel per procedure “Removing the Left Side
Panel” for better accessibility.
2. If the probe spike or probe span flow meter is being replaced, turn off
the HCl/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 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. 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).
4. 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).
5. 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).
6. 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.
7. 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.
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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 11/32inch nut driver, tighten them until snug (Figure 5–62).
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 Instrument 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 reconnecting the wire to the connector on the electrical panel.
12. Re-install the left side panel to complete the procedure.
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Preventive Maintenance and Servicing
Service Locations
Service
Locations
For additional assistance, Thermo Fisher Scientific has service available
from exclusive distributors worldwide. Contact one of the phone numbers
below for product support and technical information or visit us on the web
at www. thermoscientific.com/aqi.
1-866-282-0430 Toll Free
1-508-520-0430 International
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Omni FTIR Multi Gas CEMS Instruction Manual
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Chapter 6
Troubleshooting
This chapter provides the following troubleshooting and service support
information for the Omni FTIR Multi Gas CEMS:
●
“Concentration Errors” on page 6-3
●
“Boot Up Error/IMACC Software Error” on page 6-4
●
“Temperature Errors” on page 6-4
●
“Cell Pressure Errors/Sampling System Errors” on page 6-5
●
“Communication Errors” on page 6-6
●
“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
●
Visual Inspection of Operating Parameters:
●
Pressure on system regulator on right side of rack:
●
●
●
Pressures on pneumatic panel:
●
CO2 Free Air = 2.0 – 3.0 bar (30 – 44 PSI)
●
Pump Air = 1.0 – 3.0 bar (12 – 44 PSI)
Flows on pneumatic panel:
●
Thermo Fisher Scientific
System pressure = 75 PSI
FTIR Purge Air = 1.0-1.5 LPM
Omni FTIR Multi Gas CEMS Instruction Manual
6-1
Troubleshooting
Service Locations
●
●
●
●
Instrument Zero Air = 6 LPM when in instrument zero mode
●
Flowback = 3 LPM when in instrument zero mode
●
Probe Zero Cal Gas = 6 LPM when in probe zero mode
●
Probe Span Cal Gas = 6 LPM when in probe span mode
●
Probe Spike Cal Gas = ~0.5 LPM when in probe spike mode
Temperatures in IMACC software:
●
Heated sample line = 185 Deg. C
●
Heated pump/valve assembly = 180 Deg. C (after 30 minute
ramp-up)
●
FTIR Sample Cell = 180 Deg. C (after 2 hour ramp-up)
●
Internal Heated Lines (if installed) = 180 Deg. C
LED indicators on FTIR:
●
“Power” should be on continuously, if not check circuit breaker
and power supply
●
“Laser” should be on continuously, if not check laser assembly
●
“Source” should be on continuously, if not check source
●
“Scan” should be flashing during normal operation, if not check
if IMACC software is running
Readings in IMACC software:
●
FTIR Vmax > 0.9
●
FTIR Vmin < 0.0
●
If voltages are too small, check source, beamsplitter, detector,
cell windows and cell mirrors.
●
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.
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Troubleshooting
Concentration Errors
Concentration
Errors
Low Concentration
●
System fail-safe
●
●
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.
Leaks
●
Check Probe tubing for melted or cut sections.
●
Check for loose fittings.
●
Check for cold spots – ensure proper insulation at both ends of
the heated umbilical.
Low or High Concentration
●
Improper cell temperature reading
●
●
Improper cell pressure reading
●
●
●
Check “Last Pressure” screen readout in ‘Status’ on Imacc
monitor software main screen; see ‘Cell Pressure
Errors/Sampling System Errors’.
Instrument air issues
●
Check that instrument air regulator on side of rack reads at least
75 PSI.
●
Check that CO2 Free Air Gauge on pneumatic panel reads at
least 22 PSI.
●
Check that indicating filter on FTIR purge gas generator on
side of rack is green. If yellow, service purge gas generator and
filters.
Bad background file
●
Thermo Fisher Scientific
Check “Last Temperature” screen readout in ‘Status’ on
IMACC monitor software main screen; see ‘Temperature
Errors’.
