Galvanic Applied Sciences 943-TGXeNA Operation Manual

943-TGXeNA
Automatic Process UV Spectrophotometer for Tail Gas Analysis
OPERATION MANUAL
Revision 5
August 2021
Galvanic Applied Sciences, Inc.
7000 Fisher Road S.E.
Calgary, Alberta, T2H 0W3
Canada
Toll Free (North America): 1 800 458 4544wrong number
International +1 978 848 2701 (wrong number)
E-mail: [email protected]
www.galvanic.com
NOTICES
This system is covered by a limited warranty. A copy of the warranty is included with this manual.
The operator is required to perform routine maintenance as described herein on a periodic basis to
keep the warranty in effect. For routine maintenance procedures, refer to Section 6.
All information in this manual is subject to change without notice and does not represent a
commitment on the part of Galvanic Applied Sciences, Inc.
No part of this manual may be reproduced or transmitted in any form or by any means without the
written permission of Galvanic Applied Sciences, Inc.
Note: Changes or modifications not expressly approved by Galvanic Applied Sciences, Inc.
could void the user's authority to operate the equipment.
© Copyright 2020 Galvanic Applied Sciences, Inc. All rights reserved.font
Printed in Canada
Table of Contents
REPAIRED PRODUCTS ................................................................................................................... 13
LIMITATION OF REMEDY AND LIABILITY .......................................................................................... 13
SECTION 1 943-TGXENA TAIL GAS ANALYZER INTRODUCTION ........................................................14
1.1
1.2
1.3
1.4
1.5
1.6
OVERVIEW ........................................................................................................................... 14
ANALYTICAL METHOD ........................................................................................................... 14
ANALYZER DESIGN............................................................................................................... 15
SAMPLE HANDLING SYSTEM ................................................................................................ 16
SYSTEM OPERATING CONTROL ............................................................................................ 17
CONTENTS OF THIS MANUAL ................................................................................................. 18
SECTION 2 INSTALLATION................................................................................................................ 19
2.1
2.2
2.3
2.4
RECEIVING THE SYSTEM ...................................................................................................... 19
ENVIRONMENTAL REQUIREMENTS ........................................................................................ 19
2.2.1 Electrical Requirements ........................................................................................ 19
2.2.2 Temperature ......................................................................................................... 19
2.2.2 Space Requirements ............................................................................................ 19
2.2.4 Instrument Air ....................................................................................................... 20
2.2.5 Steam ................................................................................................................... 20
2.2.6 Area Classification ................................................................................................ 20
UNPACKING ........................................................................................................................ 20
INSTALLATION PROCEDURE ................................................................................................. 21
2.4.1 Mounting of the Analyzer System ......................................................................... 22
2.4.2 Mating of the Process and Analyzer System Flanges ..........................................23
2.4.3 Installation of the Sample Probe .......................................................................... 24
2.4.3 Connection of the AC Power Service ................................................................... 27
2.4.4 Connection of the Analog Signal Cables .............................................................. 27
2.4.5 Connection of the Digital Signal Cables ............................................................... 28
2.4.6 Connection of the Instrument Air .......................................................................... 29
2.4.7 Connections of Steam .......................................................................................... 31
2.4.8 Connection of the Loss of Purge Signal ............................................................... 31
SECTION 3 OPERATION ................................................................................................................... 32
3.1
3.2
3.3
OVERVIEW ........................................................................................................................... 32
FLOW CONTROL SETTINGS .................................................................................................. 33
3.2.1 Cabinet Purge Air Flow Adjust Valve ................................................................... 33
3.2.2 Cabinet Cooler Air Valve ...................................................................................... 34
3.2.3 Condenser Cooling Air Flow Adjust Valve............................................................ 35
3.2.4 Zero Air Flow Adjust Valve ................................................................................... 36
3.2.5 Aspirator Drive Air Flow Adjust Valve ................................................................... 37
3.2.6 System Regulator ................................................................................................. 38
ANALYZER OUTPUTS ............................................................................................................ 38
3.3.1 Analog Outputs ..................................................................................................... 38
3.3.2 Digital Outputs (Relays)....................................................................................... 39
3.3.2.1 Status ........................................................................................................ 39
3.3.2.2 Service ...................................................................................................... 40
3.3.2.3 Mode ......................................................................................................... 40
3.3.2.4 Control ....................................................................................................... 41
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3.3.2.4
Loss of Purge ............................................................................................ 41
SECTION 4 LOCAL SYSTEM CONTROL .............................................................................................. 43
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
OVERVIEW .......................................................................................................................... 43
USING THE LOCAL DISPLAY AND HANDHELD KEYPAD ............................................................ 43
4.2.1 Local Display User Interface................................................................................. 43
4.2.2 The Handheld Keypad .......................................................................................... 44
ANALYSIS 1 PANEL .............................................................................................................. 45
4.3.1 Online/Offline Mode Toggle .................................................................................. 45
4.3.2 Concentration Fields ............................................................................................. 45
4.3.3 Air Demand ........................................................................................................... 46
4.3.4 Relay Indicator Fields ........................................................................................... 47
4.3.4 Manual Zero ......................................................................................................... 47
4.3.5 Back Purge Indicator and Control ........................................................................ 48
ANALYSIS 2 PANEL .............................................................................................................. 49
4.4.1 Online / Offline Control ......................................................................................... 50
4.4.2 Concentrations, Air Demand, and Trend Graph ...................................................50
4.4.3 System Operating Parameters ............................................................................. 51
INDICATORS PANEL ............................................................................................................. 51
4.5.1
Fault Conditions ................................................................................................... 53
4.5.2 Warning Conditions .............................................................................................. 53
SPECTRUM PANEL ............................................................................................................... 54
4.6.1 Factory Reference ................................................................................................ 56
ABSORBANCE PANEL........................................................................................................... 57
CONFIG PANEL ................................................................................................................... 59
4.8.1 Outputs ................................................................................................................. 59
4.8.2 Calculation Sub-Panel .......................................................................................... 61
4.8.2.1 Calculation Parameters ............................................................................. 61
4.8.2.2 Cell Length ................................................................................................ 62
4.8.2.3 Fixed Temperature and Pressure ............................................................. 63
4.8.2.4 Sample and Zero Sample Rate ................................................................. 63
4.8.3 Display .................................................................................................................. 63
4.8.3.1 Analysis 1 and 2 Trend Graph Ranges .....................................................63
4.8.3.2 Backlight Adjustment................................................................................. 64
4.8.4 Timers/Alarms Sub-Panel..................................................................................... 64
4.8.4.1 Timers ....................................................................................................... 65
4.8.4.2 Temperature Control ................................................................................. 65
4.8.4.3 Alarms ....................................................................................................... 67
4.8.5 Network Sub Panel ............................................................................................... 68
4.8.5.1 Direct Connect ...................................................................................................... 68
4.8.5.2 Network ..................................................................................................... 68
SECTION 5 WEB-BASED GRAPHICAL USER INTERFACE (GUI) ...........................................................70
5.1
5.2
OVERVIEW .......................................................................................................................... 70
ANALYSIS SECTION ............................................................................................................. 71
5.2.1 Analysis Page ....................................................................................................... 71
5.2.1.1 Value Display ............................................................................................ 72
5.2.1.2 Status and Control .................................................................................... 73
5.2.1.3 Relay Indicators ........................................................................................ 73
5.2.1.4 Air Demand and H2S/SO2 Trends ............................................................ 74
5.2.2 Calibration Matrix Page ........................................................................................ 75
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5.3
5.4
5.5
5.2.3 Indicators Page ..................................................................................................... 76
5.2.4 Spectrum Page ..................................................................................................... 78
1.1.1 5.2.5 Absorbance Page ........................................................................................ 80
CONFIGURATION SECTION .................................................................................................... 83
1.1.2 5.3.1 Parameters Page......................................................................................... 83
1.1.3 5.3.2 Modbus Page .............................................................................................. 86
5.3.2.1 Enron Modbus Format .............................................................................. 89
5.3.2.3 Modicon 16 Format ................................................................................... 90
5.3.2.4 Modicon with Floating Point Format ..........................................................91
FACTORY SECTION .............................................................................................................. 91
5.4.1 Changing the Passwords...................................................................................... 94
HELP SECTION..................................................................................................................... 94
5.5.1 Drawing Page ....................................................................................................... 94
5.5.2 User Manual Page ................................................................................................ 95
5.5.3 Revision History Page .......................................................................................... 95
SECTION 6 MAINTENANCE............................................................................................................... 96
6.1
6.2
6.3
6.4
OVERVIEW .......................................................................................................................... 96
ROUTINE PREVENTATIVE MAINTENANCE ............................................................................... 96
6.2.1 Visual Inspection of Key Operating Parameters...................................................96
6.2.2 Maintenance Check Out Procedure ..................................................................... 97
CHANGING THE ANTI-SOLARANT SOLUTION ........................................................................ 100
OPTIMIZING THE SPECTROMETER SIGNAL........................................................................... 102
6.4.1 Automated Optimization ..................................................................................... 103
6.4.2 Manual Optimization ........................................................................................... 103
SECTION 7 SERVICEWHAT IS GOING ON HERE................................................................................. 105
7.1
7.2
7.3
7.4
7.5
7.6
7.8
7.9
7.10
OVERVIEW ........................................................................................................................ 105
INDICATORS PANEL TROUBLESHOOTING ............................................................................. 105
TESTING AND REPLACEMENT OF THE OPTICAL FIBRES .........................................................107
TROUBLESHOOTING THE UV SOURCE LAMP ........................................................................ 110
MEASUREMENT CELL BLOCK REMOVAL .............................................................................. 115
CELL WINDOWS CLEANING / REPLACEMENT ....................................................................... 117
MEASUREMENT CELL INSTALLATION ................................................................................... 119
STEAM PURGING THE SAMPLE PROBE................................................................................ 120
SPECTROMETER REPLACEMENT ......................................................................................... 122
SECTION 8 THE PRODUCT QUALITY ASSURANCE PROGRAM ...........................................................127
8.1
8.2
8.3
OVERVIEW ........................................................................................................................ 127
OVERALL SYSTEM IDENTIFICATION ..................................................................................... 127
QA DOCUMENT PACKAGE CHECK LIST AND REQUIREMENTS ...............................................128
SECTION 9 DRAWINGS .................................................................................................................. 129
SECTION 10 SPECIFICATIONS .......................................................................................................... 136
SECTION 11 RECOMMENDED SPARE PARTS .................................................................................... 137
SECTION 12 INPUT / OUTPUT (IO) BOARD CONFIGURATION .............................................................. 138
12.1 IO BOARD WEB GUI .......................................................................................................... 138
12.2 STATUS PAGE.................................................................................................................... 139
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12.3 MANUAL OVERRIDE PAGE .................................................................................................. 140
12.3.1 Analog Output Calibration and Testing .............................................................. 141
12.3.2 Testing the Digital Input ...................................................................................... 143
12.3.3 Testing Digital Outputs ....................................................................................... 143
INDEX
145
Figures
FIGURE 1: MODEL 943-TGXENA ...................................................................................................... 16
FIGURE 2: MOUNTING DIMENSIONS .................................................................................................... 22
FIGURE 3: SERVICE CONNECTIONS .................................................................................................... 23
FIGURE 4: HOLE PLUG IN OVEN CABINET REMOVED ........................................................................... 24
FIGURE 5: OVEN ENCLOSURE TUBING REMOVED................................................................................ 25
FIGURE 6: INSERTING THE SAMPLE PROBE ......................................................................................... 25
FIGURE 7: OVEN ENCLOSURE TUBING REINSTALLED .......................................................................... 26
FIGURE 8: LOCATION OF ACTS IN CONTROL CABINET ........................................................................ 27
FIGURE 9: LOCATION OF ANALOG OUTPUT TERMINALS ON IO BOARD ..................................................28
FIGURE 10: LOCATION OF DIGITAL OUTPUT TERMINALS ON IO BOARD .................................................29
FIGURE 11: LOCATION OF INSTRUMENT AIR REGULATOR .................................................................... 30
FIGURE 12: CONTROL CABINET PURGE CONTROL BOX ....................................................................... 30
FIGURE 13: LOCATION OF AIR FLOW CONTROL VALVES IN OVEN CABINET ...........................................32
FIGURE 14: SAMPLE SYSTEM FLOW DIAGRAM .................................................................................... 33
FIGURE 15: LOCATION OF VORTEX COOLER ....................................................................................... 34
FIGURE 16: SAMPLE PROBE .............................................................................................................. 35
FIGURE 17: MEASUREMENT CELL BLOCK (EXPLODED VIEW) ............................................................... 37
FIGURE 18: LOCAL DISPLAY USER INTERFACE.................................................................................... 43
FIGURE 19: HANDHELD KEYPAD ........................................................................................................ 44
FIGURE 20: ONLINE / OFFLINE MODE TOGGLE .................................................................................... 45
FIGURE 21: ANALYSIS 1 CONCENTRATION FIELDS .............................................................................. 46
FIGURE 22: AIR DEMAND VALUE AND TREND ...................................................................................... 46
FIGURE 23: RELAY INDICATORS ......................................................................................................... 47
FIGURE 24: MANUAL ZERO CONTROL ................................................................................................ 47
FIGURE 25: BACK PURGE INDICATOR AND MANUAL CONTROLS ...........................................................49
FIGURE 26: ANALYSIS 2 PANEL.......................................................................................................... 49
FIGURE 27: ONLINE / OFFLINE CONTROL............................................................................................ 50
FIGURE 28: DATA FIELDS AND TREND GRAPH .................................................................................... 50
FIGURE 29: SYSTEM OPERATING PARAMETERS .................................................................................. 51
FIGURE 30: INDICATORS PANEL ......................................................................................................... 52
FIGURE 31: SPECTRUM PANEL .......................................................................................................... 54
FIGURE 32: SPECTROMETER PARAMETERS ........................................................................................ 54
FIGURE 33: INTEGRATION PERIOD DIALOG BOX .................................................................................. 56
FIGURE 34: FACTORY REFERENCE .................................................................................................... 56
FIGURE 35: ABSORBANCE PANEL ...................................................................................................... 57
FIGURE 36: ABSORBANCE SPECTRUM FOR H2S.................................................................................. 58
FIGURE 37: ABSORBANCE SPECTRUM FOR SO2 ................................................................................. 58
FIGURE 38: OUTPUTS SUB-PANEL ..................................................................................................... 59
FIGURE 39: CALCULATION SUB-PANEL............................................................................................... 61
FIGURE 40: DISPLAY SUB-PANEL ....................................................................................................... 63
FIGURE 41: TIMERS / ALARMS SUB-PANEL ......................................................................................... 64
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FIGURE 42: NETWORK SUB-PANEL .................................................................................................... 68
FIGURE 43: CONTROLLER BOARD ...................................................................................................... 69
FIGURE 44: BRIMSTONE WEB GUI SPLASH SCREEN ........................................................................... 70
FIGURE 45: NAVIGATION MENU AND TIPS ........................................................................................... 71
FIGURE 46: ANALYSIS SECTION - ANALYSIS PAGE .............................................................................. 72
FIGURE 47: TREND GRAPH Y-AXIS RANGE CHANGE DIALOG BOX .......................................................75
FIGURE 48: SPECTROMETER ............................................................................................................. 75
FIGURE 49: CALIBRATION MATRIX...................................................................................................... 76
FIGURE 50: INDICATORS PAGE .......................................................................................................... 77
FIGURE 51: SPECTRUM PAGE ............................................................................................................ 78
FIGURE 52: SPECTRUM CURVE Y-AXIS MAXIMUM VALUE DIALOG BOX ................................................79
FIGURE 53: SET INTEGRATION TIME DIALOG BOX ............................................................................... 80
FIGURE 54: ABSORBANCE PAGE ........................................................................................................ 81
FIGURE 55: ABSORBANCE CURVE Y-AXIS MAXIMUM VALUE DIALOG BOX ............................................81
FIGURE 56: ABSORBANCE SPECTRUM FOR H2S.................................................................................. 82
FIGURE 57: ABSORBANCE SPECTRUM FOR SO2 ................................................................................. 82
FIGURE 58: CONFIGURATION PARAMETERS PAGE .............................................................................. 83
FIGURE 59: LOGIN DIALOG BOX ......................................................................................................... 85
FIGURE 60: MODBUS PAGE ............................................................................................................... 86
FIGURE 61: MODBUS TYPE DIALOG BOX ............................................................................................ 88
FIGURE 62: EDITING A MODBUS LIST ................................................................................................. 89
FIGURE 63: ENRON MODBUS FORMAT ............................................................................................... 90
FIGURE 64: MODICON 16 FORMAT ..................................................................................................... 90
FIGURE 65: MODICON 32 FORMAT ..................................................................................................... 91
FIGURE 66: FACTORY PARAMETERS PAGE ......................................................................................... 91
FIGURE 67: CHANGE PASSWORD DIALOG BOX ................................................................................... 94
FIGURE 68: PASSWORD ENTRY ERROR MESSAGES ............................................................................ 94
FIGURE 69: REVISION HISTORY ......................................................................................................... 95
FIGURE 70: REPLACING THE ANTI-SOLARANT SOLUTION................................................................... 101
FIGURE 71: INDICATORS PANEL ....................................................................................................... 105
FIGURE 72: LOCATION OF CELL HEATER FUSE ON ACTS.................................................................. 108
FIGURE 73: UV LAMP ENCLOSURE .................................................................................................. 112
FIGURE 74: UV LAMP ENCLOSURE INTERNAL LAYOUT ...................................................................... 113
FIGURE 75: UV LAMP ORIENTATION................................................................................................. 114
FIGURE 76: OVEN ENCLOSURE ........................................................................................................ 116
FIGURE 77: MEASUREMENT CELL BLOCK (EXPLODED VIEW)............................................................. 117
FIGURE 78: SPECTROMETER ........................................................................................................... 123
FIGURE 79: UTILITY PAGE ............................................................................................................... 124
FIGURE 80: SPECTROMETER CALIBRATION MATRIX PDF EXAMPLE ...................................................125
FIGURE 81: MOUNTING AND SERVICE CONNECTIONS ........................................................................ 129
FIGURE 82: OVEN CABINET DOOR REMOVED ................................................................................... 130
FIGURE 83: CONTROL CABINET DOOR REMOVED ............................................................................. 131
FIGURE 84: POWER, STEAM, AIR, SIGNALS CONNECTION DETAILS ....................................................132
FIGURE 85: AC WIRING SCHEMATIC ................................................................................................ 133
FIGURE 86: DC SIGNALS AND WIRING DIAGRAM ............................................................................... 134
FIGURE 87: FLOW DIAGRAM ............................................................................................................ 135
FIGURE 88: IO BOARD WEB GUI ...................................................................................................... 138
FIGURE 89: STATUS PAGE............................................................................................................... 139
FIGURE 90: MANUAL OVERRIDE PAGE ............................................................................................. 141
FIGURE 91: ANALOG OUTPUT TERMINAL BLOCK P3 .......................................................................... 142
FIGURE 92: RELAY CONNECTION TERMINAL BLOCK P4 ..................................................................... 144
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Tables
TABLE 1: AMBIENT TEMPERATURE RANGE BY MODEL ........................................................................ 19
TABLE 2: STEAM SUPPLY REQUIREMENTS .......................................................................................... 20
TABLE 3: STATUS RELAY STATES ...................................................................................................... 39
TABLE 4: SERVICE RELAY STATES ..................................................................................................... 40
TABLE 5: MODE RELAY STATES ......................................................................................................... 40
TABLE 6: CONTROL RELAY STATES.................................................................................................... 41
TABLE 7: KEYPAD RED KEY FUNCTIONS ............................................................................................. 44
TABLE 8: SYSTEM OPERATING PARAMETERS...................................................................................... 51
TABLE 9: ANALYZER FAULTS.............................................................................................................. 53
TABLE 10: ANALYZER WARNINGS ...................................................................................................... 53
TABLE 11: SPECTROMETER PARAMETERS .......................................................................................... 55
TABLE 12: ANALOG OUTPUT PARAMETERS......................................................................................... 60
TABLE 13: CALCULATION PARAMETERS.............................................................................................. 62
TABLE 14: TIMERS PARAMETERS ....................................................................................................... 65
TABLE 15: TEMPERATURE CONTROL PARAMETERS............................................................................. 66
TABLE 16: ALARMS PARAMETERS ...................................................................................................... 67
TABLE 17: VALUE DISPLAY PARAMETERS ........................................................................................... 72
TABLE 18: STATUS AND CONTROL ..................................................................................................... 73
TABLE 19: RELAY INDICATORS ........................................................................................................... 74
TABLE 20: ANALYZER FAULTS ........................................................................................................... 77
TABLE 21: ANALYZER WARNINGS ...................................................................................................... 78
TABLE 22: SPECTRUM PARAMETERS.................................................................................................. 79
TABLE 23: PARAMETERS PAGE COLOUR CODE .................................................................................. 83
TABLE 24: CONFIGURATION PARAMETERS.......................................................................................... 84
TABLE 25: MODBUS COMMUNICATION PARAMETERS........................................................................... 87
TABLE 26: AVAILABLE MODBUS POINTS ............................................................................................. 88
TABLE 27: MODBUS LIST COLUMNS ................................................................................................... 89
TABLE 28: FACTORY PARAMETERS COLOUR CODE............................................................................. 92
TABLE 29: FACTORY PARAMETERS .................................................................................................... 92
TABLE 30: NORMAL OPERATING PARAMETER AND INDICATOR CONDITIONS..........................................97
TABLE 31: MAINTENANCE RECORD SHEET ......................................................................................... 99
TABLE 32: ANALYZER FAULT / WARNING TROUBLESHOOTING ............................................................ 106
TABLE 33: LAMP TROUBLESHOOTING ............................................................................................... 111
TABLE 34: DOCUMENT PACKAGE CHECKLIST ................................................................................... 128
TABLE 35: RECOMMENDED SPARE PARTS - 1 YEAR KIT .................................................................... 137
TABLE 36: RECOMMENDED SPARE PARTS - 2 YEAR KIT .................................................................... 137
TABLE 37: IO BOARD WEB GUI PAGES............................................................................................ 139
TABLE 38: STATUS PAGE SECTIONS ................................................................................................ 140
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Safety Symbols used in Manual
The Danger symbol indicates a hazardous situation that, if not
avoided will result in death or serious injury.