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, “IMACC Script Setting” for
proper script configuration.
Omni FTIR Multi Gas CEMS Instruction Manual
6-3
Troubleshooting
Boot Up Error/IMACC Software Error
●
Bad spectrometer detector or source
●
●
Concentration not updating in IMACC
●
●
See ‘Communications Errors/No Communications with FTIR’.
H2O concentrations <2000 ppm during zero checks
●
Boot Up
Error/IMACC
Software Error
Check ‘Last Vmax’ and ‘Last Vmin’ in ‘Status’. Nominally Last
Vmax >4.0 Volts, Last Vmin <-1.0 Volts. Readings of <±0.5
Volts indicate detector or source failure. Marginal readings may
require more detailed analysis by Thermo Fisher Scientific
Technical Support Department.
Make sure hydrator is not filled with water.
System does not start automatically
●
Verify the following programs are in the setup:
Omni.layout
ImaccCurrentLoop
ImaccModbus
ImaccModbusTCP
●
Temperature
Errors
Bad temperature readings – Either in ‘Status’ or in Modbus block in
IMACC script (See Appendix E, “IMACC Script Setting”.)
●
●
“Last Temperature” reading in ‘Status’ on ImaccMonitor software
main screen reads 185.000000.
●
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.
“Pump” sampling box temperature reading is low, but other
temperatures are OK.
●
●
Omni FTIR Multi Gas CEMS Instruction Manual
Check thermostat inside pump box (See Chapter 5, “Preventive
Maintenance and Servicing”.
ERROR_QUANT_TEMPRESSCON in ImaccMonitor
●
6-4
See “System Startup” in Chapter 2.
Check temp control breaker and AC wiring connections.
Thermo Fisher Scientific
Troubleshooting
Cell Pressure Errors/Sampling System Errors
●
●
●
Cell Pressure
Errors/Sampling
System Errors
Low temperature
●
Main power supply, insufficient power for heaters, check circuit
breaker 230 VAC power supply.
●
Calogix controller error, see Appendix D, “Calogix Setup”.
●
Burned out heater element, see Chapter 7, “System Component
Description” and check terminals 1&2 of heater cable.
●
Blown fuse in temperature controller (See Chapter 5,
“Preventive Maintenance and Servicing”.
●
Broken temperature sensor, see Chapter 7, “System
Component Description” and check terminals 5&6 of heater
cable.
High temperature
●
Calogix controller error, see Appendix D, “Calogix Setup”.
●
Broken temperature sensor, see Chapter 7, “System
Component Description” and check terminals 5&6 of heater
cable.
Proper cell pressure range must be determined during setup and
installation (See Chapter 2.)
●
●
Thermo Fisher Scientific
Check power and communications connecting between
temperature control board and controller base assembly inside
temperature control box.
Low pressure in Cell
●
Check for blocked flow in sample system.
●
Check for correct eductor pressure, eductor pressure too high.
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
●
●
●
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.
System in failsafe mode – zero air
●
Check alarm system continuity at 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”.
“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.
External communications errors
●
●
Ethernet not communicating
●
Check IMACC Modbus TCP server running on PC.
●
Check power LED on ADAM hub Chapter 7, “System
Component Description”. If off, check 24 VDC breaker and
wiring to and from power supply.
●
Check Ethernet cable between computer and ADAM hub; see
Chapter 7, “System Component Description”.
Serial
●
Check IMACC Modbus TCP server running on PC.
●
Check serial cable connection.
●
Check ‘Hardware’ setup in Windows system menu.
Internal communications errors
●
No temperature readings or heating of system components
●
●
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Omni FTIR Multi Gas CEMS Instruction Manual
See ‘Temperature errors’ in this chapter.
No communications with FTIR
Thermo Fisher Scientific
Troubleshooting
I/O Errors
●
●
●
Check FTIR LED activity light Chapter 7, “System
Component Description”. If no LEDs on, check 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
●
I/O Errors
See ‘Temperature errors’ in this chapter.