The Warning symbol indicates a hazardous situation that, if not
avoided could result in death or serious injury.
The Caution symbol with the safety alert symbol indicates a
hazardous situation that, if not avoided could result in minor or
moderate injury.
The Notice symbol is used to highlight information that will
optimize the use and reliability of the system.
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Important Safety Guidelines for the 943-TGXeNA
Field Programmable Tail Gas Analyzer System
Please read the following warnings and cautions carefully before using the 943-TGXeNA Tail Gas
Analyzer System:
be impaired.
This equipment must be used as specified by the manufacturer or overall safety will
Access to this equipment should be limited to authorized, trained personnel ONLY.
time.
Due to the thermal mass of the hardware, cooling of the items takes substantial
Observe all warning labels on the analyzer enclosures.
Install fuses of the Type and Rating as shown on the Fuse Identifier labels.
The analog outputs and alarm relay contacts may be powered by a source separate from the
one (s) used to power the analyzer system. Disconnecting the AC Mains Source (s) may not remove
power from the analog output signals.
Any safety recommendations or comments contained herein are suggested guidelines only.
Galvanic Applied Sciences Inc. bears no responsibility and assumes no liability for the use and/or
implementation of these suggested procedures.
This system, when operating in its normal mode, and/or when it is being serviced, maintained,
installed and commissioned contains items which may be hazardous to humans if handled or
operated incorrectly or negligently. These items include, but are not limited to:
High Voltage Electrical Energy
Toxic and Explosive Gases
Intense Ultraviolet Radiation
High Temperature Surfaces
Installation of the system requires the opening of the process sample point to allow for the insertion
of the system sample probe assembly. To achieve this, removing the process access point blind
flange is necessary. When the flange is removed, toxic, hot (approximately 150ºC/300ºF) gases
and molten sulfur may be expelled to the atmosphere until the system sample probe and its
associated flange are in place and securely fastened.
It is recommended that the personnel installing the probe wear plant approved breathing air
apparatus, and approved personal protective equipment (i.e. gloves, coveralls and protective eye
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wear) suitable for high temperature work. This applies even if the Tail Gas Line (Process Stream)
is believed to be at negative pressure.
During normal operation, toxic gases, (H2S, SO2, COS and CS2) are present in the tubing,
measurement cell, aspirator and all other system components through which the tail gas sample
flows. They should not be opened before the complete system is purged with zero gas (an inert
gas or instrument air), and the system is blocked using the two valves in the sample oven identified
as the Sample Flow and Vent Flow on/off valves.
Purging of the system should be performed with both valves in the open position and maintained
for approximately five (5) minutes. Once purging is complete, and with the purge gas still flowing,
the two valves should be switched to the Off position. The purge gas can now be shut off and the
tubing or associated apparatus opened.
The sampling system will be under positive pressure. Loosen a fitting and allow the pressure to be
released before completely disconnecting the tubing.
The entire system is enclosed in an oven cabinet that is heated and maintained at approximately
150ºC/300ºF to prevent the condensation of sulfur. Maintenance performed before the cooling of
the oven and hardware should be done while wearing suitable protective clothing, eye wear, and
gloves to prevent burns to the hands and arms.
The system includes an Ultraviolet spectrometer which employs a source that generates intense
UV radiation that is transmitted to the measurement cell and spectrometer through fibre optic
cables.
This radiation is extremely harmful to the naked eye and skin, even in short duration exposures.
Always extinguish the UV radiation source (lamp) before removing a fibre optic cable or the lamp
power supply cover by turning the AC power to the lamp power supply ‘Off’. Should the lamp be
turned on for any reason while the cover is off, ensure that certified eye protection is worn, and that
the exposure is limited to the bare minimum.
Although the UV radiation is transmitted through a narrow diameter fibre, it should never be viewed
directly. The beam is extremely intense and will cause permanent eye damage. Should visual
inspection of the beam be required, point the end of the fibre at an inanimate object and view the
illumination reflection. Never expose human skin to the radiation from the optical fibres.
943-TGXeNA (CSA)
Class I, Division 2, Groups C and D, Temperature Code T3, Type Z Purge
IP Protection:
NEMA 4
Ambient Temperature:
-20°C to 50°C
The control cabinet purge gas is to be instrument air only.
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Manufacturer’s Warranty Statement
Galvanic Applied Sciences Inc. (“Seller”) warrants that its products will be free from defects in materials
and workmanship under normal use and service in general process conditions for 12 months from the
date of Product start-up or 18 months from the date of shipping from Seller’s production facility,
whichever comes first (the “Warranty Period”). Products purchased by Seller from a third party for
resale to Buyer ("Resale Products") shall carry only the warranty extended by the original
manufacturer. Buyer agrees that Seller has no liability for Resale Products beyond making a
reasonable commercial effort to arrange for procurement and shipping of the Resale Products. Buyer
must give Seller notice of any warranty claim prior to the end of the Warranty Period. Seller shall not
be responsible for any defects (including latent defects) which are reported to Seller after the end of
the Warranty Period.
THIS WARRANTY AND ITS REMEDIES ARE IN LIEU OF ALL OTHER WARRANTIES OR
CONDITIONS EXPRESSED OR IMPLIED, ORAL OR WRITTEN, EITHER IN FACT OR BY
OPERATION OF LAW, STATUTORY OR OTHERWISE, INCLUDING BUT NOT LIMITED TO,
WARRANTIES OR CONDITIONS OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE, WHICH SELLER SPECIFICALLY DISCLAIMS.
Seller’s obligation under this warranty shall not arise until Buyer notifies Seller of the defect. Seller’s
sole responsibility and Buyer’s sole and exclusive remedy under this warranty is, at Seller’s option,
to replace or repair any defective component part of the product upon receipt of the Product at
Seller’s production facility, transportation charges prepaid or accept the return of the defective
Product and refund the purchase price paid by Buyer for that Product. If requested by Buyer, Seller
will use its best efforts to perform warranty services at Buyer’s facility, as soon as reasonably
practicable after notification by the Buyer of a possible defect provided that Buyer agrees to pay for
travel time, mileage from the Seller’s facility or travel costs to the airport / train station closest to
Buyer’s facility plus all other travel fees, hotel expenses and subsistence.
Except in the case of an authorized distributor or seller, authorized in writing by Seller to extend
this warranty to the distributor’s customers, the warranty herein applies only to the original
purchaser from Seller (“Buyer”) and may not be assigned, sold, or otherwise transferred to a third
party. No warranty is made with respect to used, reconstructed, refurbished, or previously owned
Products, which will be so marked on the sales order and will be sold “As Is”.
Limitations
These warranties do not cover:
•
Consumable items such as lamps.
•
Analyzer components which may be damaged by exposure to contamination or fouling
from the process fluid due to a process upset, improper sample extraction techniques or
improper sample preparation, fluid pressures in excess of the analyzer’s maximum rated
pressure or fluid temperatures in excess of the analyzer’s maximum rated
temperature. These include but are not limited to sample filters, pressure regulators,
transfer tubing, sample cells, optical components, pumps, measuring electrodes, switching
solenoids, pressure sensors or any other sample wetted components.
•
Loss, damage, or defects resulting from transportation to Buyer’s facility, improper or
inadequate maintenance by Buyer, software or interfaces supplied by Buyer, operation
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outside the environmental specifications for the instrument, use by unauthorized or
untrained personnel or improper site maintenance or preparation.
•
Products that have been altered or repaired by individuals other than Seller personnel or
its duly authorized representatives, unless the alteration or repair has been performed by
an authorized factory trained service technician in accordance with written procedures
supplied by Seller.
•
Products that have been subject to misuse, neglect, accident, or improper installation.
•
The sole and exclusive warranty applicable to software and firmware products provided by
Seller for use with a processor internal or external to the Product will be as follows: Seller
warrants that such software and firmware will conform to Seller’s program manuals or other
publicly available documentation made available by Seller current at the time of shipment
to Buyer when properly installed on that processor, provided however that Seller does not
warrant the operation of the processor or software or firmware will be uninterrupted or errorfree.
The warranty herein applies only to Products within the agreed country of original end destination.
Products transferred outside the country of original end destination, either by the Seller at the
direction of the Buyer or by Buyer’s actions subsequent to delivery, may be subject to additional
charges prior to warranty repair or replacement of such Products based on the actual location of
such Products and Seller’s warranty and/or service surcharges for such location(s).
Repaired Products
Repaired products are warranted for 90 days with the above exceptions.
Limitation of Remedy and Liability
IN NO EVENT SHALL SELLER BE LIABLE TO BUYER FOR ANY INDIRECT, CONSEQUENTIAL,
INCIDENTAL, SPECIAL OR PUNITIVE DAMAGES, OR FOR ANY LOSS OF USE OR
PRODUCTION, OR ANY LOSS OF DATA, PROFITS OR REVENUES, OR ANY CLAIMS RAISED
BY CUSTOMERS OF BUYER OR ANY ENVIRONMENTAL DAMAGE OR ANY FINES IMPOSED
ON BUYER BY ANY GOVERNMENTAL OR REGULATORY AUTHORITIES, WHETHER SUCH
DAMAGES ARE DIRECT OR INDIRECT, AND REGARDLESS OF THE FORM OF ACTION
(WHETHER FOR BREACH OF CONTRACT OR WARRANTY OR IN TORT OR STRICT
LIABILITY) AND WHETHER ADVISED OF THE POSSIBILITY OF SUCH DAMAGES OR NOT.
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Section 1
943-TGXeNA
Introduction
1.1
Tail
Gas
Analyzer
Overview
The use of a Tail Gas Analyzer to assist in the control of combustion air to acid gas ratios in
Claus Sulfur Recovery Plants is a standard procedure in industry. The plant tail gas is analyzed
using ultraviolet spectroscopy and an output signal that corresponds to the air requirement is
determined. This observed signal is proportional to the percentage change required in the
combustion air to provide stoichiometric concentrations of the principal reactants; H2S and SO2.
When the process is optimized and the correct stoichiometric concentrations of H2S and SO2
are achieved, the feedback signal (normally referred to as Air Demand) is zero (which means
that no change is required).
The simplified Air Demand equation is:
where:
𝐴𝐴𝐴𝐴𝐴𝐴 𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷 = 𝐹𝐹 × ([𝐻𝐻2 𝑆𝑆] − 𝑅𝑅𝑜𝑜𝑜𝑜 [𝑆𝑆𝑂𝑂2 ])
F = plant specific gain factor
[H2S] = concentration of H2S
[SO2] = concentration of SO2
Rop = operating ratio (typically 2)
When the ratio of stoichiometric concentration of H2S to SO2 equals the operating ratio (Rop),
the Air Demand output becomes zero regardless of the plant specific gain factor (Plant
Factor) (F). When the plant factor (F) is established for a particular process, the units of Air
Demand become ‘percent change required in process air’. (i.e., a computed Air Demand of
+1.5% means that the process is 1.5% excess in air.) To achieve optimum performance of the
Claus Sulfur Recovery Plant, the Air Demand should be kept near zero.
The sample gas obtained from the sulfur plant waste or tail gas stream may also contain other
sulfur species such as COS, CS2, and sulfur vapour (Svap). These species, if present in
significant concentrations, must be analyzed for and a correction be made to avoid interference
with the H2S and SO2 analysis.
1.2
Analytical Method
The analyzer uses a spectrometer with a diffraction grating that is optimized in the spectral
region where the species of interest, namely hydrogen sulfide (H2S), sulfur dioxide (SO2), carbon
disulfide (CS2), carbonyl sulfide (COS), and sulfur vapour (Svap) absorb (the compounds of
interest absorb between 200 and 400 nm) coupled to a detection system that maximizes
sensitivity and resolution while minimizing dark current and stray light noise. A 2048 element
CCD detector is employed to detect light across the wavelength range of interest.
The UV radiation is supplied by a highly stable deuterium broadband source and is transmitted
to/from the measurement cell via UV fibre optic cables. This approach provides for analytical
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accuracy and allows for more precise multi-species analysis than that of a conventional
photometer which uses narrow band optical filters. The conventional photometer measures only
a few discrete wavelengths, and spectrometers having lower resolution and fewer elements in
the detector are also less precise.
If, as is frequently the case, more than one of the sulfur-containing compounds indicated above
are present, their spectra will overlap. The system uses a deconvolution protocol to separate
the signals for each component via a multi component algorithm known as the calibration
matrix .
1.3
Analyzer Design
The Model 943-TGXeNA Analyzer System is packaged in two (2) frame mounted cabinets:
1. An oven cabinet which contains the sample handling system and associated
hardware (i.e., solenoids, oven, heaters, etc.). All electrical equipment residing in the
oven cabinet is installed using appropriate explosion proof and/or intrinsically safe
wiring methods.
2. A control cabinet which contains the electrical hardware necessary for the operation
of the analyzer. Under normal operating circumstances, the interior of the control
cabinet maintains a general-purpose area classification using a Type-Z positive
pressure purge system. Both visual and electrical (contact closure) indications are
provided for monitoring the status of the control cabinet purge. Temperature control for
the control cabinet is provided by an instrument air driven Vortec vortex cooler.
All connections passing from the control cabinet to the oven cabinet are via gas-tight bulkhead
connections to prevent any process gases from passing from the oven cabinet into the control
cabinet.
An external keypad is provided for navigation of the analyzer’s user interface and for
modification of analyzer operating parameters. This keypad is connected to a port on the control
cabinet door.
The Model 943-TGXeNA uses a fully electric heating system for the measurement cell block
and the associated sample handling system.
A drawing of the Model 943-TGXeNA is shown in Figure 1.
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Figure 1: Model 943-TGXeNA
1.4
Sample Handling System
The Analyzer system utilizes a close coupled mounting arrangement of the measurement cell
block to the tail gas process sampling point to minimize the sample handling system length. The
short length allows for analyzer response times to be optimized while sample transport problems
are mitigated. A small volume of tail gas sample is drawn through the measurement cell by use
of an air-driven aspirator where the concentrations of the various species are determined
photometrically.
The measurement sample is drawn from a central point of the process duct using a specifically
sized sample probe. After measurement, the process sample (mixed with the aspirator drive
air) is vented to the wall of the process duct. The concentric chamber design of the sample
probe provides both the sampling and venting of the tail gas sample through a single sampling
point on the process duct.
The sample probe incorporates a mechanism for reducing the dew point of sulfur vapour in the
sampled gas stream. Instrument air can be introduced to provide an exposed cool surface. to
the incoming sample gas. Excess condensed sulfur is hydrostatically returned to the process
duct. The sulfur vapour concentration is measured and displayed on the analyzer display. The
sulfur vapour concentration is useful for system troubleshooting.
Incoming sample gas is filtered to 60 micron and drawn through the measurement cell by the
aspirator. The measurement cell exposes a known length of sample to UV radiation for
spectroscopic analysis. The aspirator is integral to the measurement cell and uses instrument
air (or other inert gas) as the aspirator drive gas. The analyzer turns on the aspirator drive media
only when no analyzer faults are detected. In the event of a fault condition, the analyzer
automatically purges the entire sample handling system with instrument air.
Analyzer zeroing is accomplished by introducing higher pressure instrument air (or other inert
gas) upstream of the measurement cell. The zero gas flushes the entire sample handling system
(probe to vent) and allows readings to be taken through the measurement cell when no
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absorbing species are present. To the sample system, zeroing and back purging are the same
thing. The default state (power ‘off’) of the analyzer is to have the sample system in the back
purge mode. Valving is provided for isolating the sample system components from the process
stream. A provision is included in the oven plumbing for the steam purging of the sample probe
after a plant shut-down or turn-around, or in the event of plugging of the sample probe, should
it be required.
A temperature-controlled oven enclosure maintains all components exposed to the tail gas
sample at higher than dew point values. The oven and sample probe are mounted to an interface
plate, which in turn is directly mounted to the steam heated process duct sample nozzle
(typically a 2-inch, 150 pound pipe flange configuration). Electrical heat is applied to the
measurement cell to achieve precise temperature control of the entire oven enclosure, which
contains the measurement cell block and the associated sample handling system tubing and
valves. This electrical heat is supplemented using a steam heater in the bottom of the oven
enclosure that provides additional heat from a medium pressure steam source.
1.5
System Operating Control
The analyzer system operation is controlled by a dedicated data acquisition system which
provides supervisory control of all analyzer inputs and outputs, performs all calculations, and
provides the user interface.
The system includes an onboard computer system which provides a graphic display of key
system control parameters and their status, a digital display of the instantaneous value of the
Air Demand, H2S, SO2, and COS, and historical graphic displays of the Air Demand, H2S and
SO2. The entire control computer system, consisting of a Control Board and a Display Board,
is mounted on the door of the control cabinet. Control cabinet access is not required for viewing
or operation.
The measurement of carbonyl sulfide (CS2) is an optional measurement. Analyzers
which have not been ordered with this option cannot measure CS2.
Four loop-powered 4 – 20 mA analog outputs are provided for the output of analyzer
measurement parameters. These four analog outputs are user-configurable for the output
parameter and range. Additionally, four solid-state relay outputs are provided for the output of
system status data. An RS485 serial port is also provided which can be used for available for
Modbus communication. Two Ethernet ports are provided for use either for Modbus TCP/IP
communication OR for connection of a computer for GUI access. Aside from the Ethernet ports,
one of which is located on the front door of the control cabinet and the other which is located on
the control board, all inputs and outputs are found on the analyzer’s Input / Output Board inside
the control cabinet.
A handheld keypad is provided for user interface with the analyzer. Operation of the system
with the keypad is described in Section 4. As an alternative, a web based graphical user
interface (GUI) can be used to view and enter information on a remote basis. Operation using
the web GUI is described in Section 5.
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1.6
Contents of this Manual
This manual contains the following information:
Section 1: 943-TGXeNA Tail Gas Analyzer Introduction presents introductory information
about the analyzer system.
Section 2: Installation describes unpacking the analyzer, installing it in the facility and
interfacing with other devices.
Section 3: Operation of the System explains how the operator interacts with the analyzer.
Section 4: Local System Control describes how the user enters data and views system
parameters using the keypad and the local display
Section 5: Web-based Graphical User Interface describes how to operate the analyzer
and edit the analyzer configuration using the web-based graphical user interface.
Section 6: Maintenance describes the various regular maintenance procedures that
should be followed to keep the analyzer functioning normally.
Section 7: Service gives some important service procedures that may be necessary to
keep the analyzer in operational condition.
Section 8: Product Quality Assurance includes various documentation of the Quality
Assurance that was done at the factory prior to shipping.
Section 9: Drawings gives a variety of generic drawings related to the analyzer system.
Section 10: Spare Parts lists a number of items which may be required to maintain
operation of the analyzer.
Section 11: Specifications presents the specifications for the analyzer.
Section 12: Input / Output Board Configuration provides information for the testing and
calibration of the various inputs and outputs available on the analyzer’s IO board.
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Section 2
Installation
The initial installation of the analyzer system is usually completed by the purchaser.
The start-up and commissioning is usually performed by Galvanic Applied Sciences
Inc. personnel.
2.1
Receiving the System
When the system arrives, inspect the packaging for external signs of damage. If there is any
obvious physical damage, contact the shipping agent and Galvanic Applied Sciences to report
the damage and request that the carrier's agent be present when the unit is unpacked. It is
recommended that you retain the shipping container so that it may be used for future shipment
of the unit, if necessary.
2.2
Environmental Requirements
2.2.1 Electrical Requirements
The power input is 100 – 240 Vac, 1 phase, 50/60 Hz, 800 W. The operating voltage is
specified on the serial number name plate
2.2.2 Temperature
The ambient temperature range the analyzer can operate in is shown in Table 1.
Table 1: Ambient Temperature Range by Model
Model
943-TGXeNA
Ambient Temperature Range
-20 to 50°C (-4 to 122°F)
Galvanic offers complete analyzer shelters from sunshades to complete buildings; please
contact Galvanic Applied Sciences, Inc. (or your local representative) for additional
information.