4-20mA analog output errors
●
Wrong concentration reported for one or more gases
●
Check ImaccCurrentLoop server “value” and “outputs (mA)”
readings. If “value” doesn’t look correct, see “Concentration
Errors”. Otherwise, if “output (mA)” doesn’t look correct,
check the “channel”, “min cutoff”, and “max cutoff” settings in
ImaccCurrentLoop; see Chapter 3, “Imacc CurrentLoop
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 reporting
the expected mode
●
Thermo Fisher Scientific
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 SYSTEM.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).
●
●
Check wiring from terminal block to breakout board on
opposite side of electrical panel.
●
Check cable from breaker board to NI PCI-6709 board inside
PC.
Maintenance digital output is not reporting the expected mode
●
Service
Locations
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.
For additional assistance, Thermo Fisher Scientific has service available
from exclusive distributors worldwide. Contact one of the phone numbers
below for product support and technical information or visit us on the web
at www. thermoscientific.com/aqi.
1-866-282-0430 Toll Free
1-508-520-0430 International
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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:
Thermo Fisher Scientific
●
“Sample Probe” on page 7-2
●
“Temperature Controller” on page 7-3
●
“Heated Sample Line” on page 7-3
●
“Heated Pump/Valve Assembly” on page 7-4
●
“Hydrator” on page 7-4
●
“Pneumatic Panel” on page 7-4
●
“FTIR” on page 7-7
●
“Air Purifier” on page 7-12
●
“Industrial PC” on page 7-13
●
“Console” on page 7-14
●
“Datalogger” on page 7-14
●
“Electrical Panel Assembly” on page 7-14
●
“AC Power Input” on page 7-15
Omni FTIR Multi Gas CEMS Instruction Manual
7-1
System Component Description
Sample Probe
Figure 7–1. FTIR Multi Gas CEMS System Component Layout
Sample Probe
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
7–2). 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.
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Thermo Fisher Scientific
System Component Description
Temperature Controller
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.
Temperature
Controller
The system includes a temperature control module which is used to control
the temperatures of the following system components:
●
FTIR cell
●
Heated pump/valve assembly
●
Heated sample lines
In addition, the FTIR cell pressure is measured with this controller.
A USB connection is included to report the system temperatures and
pressure to the PC.
Heated Sample
Line
Thermo Fisher Scientific
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
Assembly
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.
Hydrator
Pneumatic Panel
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Omni FTIR Multi Gas CEMS Instruction Manual
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 by the system.
The pneumatic panel (Figure 7–3) includes pressure regulators and flow
meter/regulators to control various system flows:
●
Ejector Pump Pressure (7.3 – 43.5 PSI)
●
CO2 Free Air Pressure (22 – 29 PSI)
●
FID Combustion Air Pressure (optional, 45 PSI)
●
FTIR Purge Gas Flow (1.0 L/min)
●
FTIR Zero Air Flow (4.0 L/min)
●
Sample Line Flowback Flow (4.0 L/min)
●
Probe Zero Flow (6.0 L/min)
●
Probe Span Flow (6.0 L/min)
●
Probe Spike Flow (0.4 L/min)
Thermo Fisher Scientific
System Component Description
Pneumatic Panel
Figure 7–3. Pneumatic Panel
Sample mode
Blowback
Instrument
Background Scan
and Flowback
Thermo Fisher Scientific
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-filter. Depending on
the particulate loading in the tested stack, the blowback can be executed
multiple times per day.
During the instrument background scan and flowback mode, the sample
control valve is closed, and the instrument zero control valve is opened.
The CO2 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 CO2 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 the cal/zero port at a reduced rate (typically
not more than 10% 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.
Figure 7–4. Sample and Calibration Gas Flow Diagram
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Omni FTIR Multi Gas CEMS Instruction Manual
Thermo Fisher Scientific
System Component Description
FTIR
FTIR
The FTIR analyzer (Figure 7–5) measures the interaction of infrared (IR)
radiation with 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
relationship between the position of the moving mirror relative to the fixed
mirror and the wavelength of the light.
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Omni FTIR Multi Gas CEMS Instruction Manual
7-7
System Component Description
FTIR
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
ADC
FT
Interferogram
Single-beam spectrum
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
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
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Omni FTIR Multi Gas CEMS Instruction Manual
Thermo Fisher Scientific
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.
Optical Components
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-inplace for easy service and maintenance.
Figure 7–7. Spectrometer Compartment
Source
Thermo Fisher Scientific
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 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. ▲
Laser
Mirrors
Aperture
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 prealigned and needs no adjustment when it is installed.
The analyzer uses a number of precision mirrors to focus and direct the
infrared beam for optimum performance.
The aperture is a fixed-diameter opening that optimizes spectral 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.
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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. ▲
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 reliably 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
Jacket
Thermo Fisher Scientific
The 5.2-meter gas cell is supplied with a heating jacket. The heating 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.
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
Computer Interface
Humidity Control
Air Purifier
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Omni FTIR Multi Gas CEMS Instruction Manual
The FTIR analyzer provides sampling through the gas cell using an upper
sample beam path. The gas cell interface includes:
●
A stainless steel, pin-aligned mechanical interface to mount the gas cell
to the analyzer
●
A stainless steel mechanical interface to maintain the gas cell gasket seal
on the sample beam path
●
An optical interface to allow the infrared beam to pass between the
analyzer and the gas cell sample beam path
●
An electrical interface used by the software to control the gas cell
temperature with the heater
●
A power interface to support the gas cell heater, temperature controller
and pressure sensor
Interface between the FTIR analyzer and the computer is provided through
a USB interface.
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.
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
CO2 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, CO2-free air from a standard compressed air supply.
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 & optional FID, and report this data.
The PC provides several methods for establishing data communication
with a DCS/PLC including:
●
Modbus protocol (RS-232 Serial or Ethernet)
●
Analog output connections
●
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 30screw terminal connector board on the electrical panel assembly.
Console
A 1U 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
Electrical Panel
Assembly
7-14
Omni FTIR Multi Gas CEMS Instruction Manual
An optional data logger may be used to:
●
Capture user-selected measurement data in real-time
●
Allow the operator to trigger calibration sequences
●
Manually and automatically control calibration gases
●
Mark data taken during any calibration purge or activity
The electrical panel (Figure 7–11) includes screw terminal connections for
the following user connections:
●
4-20 mA Analog Outputs (one for each gas)
●
Digital solid state relay outputs (Temperature Alarm, Pressure Alarm,
Maintenance, FID Alarm, FTIR Data Valid, System Gas Mode)
●
Digital Inputs (System Gas Mode)
●
Probe Connections (AC Power, Temperature Alarm, and Valve
Control)
Thermo Fisher Scientific
System Component Description
AC Power Input
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
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.
Figure 7–12. AC Mains
Thermo Fisher Scientific
Omni FTIR Multi Gas CEMS Instruction Manual
7-15
Appendix A
Warranty
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, which 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
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
Thermo Fisher Scientific
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 DEFECTIVE PRODUCT
SHALL BE THE SOLE REMEDY OF BUYER 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.
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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 ImaccModbus 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 Omni FTIR Multi Gas CEMS Modbus Protocol
specification, see the following topics:
●
“Serial Communication Parameters” on page B-2
●
“TCP Communication Parameters” on page B-2
●
“Application Data Unit Definition” on page B-2
●
“Function Codes” on page B-3
●
“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.
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Omni FTIR Multi Gas CEMS Instruction Manual
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Modbus Protocol
Serial Communication Parameters
Serial
Communication
Parameters
The Modbus/RTU protocol is supported using the ImaccModbus 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
: 1 to 255 (70 is default)
In addition, the poll delay (10 mS) and response delay (0 mS) are userprogrammable.
TCP
Communication
Parameters
Application Data
Unit Definition
The Modbus/TCP protocol is supported using the ImaccModbusTCP
server. The register definition is the same as for the serial interface.
TCP connection port for Modbus
Here are the Modbus ADU (Application Data Unit) formats over serial
and TCP/IP:
Serial:
B-2
: 502 (user configurable)
Slave Address
Function Code
Data
TCP/IP: MBAP Header Function Code
Data
Error Check
Slave Address
The Modbus slave address is a single byte in length. This value can be
between 1 and 255 decimal (i.e. 0x01 hex to 0xFF hex). The default value
is 70.