2.2.2 Space Requirements
The 943-TGXeNA system is composed of two cabinets mounted side by side on a mounting
frame. The dimensions of each cabinet are 30” (76 cm) H x 24” (61 cm) W x 12” (30 cm) D.
The overall outer dimension of the system with the mounting frame is 41.75” (106 cm) H x
57” (145 cm W) x 16” (41 cm) D. The weight of the system is approximately 275 lb (125 kg);
the exact weight will depend on the specifics of the analyzer. The installation location should
allow both cabinet doors to swing open to at least 90 degrees. The analyzer should also be
mounted so that the analyzer display is at or near eye level for ease of operation.
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2.2.4 Instrument Air
The system requires instrument air at 55 to 116psig (3.8 to 8 barg) at a delivery rate of 22
SCFM (37m3 / h). Instrument air is used for cabinet cooling, cabinet purge, zero gas, and
aspirator drive air, so it is essential that the provided air meet the above pressure and flow
rate requirements. The instrument air must be clean and dry, and meet the requirements for
instrument air stipulated in ANSI/ISA Standard 57.3-1975 R (1981).
2.2.5 Steam
For the Model 943-TGXeNA, a single low pressure steam supply is required, as indicated in
Table 2.
Table 2: Steam Supply Requirements
Location
Sample
Probe Nozzle
Minimum
Pressure
2.8 barg
(40 psig)
Maximum
Pressure
5.5 barg
(80 psig)
Minimum
Temperature
140°C (285°F)
Maximum
Temperature
160°C
(320°F)
2.2.6 Area Classification
The hazardous area classification and ingress protection for the Model 943-TGXeNA is
shown below:
943-TGXeNA
Class I, Division 2, Groups C and D, Temperature Code T3, Type Z Purge
IP Protection:
NEMA 4
2.3
Unpacking
The 943-TGXeNA analyzer system is packed for shipment in a wooden crate.
Galvanic Applied Sciences Inc. advises unpacking the system according to the following
procedure.
1. Remove the lid by undoing the marked lag bolts.
2. Once the lid is off, remove the excess packing material, boxes and sample probe from
the shipping crate. The sample probe will be wrapped in packing material. Probes with
a guide length of 5.5 feet (165cm) or longer are packed in a separate crate.
3. Visually inspect the small packages and the sample probe to ensure that no major
damage has occurred. If damage has occurred, contact the shipping company and
Galvanic Applied Sciences. Place the small packages and the sample probe aside in
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a safe, secure storage area as they are not needed at this stage of the system
installation.
The analyzer weighs approximately 275 lb (125 kg). Use suitable precautions
when removing it from the crate and placing it in the facility.
4. Locate and remove the four (4) bolts that secure the analyzer framework to the 2' x 4'
boards at the bottom of the shipping crate.
5. Once the bolts are removed the analyzer system can be lifted from the crate.
6. Lay the analyzer system frame onto a structurally strong and level surface and inspect
for any visual damage.
7. Remove the plastic wrap from the analyzer system to gain access to the doors of the
cabinets.
8. Open the cabinet doors and carefully remove the packing material from inside each of
the two (2) analyzer cabinets.
Care should be taken while removing the cabinet packing material so that
no hardware or wiring is damaged.
9. Inspect the internal equipment to ensure that no damage has occurred and that no
components have become loose during transport.
If any damage is visible contact Galvanic Applied Sciences Inc. immediately and do
not proceed with the system installation. Do not attempt to facilitate repairs yourself as
this will negate and/or invalidate any possible insurance claim or equipment warranty.
10. If no damage is apparent, the analyzer system is ready for transport to the installation
(sample point) site. The analyzer system framework has two (2) lifting rings located at
the top. Installation of proper clevises is recommended. The lifting rings are rated for
approximately 227 kg / 500 lbs per ring.
2.4
Installation Procedure
The installation procedure of the 943-TGXeNA analyzer system consists of the following steps
1. Mounting of the Analyzer System (Section 2.4.1)
2. Mating of the Process and Analyzer System Flanges (Section 2.4.2)
3. Connection of the AC Power Service (Section 2.4.3)
4. Connection of the Analog Signal Cables (Section 2.4.4)
5. Connection of the Digital Signal Cables (Section 2.4.5)
6. Connection of the Instrument Air Services (Section 2.4.6)
7. Connection of Steam (Section 2.4.7)
8. Connection of the ‘Loss of Purge Signal’ (Section 2.4.8)
The user should fully understand each step of the installation process prior to
proceeding with installation. If there are any concerns with the installation process,
please contact Galvanic Applied Sciences Inc. for assistance.
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2.4.1 Mounting of the Analyzer System
The framework that is used in the analyzer system must be securely attached to a support
structure provided by the end user. The support structure must be positioned so that when
the analyzer framework is bolted in place, the flange of the analyzer cabinet and the process
sample access point are correctly aligned. The plant support structure should be suitable for
mounting the analyzer frame as shown in the Mounting Dimensions drawing given in Figure
2.
Figure 2: Mounting Dimensions
The steam jacketed ball valve must be installed on the process sample point
before mounting the analyzer system. The Steam jacketed ball valve must remain
closed until the sample probe is installed and connected in the sample handling
oven.
Figure 3 indicates the location of the various connections that must be made.
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Figure 3: Service Connections
2.4.2 Mating of the Process and Analyzer System Flanges
The analyzer is shipped with a 316 SS blind flange plate and gasket mounted inside the oven
enclosure to prevent the process gas from flowing into the compartment before installation
of the sample probe assembly. Check to ensure that this blind flange is in place and secure.
Explosive, toxic and hot gases and molten sulfur may be released once the
stream jacketed ball valve is opened. All company and/or regulatory agency
safety procedures and rules should be adhered to. Breathing apparatus and
personal protective equipment (ie. gloves, coveralls and protective eye wear)
should be worn and a safety person(s) should be observing. Do not take
unnecessary risks even if you believe the tailgas line to be at negative pressure.
Before mounting the analyzer at the process (sample) connection, check to ensure that the
following conditions have been met.
1. The bolt holes in the steam jacketed nozzle flange are large enough to accommodate
the four (4) bolts on the analyzer system flange
2. The two (2) flanges are correctly aligned
3. A new gasket of proper size and material is available
4. The appropriately sized nuts are available to put onto the system flange bolts (5/8”, 11
UNC).
The sample probe length is unique to each individual analyzer. The length of the
probe is determined at time of ordering based on process pipe diameter and other
relevant dimensions such that the probe provides a minimum of 25% (i.e at
minimum one quarter of the pipe’s inner diameter) penetration into the process
pipe.
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If all the above conditions are satisfied:
1. Put the new gasket in place and move the analyzer system into position placing the
four bolts through the steam jacketed nozzle flange holes.
2. Place the four nuts onto the bolts and tighten.
3. Inspect the flange connection using company and/or regulatory agency procedures to
ensure that the connection is leak-tight (no gases are escaping).
4. Check that process gas is not leaking into the analyzer oven.
When the analyzer system is securely fastened to the process sample point flange, make
sure that the analyzer framework is secured to the support structure. This is to ensure that
the framework and support structure, not the flange connection, are bearing the weight of
the analyzer system.
2.4.3
Installation of the Sample Probe
Once the analyzer system is securely installed on the process pipe, the sample probe can
be installed by following the procedure below.
1. Remove the hole plug from the top of the oven cabinet as shown in Figure 4.
Cover removed.
Replace after sample probe
installed.
Figure 4: Hole Plug in Oven Cabinet Removed
2. Remove the black cover from the oven enclosure and disconnect the tubing
connected to the measurement cell block as shown in Figure 5.
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Tubing removed
Figure 5: Oven Enclosure Tubing Removed
3. Insert the probe into the packing gland at the bottom of the oven indicated in Figure 6
until it reaches the steam jacketed ball valve.
Sample probe
Packing gland
Figure 6: Inserting the Sample Probe
4. Open the steam jacketed ball valve and continue inserting the probe until the probe
flange contacts the packing gland.
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Explosive, toxic and hot gases and molten sulfur may be released once the
stream jacketed ball valve is opened. All company and/or regulatory agency
safety procedures and rules should be adhered to. Breathing apparatus and
personal protective equipment (ie. gloves, coveralls and protective eye
wear) should be worn and a safety person(s) should be observing. Do not
take unnecessary risks even if you believe the tailgas line to be at negative
pressure.
5. Tighten the packing gland and connect the tubing to the probe as shown in Figure 7.
Make sure the three valves on the left of the oven enclosure (V1, V3, V5) are in the
open position as shown in Figure 7. Close the two block valves indicated on the right
side of Figure 7 (V2, V4). Install the probe RTD in the location indicated.
Return to the closed position
Probe
RTD
Location
Installation
Figure 7: Oven Enclosure Tubing Reinstalled
If the connections are leak-tight and company safety personnel have deemed
the atmosphere to be safe, breathing apparatus may now be removed.
6. Reinstall the hole plug at the top of the the oven cabinet.
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2.4.3 Connection of the AC Power Service
The conduit connections for the AC power cable(s) are at the bottom of the analyzer system,
slightly to the right of the centreline, as indicated in Figure 4. The LIVE / HOT power lead is
connected to the AC Terminal Strip (ACTS) Terminal 25, the NEUTRAL power lead is
connected to ACTS:2, and the GROUND lead is connected to ACTS:21. The ACTS is
located at the bottom left of the inside of the control cabinet, as shown in Figure 8. The fused
terminals can be opened by lifting the tab.
Figure 8: Location of ACTS in Control Cabinet
Installation of the conduit, wiring, and disconnect deices must comply with all
applicable, national, local, and company electrical codes. All connections must
be ‘sealed’.
DO NOT energize the AC power supply to the analyzer at this time. The analyzer
system will be powered up at the time of commissioning by Galvanic Applied
Sciences Inc. personnel.
2.4.4 Connection of the Analog Signal Cables
The conduit connector for the Analog Signals, with the label ‘Analog Signals’, is provided on
the bottom right side of the analyzer system control cabinet, towards the front of the cabinet,
as indicated in Figure 3. There is a total of four analog output signal terminals available on
the Input / Output (IO) Board inside the control cabinet, in the location indicated in Figure
9.
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Figure 9: Location of Analog Output Terminals on IO Board
The user may connect to any or all of the available analog output signal terminals as per
their specific requirements. The analog outputs are all loop powered. When loop power is
provided and the current loop between the analyzer and the external control computer is
complete, green LEDs above the connection terminals will illuminate for each connected
analog output signal connected. For a detailed drawing showing the analog signals
connections on the IO board, refer to the DC Signals and Wiring DIagram drawing (Figure
86) in Section 9 of this manual.
Installation of the conduit, wiring, and disconnect devices must comply with all
applicable, national, local, and company electrical codes. All connections must
be ‘sealed’.
2.4.5 Connection of the Digital Signal Cables
The conduit connector for the Digital Signals, with the label ‘Digital Signals’, is provided on
the bottom right side of the analyzer system control cabinet, towards the back of the cabinet,
as indicated in Figure 3. There is a total of four digital signal (relay) terminals available on
the Input / Output (IO) Board inside the control cabinet, in the location indicated in Figure
10.
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Figure 10: Location of Digital Output Terminals on IO Board
The user may connect to any or all of the available digital signal terminals as per their specific
requirements. For a detailed drawing showing the digital signals connections on the IO
board, refer to the DC Signals and Wiring Diagram drawing (Figure 86) in Section 9 of this
manual.
Installation of the conduit, wiring, and disconnect devices must comply with all
applicable, national, local, and company electrical codes. All connections must
be ‘sealed’.
2.4.6 Connection of the Instrument Air
The installation of the analyzer system requires the connection of instrument air to the air
filter. The instrument air must be at a pressure of 80-100 psig (5.5-6.9 barg), and must be
clean, dry, and oil-free as per ANSI/ISA Standard 57.3-1975 R (1981). The instrument air
supplied to the analyzer must be capable of a sustained flow rate of 22 SCFM (37m3/hour)
at 80 to 100 psig.
Prior to connecting the instrument air line to the analyzer, all air lines should be blown down
to remove any possible debris such as dirt, scale, water, oil, etc., that could contaminate the
analyzer system.. The system air pressure regulator, complete with a pressure gauge, is
mounted on the left side of the analyzer system as shown in Figure 11.
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Figure 11: Location of Instrument Air Regulator
Do not adjust the instrument air pressure with this regulator until all internal tubing has been
installed in the oven enclosure as shown in Figure 8. Once all the tubing is installed, the
instrument air pressure indicated on the gauge can be adjusted to a suitable value (typically
30-50 psig).
The control cabinet is purged for two reasons: for hazardous area classification and to
maintain a positive pressure inside the control cabinet to minimize the exposure of electrical
equipment to the corrosive atmosphere commonly found in sulfur recovery units. The cabinet
purge should be initiated as soon as practical after the analyzer system is installed until the
analyzer is commissioned.
The control cabinet purge flow control valve is located inside the purge control box
mounted on top of the analyzer, shown in Figure 12.
Figure 12: Control Cabinet Purge Control Box
To open the purge control box, use the supplied purge system access key. As soon as
instrument air is available, initiate a small purge air flow rate through the control cabinet.
Normal purge flow rates cannot be adjusted until all conduit connections are sealed, and the
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control cabinet door is latched closed. Once normal purge flow has been established, the
conduit connections are sealed, and the control cabinet door is latched shut, the purge
indicator on the front of the purge control box will change colour from red (insufficient
cabinet pressure) to green (normal purge pressure).
2.4.7
Connections of Steam
The steam pressure and temperature requirements for the sample probe steam jacketed
nozzle is given in Table 2 of this manual.
The steam inlet for the sample probe steam jacketed sample probe nozzle should be at the
top of the nozzle, and the outlet should be at the bottom. The outlet of the nozzle should be
connected to the inlet of the steam jacketed ball valve, and the outlet of the steam jacketed
ball valve should be connected into the plant condensate collection system.
All steam lines, the steam jacketed sample probe nozzle, the steam jacketed ball valve, and
the flange between the nozzle and the analyzer system should all be well insulated to prevent
heat loss and improve temperature control.
2.4.8
Connection of the Loss of Purge Signal
The control cabinet purge control box shown in Figure 12 has an integrated pressure switch
that can indicate loss of sufficient control cabinet protective purge air flow. This pressure
switch is equipped with a discrete output to indicate loss of purge. The wires for this pressure
switch are located on the right side of the purge control box. If these wires are connected to
the plant control system, they can be used to generate an alarm in the control room if purge
air is lost. The pressure switch discrete output will generate an alarm signal when the local
purge indicator is red; when this indicator becomes green, no alarm signal is generated.
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Section 3
3.1
Operation
Overview
The 943-TGXeNA analyzer system is designed to operate automatically with a minimum need
for human intervention. Once installation, commissioning and initial start-up have been
completed, the only human intervention required is when the system indicates a problem or
when routine preventative maintenance is scheduled. Section 4 of this manual describes the
local user interface (UI) displayed on the analyzer’s full-colour display and its operation using
the handheld keypad.
The analyzer system computer automatically performs all the normal operational procedures
including sample flow initiation, analysis, back purge and zero calibration, range sensitivity
selection, fault detection, temperature zone control, and fail-safe back purge in the event of an
analyzer fault. Operators are alerted to an abnormal state or fault occurrence through indicators
on the local display located on the control cabinet door as well as fault and warning relay contact
closures.
The only manual adjustments to system controls (not through the computer) are the flow control
of various instrument air streams. Flow adjustment valves for the zero/purge gas flow rate, the
aspirator drive air flow rate and the probe cooler (used for sulfur vapour condensation at the
probe tip) air flow rate are located in the oven cabinet, as shown in Figure 13.
Figure 13: Location of Air Flow Control Valves in Oven Cabinet
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All valves are clearly labeled according to their title and function. The Flow Diagram drawing
shown in Figure 14 provides a schematic of the flow streams in the analyzer sample handling
system.
Figure 14: Sample System Flow Diagram
In normal operation, valves V1, V3, and V5 inside the oven enclosure are open. Isolation on/off
block valves V2 and V4 are provided in the oven enclosure to do the sample probe steam-out
procedure, if required. Refer to Section 7.9 for the sample probe steam out procedure.
3.2
Flow Control Settings
The flow control settings govern system operation. Once the system has been commissioned
and the flow rates have been set, only occasional adjustments should be required. Flow settings
will be checked and verified when doing the recommended routine preventative maintenance
procedure given in Section 6.2.
3.2.1 Cabinet Purge Air Flow Adjust Valve
The Cabinet Purge Air Flow Adjust Valve controls the rate of purge air entering the control
cabinet. The Cabinet Purge Air Flow Adjust Valve is located inside the purge control box
mounted on top of the analyzer, shown in Figure 12. This control box can only be opened
with the key that is supplied along with the analyzer system. As a minimum, this valve is
adjusted until the control cabinet purge pressure indicator goes from Red to Green plus ½ a
turn. The control cabinet door must be closed and fully latched (top and bottom latches both
closed) when adjusting the cabinet purge air flow adjust valve. If the control cabinet
overpressure relief valve mounted on the upper right hand side of the exterior of the control
cabinet opens, reduce the cabinet purge flow rate until the valve is midway between the safe
purge indication flag (Red to Green transition) and the over-pressure release point (audible
‘flapping’ of the relief valve).
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The safe purge indication (Red to Green flag) occurs at a control cabinet pressure positive
pressure of 1" H2O (0.25kPa) above atmospheric pressure. The over-pressure relief valve
opens at a control cabinet pressure of 4" H2O (1kPa) above atmospheric pressure. The
normal control cabinet purge flow rate is 1.3 SCFM (2.2m3/h), as governed by selected
orifices mounted in the cabinet purge vents.
Purging of the control cabinet is required for hazardous area classification and to mitigate
corrosive element exposure on the system electrical equipment. This adjustment must be
performed with the Cabinet Cooler Air Valve closed, as the cabinet cooler adds additional
air flow into the control cabinet. If the cabinet cooler air valve is NOT closed when adjusting
the purge air flow, it is possible that the cabinet internal pressure will be sufficient when the
cooler is on (green flag) but insufficient when the cooler is off (red flag).
Seventeen minutes of normal purge air flow is required before the interior of the
control cabinet may be considered safe. DO NOT apply power to the control
cabinet until the control cabinet has been purged, with a green flag indicated on
the purge control box, for at least 17 minutes.
If a green flag cannot be achieved, this indicates that there is a leak somewhere in the control
cabinet that is preventing the necessary positive pressure from being established inside the
control cabinet. Check the retaining nuts on the cabinet door latches and tighten if necessary.
Also check the rubber sealing strip around the door opening for damage.
3.2.2 Cabinet Cooler Air Valve
A vortex cooler is mounted on the top of the analyzer control cabinet to maintain the control
cabinet interior temperature at or below a given setpoint. The location of the vortex cooler is
shown in Figure 15.
Figure 15: Location of Vortex Cooler
Air flow is automatically switched on to the vortex cooler by a control solenoid when the
temperature inside the control cabinet exceeds a user-configurable set-point (by default,
35°C). Additionally, there is a Cabinet Cooler Air Valve mounted behind the purge control
box on the top of the control cabinet. This block valve is used for coarse flow rate adjustment
to the cabinet cooler and is typically set to fully open or fully closed. Minor throttling of the air
flow to the cabinet cooler is possible by opening this valve only partially. The interior
temperature of the control cabinet is indicated on the analyzer display as Cabinet
Temperature. When the cooler solenoid switches on, supplying air to the vortex cooler, the
additional air flow into the control cabinet will cause the over-pressure relief valve to open.
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3.2.3 Condenser Cooling Air Flow Adjust Valve
Sulfur vapour is always present in tail gas streams in sulfur recovery units. However, the
presence of this sulfur vapour inside the analyzer sample probe and sample handling system
is detrimental for two reasons. Firstly, sulfur vapour can interfere with the measurement of
both hydrogen sulfide and sulfur dioxide. Secondly, if sulfur vapour inside the sample probe
or sample handling system were to condense, it could lead to flow blockages inside the probe
or sample handling system. For this reason, the sample probe is designed to eliminate as
much sulfur vapour from entering the sample probe and sample handling system as possible.
This is accomplished using a ‘cold finger’ sample probe condenser at the probe tip that
condenses sulfur vapour inside the process pipe, as shown in Figure 16.
Figure 16: Sample Probe
Sulfur condensing on the probe’s ‘cold finger’ is hydrostatically returned to the process
stream and does not enter the sample probe. Air flow to the probe condenser is controlled
via a solenoid valve.
Actuation of the probe cooler solenoid is determined by either the temperature of
the incoming sample gas OR by the sulfur vapour content in the incoming sample
gas as measured by the analyzer. The control point for the probe cooler solenoid
is user configurable – refer to Section 5.4 for more details.
The Condenser Cooling Air Adjust Valve allows the user to control the flow rate of the
instrument air used to cool the condenser section of the sample probe.