MBAP Header
In Modbus over TCP/IP, a Modbus Application Protocol Header (MBAP)
is used to identify the message. This header consists of the following
components:
Omni FTIR Multi Gas CEMS Instruction Manual
Thermo Fisher Scientific
Modbus Protocol
Function Codes
Function Code
Transaction Identifier
2 Bytes
0x0000 to 0xFFFF (Passed back in response)
Protocol Identifier
2 Bytes
0x00 (Modbus protocol)
Length
2 Bytes
0x0000 to 0xFFFF (Number of following bytes)
Unit Identifier
1 Byte
0x00 to 0xFF (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.
Data
The data field varies depending on the function. For more description of
these data fields, see “Function Codes” below.
Error Check
In Modbus over serial, an error check is included in the message. This is
not necessary in Modbus over TCP/IP because the higher-level protocols
ensure error-free transmission. The error check is a two-byte (16 bit) CRC
value.
Function Codes
This section describes the various function codes that are supported by the
Omni FTIR Multi Gas CEMS.
(0x03) Read Holding
Registers
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.
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B-3
Modbus Protocol
Function Codes
Request
Function Code
1 Byte
0x03
Starting Address
2 Bytes
0x0000 to maximum allowed by instrument
Quantity of Registers
2 Bytes
1 to maximum allowed by instrument
Function Code
1 Byte
0x03
Byte Count
1 Byte
2 x N*
Register Value
N* x 2 Bytes
N = N or N+1
Response
*N = Quantity of Registers
Here is an example of a request and response to read registers 9–12:
Request
Field Name
(Hex)
Function
0x03
Starting Address Hi
0x00
Starting Address Lo
0x08
No. of Registers Hi
0x00
No. of Registers Lo
0x04
Response
Field Name
(Hex)
Function
0x03
Byte Count
0x06
Register Value Hi (9)
0x02
Register Value Lo (9)
0x2B
Register Value Hi (10)
0x00
Register Value Lo (10)
0x00
Register Value Hi (11)
0x00
Register Value Lo (11)
0x64
Register Value Hi (12)
0x00
Register Value Lo (12)
0x64
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.
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Modbus Protocol
Modbus Parameters Supported
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. ▲
Note For additional information on how to read registers and interpret the
data, refer to the “(0x03) Read Holding Registers” section in this
appendix. ▲
Table B–1. Modbus Read Registers
Thermo Fisher Scientific
Register Number
Variable
1&2
SO2 CONC
3&4
NO CONC
5&6
NO2 CONC
7&8
N2O CONC
9 & 10
NH3 CONC
11 & 12
HCl CONC
13 & 14
HF CONC
15 & 16
CO CONC
17 & 18
CO2 CONC
19 & 20
H2O CONC
21 & 22
SF6 CONC
101 & 102
SYSTEM STATUS
103 & 104
SYSTEM FLAGS
105 & 106
SAMPLE TEMP
107 & 108
PUMP TEMP
109 & 110
INLET TEMP
111 & 112
OUTLET TEMP
113 & 114
CELL TEMP
115 & 116
CELL PRES
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B-5
Modbus Protocol
Modbus Parameters Supported
Table B–2. Modbus Write Registers
Register Number
Variable
201
SYSTEM COMMAND
Table B–3. System Command Values
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Omni FTIR Multi Gas CEMS Instruction Manual
Value
Description
System Status Description
0
N/A
1
SAMPLE MODE
Sample solenoid valve is triggered, only sample flow
is pumped into the gas cell.
2
BLOWBACK MODE
System auto blowback is triggered. At the end of
three pulsed blowbacks, the system is switched
back to sample mode.
3
BACKGROUND MODE
Sample valve is closed, and instrument zero and
flowback flows are triggered. This mode is
independent of spectrum collection.
4
SAVE BACKGROUND
The FITR is commanded to collect the spectrum. In
general, this mode should be selected after mode 3
is trigged.
5
BACKGROUND MODE
& SAVE BACKGROUND
This mode is the combination of mode 3 and mode 4.
After flowing the zero air into the gas cell for five
minutes, the FTIR starts to collect zero air spectrum,
and then saves the spectrum to replace the file
“C:\backgrounds\bkg.spa”. At the end, the system is
switched back to sample mode.
6
CHECK ZERO 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.
7
CHECK SPIKE MODE
The standard gas flows into the probe at a flow rate
of 10% 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.
8
CHECK SPAN MODE
Calibration gas flows into the probe, and is pumped
into the gas cell. This mode is used to check the
system span
9
CHECK SPAN2 MODE
(N/A)
This mode is used to perform an extra span check, in
addition to the target gas.
10
CHECK SPAN3 MODE
(N/A)
Thermo Fisher Scientific
Modbus Protocol
Modbus Parameters Supported
Table B–4. System Flag Bits
Thermo Fisher Scientific
Value
Description
0x00000000
Data Valid
0x00000001
Data Invalid
Omni FTIR Multi Gas CEMS Instruction Manual
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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 data
communications.
For details on interfacing a DCS/PLC with the Omni FTIR Multi Gas
CEMS, see the following topics:
Introduction
●
“Introduction” on page C-1
●
“Connecting a DCS/PLC to the Omni FTIR Multi Gas CEMS” on
page C-2
●
“Establishing Communications” on page C-3
Typical communications 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)
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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
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
application. ▲
Figure C–1. Rear Panel Terminal Connectors
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Interfacing a DCS/PLC with the Omni FTIR Multi Gas CEMS
Establishing Communications
Establishing
Communications
Analog Outputs
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 Output Connections
Thermo Fisher Scientific
Analog No.
Signal
1
SO2
2
NO
3
NO2
4
N2O
5
NH3
6
HCl
7
HF
8
CO
9
CO2
10
H2O
11
SF6
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C-3
Interfacing a DCS/PLC with the Omni FTIR Multi Gas CEMS
Establishing Communications
Figure C–2. Analog Outputs
Digital I/O
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 accessing system status. Refer to
Figure C–3 to locate the pins on the rear panel terminal connector.
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Interfacing a DCS/PLC with the Omni FTIR Multi Gas CEMS
Establishing Communications
Table C–2. Digital I/O Connections
Digital No.
Block Terminal
Description
1
1
Digital Input Ground
2
2
Gas Mode Input: Check Span
3
3
Gas Mode Input: Check Spike
4
4
Gas Mode Input: Check Zero
5
5
Gas Mode Input: Bkg & Flowback
6
6
Gas Mode Input: Blowback
7
7&8
Gas Mode Output: Check Span
8
9 & 10
Gas Mode Output: Check Spike
9
11 & 12
Gas Mode Output: Check Zero
10
13 & 14
Gas Mode Output: Background & Flowback
11
15 & 16
Gas Mode Output: Blowback
12
17 & 18
Gas Mode Output: Sample
13
19 & 20
FTIR Data Valid
14
21 & 22
Temperature Alarm
15
23 & 24
Maintenance Status Key Switch
16
25 & 26
N/C
17
27
N/C
18
28
N/C
Figure C–3. Digital I/O - Rear Panel Terminals
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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
(SSR)
TTL outputs from the National Instruments 6509 board are used to drive
solid state relays (SSR) for valve control and digital status outputs. The
SSRs are mounted on a DIN rail on the interior of the electrical panel
(Figure C–4).
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).
Figure C–5. SSR Indicator Light Configurations
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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:
Hardware
Description
●
“Hardware Description” on page D-1
●
“Finding the Correct COM Port” on page D-2
●
“Setting the Virtual COM Port” on page D-4
●
“Programming the Controllers and Setting Parameters” on page D-6
The pressure and temperature controller hardware is located in a 2U chassis
located in the rack. It consists of four 2-channel controllers and a base unit
(Figure 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
Temperature Controller Connection
Figure D–2. Temperature Controller Connection
Finding the
Correct COM
Port
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’.
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Calogix Setup
Finding the Correct COM Port
3. Select the Hardware tab in System Properties.
4. Select ‘Device Manager’.
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Omni FTIR Multi Gas CEMS Instruction Manual
D-3
Calogix Setup
Setting the Virtual COM Port
5. Expand ‘Ports (COM & LPT)’. Find ‘USB Serial Port (COMn)’,
where n is the number of the com port; here it is 6.