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The concentration of sulfur vapour in the process sample gas that makes it into the probe
and into the measurement cell is measured and displayed on the analyzer display as Sulfur
Vapour (Svap). The Condenser Cooling Air Adjust Valve can be adjusted to reduce the
sulfur vapour concentration. There is normally a long time constant associated with this
adjustment. Several factors can impact the temperature of the gas exiting the probe. Factors
that affect the temperature of the gas exiting the probe include:
•
•
•
•
•
Changes in process gas temperature
Changes in cooling air temperature
Changes in the process gas sample aspiration rate
Elapsed time since a probe back-purge
Duration of a probe back purge.
During a zero-calibration sequence or back purge operation, instrument air is forced into the
sample probe and the analyzer sample handling system, including the measurement cell.
The indicated sulfur vapour concentration during and immediately after a back-purge
operation is NOT representative of the sulfur vapour concentration in the process sample
gas.
The condenser cooling air flow adjust valve is typically opened two turns from fully closed.
The optimal situtation is that the indicated concentration of sulfur vapour in the
process sample gas exiting in the measurement cell is lower with the probe
cooling air on than with the probe cooling air off, without causing plugging of the
sample probe.
3.2.4 Zero Air Flow Adjust Valve
The Zero Air Flow Adjust Valve is used to adjust the flow rate of the instrument air used
for back purge and zero calibration operations. The zero calibration is performed when the
analyzer is in back-purge condition, and the probe and sample handling system, including
the measurement cell, are full of zero gas. Under normal operating circumstances, the valve
is adjusted so that the response time from sample conditions to a stable zero reading is
between 2 and 5 seconds, although depending on the sample probe length, this time may
be somewhat longer. The stabilized zero response is determined by monitoring the time
required for the analyzer gas concentration outputs to stabilize at near zero levels once the
analyzer has been switched from sampling to zero (back purge) mode. Excessive zero air
flow rates will overly cool oven components and may lead to cell temperature control issues.
If the zero air flow rate is set too low, inadequate flushing of the measurement cell before a
zero adjustment is made may result. If the analyzer is zeroed before the measurement cell
has been adequately flushed with zero gas, the concentration readings obtained on sample
gas after returning to sampling mode will likely be lower than expected. This valve is typically
opened one turn from fully closed. In extraordinary circumstances, if sample system or
sample probe clogging due to sulfur vapour condensation occurs, the Zero Air Flow Adjust
Valve may be opened wide to provide a solid back purge pressure. Alternately, the Zero Air
Flow Adjust Valve may be turned down to a trickle for an extended period (20-30 minutes)
to allow the heat of the oven and probe nozzle to re-liquefy any solid accumulation (plugging)
before increasing the flow rate dramatically to purge out the re-liquefied sulfur. If this is not
successful in clearing a blockage in the probe, a steam purge of the probe will be required.
Refer to Section 7.8.
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3.2.5 Aspirator Drive Air Flow Adjust Valve
The Aspirator Drive Air Flow Adjust Valve indirectly controls the rate of process sample
gas extraction from the tail gas duct. The aspirator drive air is plumbed to a venturi-type
eductor integral to the measurement cell block, as shown in the exploded view of the
measurement cell in Figure 17.
Figure 17: Measurement Cell Block (Exploded View)
The aspirator has a narrow nozzle, and when flowing aspirator drive air passes out of this
nozzle, it expands, causing the pressure on the aspirator suction port to drop. This aspirator
suction port is connected to the outlet of the measurement cell. The design of the analyzer
sample system is such that process sample gas is extracted from near the centre of the
process duct and vented at the wall of the process duct through the same access port.
Ideally, enough aspirator drive air is provided to present a measurement cell outlet pressure
of 2-3" H2O (0.5 to 0.75 kPa) below the process duct pressure. This pressure differential
across the measurement cell draws sample up the sample probe, and after the sample is
drawn through the measurement cell it mixes with the aspirator drive air at the aspirator
suction port and is expelled back down the sample probe nozzle and into the process pipe.
In practice, the aspirator drive air flow is adjusted such that the response time from a zero
signal to stable process measurement is less than 30 seconds, though the actual response
time is highly dependent on the sample probe length – the longer the probe, the longer the
response time will be. The adjustment of the aspirator drive air flow is made by monitoring
the amount of time it takes for the displayed concentration values on the analyzer display to
reach stable values after the analyzer has been switched from purge mode to sampling
mode.
An additional consideration that must be made when adjusting the aspirator drive air flow
rate is that if the aspirator drive air flow is set too high, the aspirator air flow will draw a
significant amount of heat out of the measurement cell block, and cause the displayed cell
temperature to drop, potentially to below the low cell alarm setpoint. Thus, care must be
taken when adjusting the aspirator drive air flow rate to obtain a balance between stable
temperature control and rapid response time from zero to sample. Typically the aspirator
drive air flow adjust valve is set to two turns from fully closed, but the optimal balance
between temperature control and response time will depend on specific conditions of the
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analyzer installation, including but not limited to steam temperature and pressure (both oven
steam and probe nozzle steam), ambient temperature, aspirator drive gas temperature, and
the quantity and quality of insulation applied to the steam lines, sample probe nozzle and
ball valve, and analyzer flange.
3.2.6 System Regulator
The system instrument air regulator is normally set to 30 psig. However, the specific value
of this setting is not critical for system operation provided that the pressure is sufficient to
provide adequate sample aspiration, system zeroing, and effective back purge. In situations
where additional supply pressure is required, the system regulator may be adjusted to its
maximum output of 50 psig without harming the analyzer.
As the cabinet cooler draws significant flow of instrument air, it is advisable to
do all adjustments of the zero and aspirator drive air with the cabinet cooler
switched on. In this fashion, deficiencies with the pressure and / or flow rate of
the instrument air supply can be immediately detected.
3.3
Analyzer Outputs
The 943-TGXeNA analyzer generates both analog and digital output signals for connection to
the users’ plant control system. The analog output signals are used to output calculated
concentration and other pertinent analysis values, and are user-configurable for range, output
parameter, and output behaviour. The digital output (relay) signals are used for outputting
analyzer and purge status signals.
3.3.1 Analog Outputs
There are four available analog outputs available on the 943-TGXeNA. The analog outputs
are all loop-powered 4-20 mA outputs which are fully user configurable for output parameter,
output range, and update behaviour when the analyzer is in back purge mode. Each analog
output can be configured to output one of the following parameters:
•
•
•
•
•
•
•
Air Demand (range starts at negative full scale for 4 mA)
H2S Concentration (% or PPM)
SO2 Concentration (% or PPM)
COS Concentration (% or PPM)
CS2 Concentration (% or PPM)
H2S:SO2 Ratio
Sigma S (sum of H2S and SO2 concentrations)
Each analog output can also be user configured to be either Track or Hold. Track and hold
refer to the behaviour of the analog output when the analyzer is placed in back-purge mode.
If an output is programmed to be Track, the output value will track along with the calculated
values when the analyzer is placed in back purge mode, and thus will go to zero (4 mA)
when the analyzer is in back purge mode. If an output is programmed to be Hold, it will hold
the last known good value from when the analyzer was in sampling mode and continue to
output this good concentration value until the analyzer goes back into sampling mode. Thus,
the analog output will NOT go to 0 (4 mA) when the analyzer is in back-purge mode.
Typically, an analog output configured to output air demand will be configured for Hold, while
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concentration outputs are configured for Track, though this is entirely up to the user to
decide. The value output by each analog output is updated once per second. The
configuration of the analog outputs can be done either using the local display and keypad,
as described in Section 4.8.1, or by using the Web GUI, as described in Section 5.4.
3.3.2
Digital Outputs (Relays)
There are four digital outputs on the analyzer which are used for outputting analyzer status
and other operational condition data. These digital outputs are all zero potential form C relay
contacts, each isolated to 250 Vrms. The four status and operational relays are Status,
Service, Mode, and Control. Each of these relays has an associated status indicator on the
analyzer display for visual confirmation of the analyzer status. In addition to the 4 digital
outputs associated with the analyzer operation, there is an independent Loss of Purge
signal output connected to the purge control box on top of the analyzer control cabinet. The
function of each relay is described in the following sections.
3.3.2.1
Status
The Status output indicates whether there are any faults present that will force the
analyzer into back-purge mode until the fault is cleared. Table 3 describes the Status
relay states.
Table 3: Status Relay States
State
Display Indicator Colour
Normal
Green
Fault
Red
Explanation
All monitored system parameters are
within normal limits. No faults are present
At least ONE of the following conditions
is true:
• Analyzer power is off
• Measurement Cell temperature
is outside specified range
• Probe temperature is outside
specified range NOTE: Only for
analyzers
equipped
with
probe temperature RTD
• Measured
sulfur
vapour
concentration is above specified
fault setpoint
• Spectrometer parameters are
outside specified range
• The system computer is unable
to communicate with the I/O
board
• The system computer is unable
to communicate with the
spectrometer
An analyzer with at least one fault condition present will be unable to carry out sampling
and analysis of the process gas. When the fault condition clears, the analyzer will
automatically perform an auto-zero calibration and then return to normal sampling mode.
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3.3.2.2
Service
The Service output indicates whether there is an issue with the analyzer that requires
operator attention. Table 4 describes the Service relay states.
Table 4: Service Relay States
Condition
Display Indicator Colour
Normal
Green
Warning
Red
Explanation
All monitored system parameters are
within normal limits. No faults are present
At least ONE of the following conditions
is true:
• Control
cabinet
interior
temperature is outside specified
range
• Spectrometer integration period
>500 ms
• Sample Absorbance >2.0 AU
• Sulfur vapour concentration
exceeds specified warning set
point
• Spectrometer peak height at
last zero calibration is too low
An analyzer with any active warnings will continue in sampling mode and provide valid
analysis results, although warnings indicate that there is an issue with the analyzer that,
if left unchecked, could lead to a fault condition. The warning condition will clear when the
parameter that caused the warning condition returns to its normal range.
3.3.2.3
Mode
The Mode output indicates when a zero calibration, either manually requested or
automatic, is in progress. Table 5 describes the Mode relay states.
Table 5: Mode Relay States
Condition
Display Indicator Colour
Run
Green
Calibrate
Yellow
Explanation
Analyzer is not performing a zerocalibration run, either manual or
according to an automated schedule.
One of the following conditions is true:
• A clock-triggered automatic zero
calibration cycle is in progress
• A manually requested zero
calibration cycle is in progress
• Analyzer power is off
When this indicator is in the ‘Calibrate’ state, the analyzer is not measuring the process
tail gas. After a calibration cycle is complete, the Calibrate state will persist for a specified
time interval (the Zero Hold Interval), allowing process gas to reach the measurement cell
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and the analyzer concentration measurements to return to stable process values prior to
returning to the Run state.