6. Close Control panel without making any changes.
Setting the
Virtual COM Port
Use the following procedure to set the virtual COM port.
1. Open CALGrafix software with the icon on the desktop.
2. Click the second icon from the left in the icon bar.
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Calogix Setup
Setting the Virtual COM Port
3. Click ‘Browse’ in the ‘Select Devices’ popup menu.
4. Select the correct number for the COM port, Select ‘OK’.
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Omni FTIR Multi Gas CEMS Instruction Manual
D-5
Calogix Setup
Programming the Controllers and Setting Parameters
5. The main Calogix control window will open. The window is a visual
representation of the hardware with readings and setpoints overlaid.
Programming the
Controllers and
Setting Parameters
The following section details the procedure for setting up temperature
values and parameters in the CALogix controllers. These settings are preconfigured 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. ▲
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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.
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.
3. Select the ‘Module 2’ tab. Enter Segment 1: Segment type RAMP,
Ramp rate 90, Target Setpoint 185, Holdback band 0, EOP Status
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Calogix Setup
Programming the Controllers and Setting Parameters
None. Enter Segment 2: Segment type SOAK, Soak time Continuous,
EOP Status None.
4. Select the ‘Module 3’ tab. Enter Segment 1: Segment type RAMP,
Ramp rate 90, Target Setpoint 185, Holdback band 0, EOP Status
None. Enter Segment 2: Segment type SOAK, Soak time Continuous,
EOP Status None.
5. Close the program menu. The changes will be automatically written to
the controllers.
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Calogix Setup
Programming the Controllers and Setting Parameters
Inputting Controller
Values
Use the following procedure to input controller values.
1. Right-click anywhere on the CALogix window. Select ‘Properties from
the pop-up menu and then select each module in turn to enter values
for it.
2. Once a module is selected, enter the correct values according to Table
D–1. Values are grouped according to subheadings.
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D-9
Calogix Setup
Programming the Controllers and Setting Parameters
Table D–1. Controller Values
Module Settings
Module 1
Module 2
Module 3
Module 4
Module Name
Sample/Inlet
Pump/Outlet
FTIR/NC
NC/Pres
Operating Units
Deg C
Deg C
Deg C
None
Display Resolution
0.1
0.1
0.1
0.1
Channel 1 Sensor Type
RTD 2 wire
RTD 2 wire
RTD 2 wire
Custom
Sensor
Channel 1 Setpoint Upper
Limit
200
200
200
1000
Channel 1 Setpoint Lower
Limit
0
0
0
0
Channel 1 Span Offset
0
0
0
0
Channel 1 Zero Offset
0
0
0
0
Channel 2 Sensor Type
RTD 2 wire
RTD 2 wire
RTD 2 wire
Custom
Sensor
Channel 2 Setpoint Upper
Limit
200
200
200
1000
Channel 2 Setpoint Lower
Limit
0
0
0
0
Channel 2 Span Offset
0
0
0
527.17
Channel 2 Zero Offset
0
0
0
-69
Channel 1 Control Output
Output1
Output1
Output1
None
Channel 2 Control Output
Output2
Output2
Output2
None
Alarm Setpoint Output
Output3
Output3
Output3
None
Output1 Burnout state
De-Energised
De-Energised
De-Energised
De-Energised
Output2 Burnout state
De-Energised
De-Energised
De-Energised
De-Energised
Output3 Burnout state
De-Energised
De-Energised
De-Energised
De-Energised
Output1 Inversion
FALSE
FALSE
FALSE
FALSE
Output2 Inversion
FALSE
FALSE
FALSE
FALSE
Output3 Inversion
FALSE
FALSE
FALSE
FALSE
Output1 Inhibit
None
None
None
None
Setpoint
185
185
185
0
Mode
PID
PID
PID
PARK
Input settings
Output settings
Channel 1 Control
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Calogix Setup
Programming the Controllers and Setting Parameters
Module Settings
Module 1
Module 2
Module 3
Module 4
Enabled
Yes
Yes
Yes
No
Setpoint
185
185
0
0
Mode
PID
PID
PID
PARK
Input Mode
Channel 1
Channel 1
Channel 1
Channel 1
Operating Mode
BAND
BAND
BAND
None
Mode
OnOff
OnOff
OnOff
PARK
Subsidiary Mode
None
None
None
None
Setpoint
10
10
10
0
Band
2
2
2
2
Cycle Time
10
10
10
10
Maximum Power
100
100
100
100
Minimum Power
0
0
0
0
Output Power
100
100
100
0
Manual Power
Off
Off
Off
Off
Display Alarm
No
No
No
No
Reset Latched Alarm
No
No
No
No
Program number
1
1
1
1
Run mode
On
On
On
Off
Channel 2 Control
Alarm Control
Programmer
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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 control version, in which all scheduled events are triggered by
users via PLC. All scripts are saved in the same directory of c:\scrips.
CEMS_SampleMode
●
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 the
file or click “load script” button to open the script.
As indicated in the figure, 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.
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Omni FTIR Multi Gas CEMS Instruction Manual
E-1
IMACC Script Setting
CEMS_SampleMode
●
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.
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 this 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).
●
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.
●
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
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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.
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.
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
(0x0a1c, in this case). Go back to the “Modbus Register Setting” panel,
click the “serial” button on the top, and view the following setting panel, as
shown.
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Omni FTIR Multi Gas CEMS Instruction Manual
E-3
IMACC Script Setting
CEMS_SampleMode
This setting is used to configure the data transmission commutation port.
They should be set by manufacturer before shipment to customers.
●
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.
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 each 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
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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.
●
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.
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.
●
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.
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IMACC Script Setting
CEMS_SampleMode
Users can edit the calculation expression displayed in the expression 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.
●
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”.
Click the green shadow block “ifTimeCondition: equal to ==”, and the
subpanel “time setup” pops up.
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IMACC Script Setting
CEMS_SampleMode
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.
●
Script setting for background spectrum collection
Double click the script setting block named “Background Spectrum
Collection”so its setting panel pops up, as shown.
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IMACC Script Setting
CEMS_SampleMode
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
solenoid valve operation setting for normal sample mode.
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IMACC Script Setting
CEMS_SampleMode
●
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.
Click the left top corner labeled “ifTimeCondition:equal to==”so the
schedule setting block pops up.
As seen in the pull down manual, there is a list of 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.
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IMACC Script Setting
Modbus Control Version
There are six subpanels included in this script block. Each of them is the
solenoid 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.
Modbus Control
Version
●
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.
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IMACC Script Setting
Modbus Control Version
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_4”.
●
System Alarm Setting
This setting is included in the first container block inside the “while
statement” loop. The calc_8 setting is the definition of the system
temperature alarm.
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
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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.
●
Script setting for system command and status
This setting is included in the second container, as shown.
There are three script setting blocks and one calculation block. The first
script setting is used to assign the digital input channels to five system
commands stating from 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
for each system mode using the “system_status” variable.
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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”.
●
Script setting for ModbusMultiSensor
Next to the script setting for system command and status is the container
for “ModbusMultiSensor” setting, as shown.
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IMACC Script Setting
Modbus Control Version
Move the cursor to the block and double click it. The detailed setting for
each monitored parameter is listed, as indicated.
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.
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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.
This setting is the same for all six parameters.
●
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.
Note that all the settings should be the same as the one included in the
background spectrum collection.
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IMACC Script Setting
Modbus Control Version
●
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.
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.
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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 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.
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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\<Username>\Start Menu\Startup, where <Username> is the
name of the logon account (this is typically FTIR User for IMACCconfigured computers).
2. Also expand the path to C: \Windows\System32\INETSRV.
3. Create a shortcut of the file inetmgr.exe and move the shortcut into the
Startup folder referred to in Step 1.
4. Close Explorer. IIS will now autostart whenever Windows opens.
Configuration of IIS for Data Transfer (FTIR Computer)
1. Create a data transfer folder (e.g., C:\Current Data).
2. Open inetmgr.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 FTIR 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.
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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 http://<address>/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 collection 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.
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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 FTIR 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.
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