If there are any faults currently present (i.e. Status relay is in fault state) the Mode
indicator CANNOT switch to Calibrate – Calibration is ONLY possible when all fault
conditions are cleared, and the Status relay is in the Normal condition. The only
condition under which the Status relay can be in Fault while the Mode relay is in
Calibrate is if the analyzer power is off.
3.3.2.4
Control
The Control output indicates whether the analog output signals are valid. Table 6
describes the Control relay.
Table 6: Control Relay States
Condition
Display Indicator Colour
Auto
Green
Manual
Yellow
Explanation
ALL the following conditions are true:
• Status indicator is Normal (i.e. no
fault conditions present)
•
Mode indicator is in Run state
(i.e. analyzer is not performing a
zero calibration)
• Online / Offline switch is in the
Online position (i.e. analyzer is
not under maintenance)
• Analyzer power is on
At least one of the conditions for the relay
to be in the Auto state is NOT true.
When the relay is in the Auto state, the analyzer is indicating that it believes that the data
being output on the analog outputs are valid current measurements of the tail gas process
steam. If the Control relay is in the Manual state, this indicates that the analyzer believes
that the data being output may not be valid. The purpose of this indicator is to signify
when the analyzer outputs are suitable for use as closed loop control inputs. When this
indicator is in the Manual state, no control action should be taken based on the analyzer
output signals. This indicator is generated on the basis of the other analyzer indicators,
as well as the condition of the Online / Offline mode toggle on the display (refer to
Section 4.3.1). The Control relay state is automatically returned to Auto once all the
conditions required for the Auto state have been met. While the Control relay is in the
Manual state, any analog output that is configured as Hold will be held.
3.3.2.4
Loss of Purge
The Loss of Purge signal relay, which is an integral component of the Purge Control box
on the top of the analyzer control cabinet, indicates the status of the analyzer’s control
cabinet safety purge. When a safe positive pressure as described in Section 3.2.1 is
present inside the analyzer’s control cabinet, the Purge indicator on the outside of the
purge control box will be green and the purge fail relay will be in the normal state. When
the safe positive pressure is lost, such as when purge air flow is lost or the control cabinet
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door is opened, the purge indicator on the outside of the purge control box will be red and
the Loss of Purge relay will be in the fault state.
The relay contacts of the Loss of Purge relay MUST be connected to a plant
alarm system in a continuously attended location, such as in the plant control
room, in order to maintain the hazardous location certification of the analyzer.
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Section 4
4.1
Local System Control
Overview
The operator can locally control the analyzer via the full colour, multi-page display mounted in
the control cabinet in conjunction with the hand-held keypad that can be connected to a port on
the control cabinet door. The keypad, in conjunction with the local display, can be used to view
a variety of analysis and status information, as well as to make changes to some analyzer
operational parameters.
4.2
Using the Local Display and Handheld Keypad
4.2.1 Local Display User Interface
The local display user interface consists of a series of panels which are accessed via tabs
at the top of the screen. The different panels of the local display user interface display a
variety of different information and are described in sections 4.3 to 4.8 of this manual. The
local display as it appears when the Analysis 1 panel is active is shown in Figure 18.
Figure 18: Local Display User Interface
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The coloured indicator circle at the top right of the display is visible on all panels. It provides
a quick indication of the analyzer status. When it is green, the analyzer has no active faults
or warnings - all monitored parameters are within their specified ranges. When it is yellow,
this indicates that the Service relay is in the Warning state. When it is red, this indicates that
the Status indicator is in the Fault state, and so the analyzer will remain in back-purge mode
until the active fault(s) have cleared.
4.2.2 The Handheld Keypad
The handheld keypad is used to navigate between the various panels of the local display
user interface, perform a variety of control operations, and enter numerical data in usereditable fields. It is shown in Figure 19.
Figure 19: Handheld Keypad
The white keys on the keypad are used for numerical data entry, including a decimal point.
The functions of the red keys are described in Table 7.
Table 7: Keypad Red Key Functions
Key Label
PANEL PREV
PANEL NEXT
FIELD PREV
FIELD NEXT
HOME
PURGE
DEL
EXIT
ENTER
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Function
Changes the active panel to the previous panel. The previous panel is the tab to the left of
the currently displayed tab. When at the left-most tab, pressing this key will move to the
right-most tab.
Changes the active panel to the next panel. The next panel is the tab to the right of the
current displayed tab. When at the right-most tab, pressing this key will move to the left-most
tab.
On a panel with actionable controls or editable fields, pressing this key will move to the
previous (top to bottom, right to left) control or field.
On a panel with actionable controls or editable fields, pressing this key will move to the next
(top to bottom, left to right) control or field
Returns to the Analysis 1 panel immediately from anywhere within the Local Display User
Interface
Pressing this key while the analyzer is in sampling mode will switch the analyzer to backpurge mode. Pressing this key while the analyzer is in back-purge mode, provided that the
Status relay state is Normal, will place the analyzer in sampling mode. This key is functional
on any panel of the local display user interface.
Deletes the last numerical value. Only functional when editing a numerical data entry field.
Leaves a data entry field when editing without saving the current value. Only functional when
editing a numerical data entry field.
After highlighting an editable numerical data entry field using the FIELD NEXT / FIELD PREV
keys, pressing ENTER will allow the user to edit the data. After editing the numerical data
using the numerical keys, pressing ENTER again will save the changes to the analyzer.
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The handheld keypad should only be connected to the analyzer or disconnected
from the analyzer when the installation location is known to be non-hazardous.
4.3
Analysis 1 Panel
The Analysis 1 panel shown in Figure 18 shows important current analytical parameter results,
status indicators, and operator controls.
4.3.1 Online/Offline Mode Toggle
The Online / Offline Mode Toggle at the top right of the Analysis 1 panel shown in Figure
20 is a button that can be used to toggle between Online and Offline modes.
Figure 20: Online / Offline Mode Toggle
When this toggle is set to Online, the indicator will be green. In this case, the Control relay
will be in the Auto (green) state, indicating that the analyzer believes the data being output
on the analyzer’s analog outputs to be valid. Prior to performing maintenance or other tasks
that may cause the output data to become invalid, this control should be toggled to the Offline
(red) state by using the FIELD NEXT / FIELD PREV keys to highlight it and then pressing
ENTER to toggle it. When this control is set to Offline mode, it will become red. At the same
time, the Control relay state will change from the Auto state to the Manual (yellow) state,
indicating that the analyzer believes the output data to be invalid. Once maintenance is
complete, this toggle should be set back to the Online state by again highlighting it using the
FIELD NEXT / FIELD PREV buttons and pressing ENTER.
The analyzer’s Online or Offline status does not affect the operation of the analyzer in any
way. Rather, this function has been implemented as a convenience to the operator, as it
provides an easy way for the operator to indicate to the control room that the analyzer is
currently undergoing maintenance or servicing and thus the data being output by the
analyzer is not valid.
When the control is toggled from Offline to Online, the Control relay will change state from
Manual to Auto ONLY if the conditions listed as prerequisite for the Auto state in Table 6
have been met.
4.3.2 Concentration Fields
The concentration fields shown in Figure 21 are non-editable fields that show the current
value of the concentrations for all analyzed components.
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Figure 21: Analysis 1 Concentration Fields
The analyzer’s physical measurement range, which is determined by the length of the
measurement cell, is optimized for typical on-ratio (that is to say, non-upset) concentrations
of H2S and SO2. COS and optionally CS2 concentrations are also displayed here. The sulfur
vapour (Svap) is monitored to indicate when there may be a problem with the sulfur condenser
“cold finger” at the tip of the sample probe (refer to Section 3.2.3) and to prevent sulfur
plugging inside the analyzer sample handling system.
4.3.3
Air Demand
The Air Demand field and Air Demand trend graph shown in Figure 22 show the current
calculated Air Demand (% Excess Air) and the recent trend in the Air Demand data. The Air
Demand field is read-only and cannot be edited.
Figure 22: Air Demand Value and Trend
The air demand reading is an indicator of the current process status relative to the optimal
ratio (typically a 2:1 ratio H2S:SO2). If the air demand value is negative, this indicates that
the H2S concentration is too high and there is insufficient air being added. If the air demand
value is positive, this indicates that the SO2 concentration is too high and there is excess air
being added. If the air demand is zero, this indicates that the H2S to SO2 ratio is at the optimal
value and the air does not need to be adjusted.
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The graphical trend displayed below the Air Demand field shows the trend in the air demand
data over a recent period of time, with the current value at the right side of the graph. The xaxis (time) and y-axis (concentration) ranges of this graph can be adjusted on the
Configuration Panel Display Sub-panel (refer to Section 4.8.3). This trend is updated once
per second.
4.3.4
Relay Indicator Fields
The relay indicators at the bottom right of the Analysis 1 panel indicate the current state of
the analyzer’s four relay outputs. The relay indicators are shown in Figure 23.
Figure 23: Relay Indicators
The relay indicators provide at-a-glance status information. If all the indicators are green,
this indicates that the analyzer is functioning normally with no faults or warnings active. If the
Status indicator is red, this indicates the analyzer has at least one fault active, and is unable
to sample until the fault condition(s) are cleared. If the Service indicator is yellow, this
indicates that maintenance will be required soon. Refer to the Indicators panel to diagnose
which fault(s) and / or warning(s) are active. See Section 4.5 for more details about specific
faults and warnings. If Mode and Control are both yellow, this indicates the analyzer is
carrying out a zero calibration. For more information on the relay outputs, refer to section
3.3.2.
4.3.4
Manual Zero
The Manual Zero control is used to manually initiate a zero calibration cycle. It is shown in
Figure 24.
Figure 24: Manual Zero Control
The Model 943-TGXeNA performs a zero calibration in order to check and adjust the
analyzer’s zero baseline. It is ONLY performed when the analyzer is in back purge and the
measurement cell is filled with a gas that doesn’t absorb UV radiation in the wavelength
range of interest (i.e. instrument air or nitrogen). The zero calibration sets the absorbance
baseline to 0 AU across the entire measurement wavelength range during this process. To
initiate a Manual Zero Calibration cycle, simply use the FIELD NEXT / FIELD PREV buttons
to highlight the Manual Zero control, then press ENTER. The zero calibration sequence is
identical whether triggered manually using the Manual Zero control, automatically when all
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existing faut conditions are cleared and prior to the analyzer returning to sampling mode, or
automatically according to the set Auto Calibration Frequency (refer to Section 4.8.4 for more
details on Auto Calibration).
No span calibration is required under normal circustances for an installed
analyzer. There is no span calibration functionality available on the Model 943TGXeNA.
A Manual Zero zero calibration cycle CANNOT be initiated while the analyzer has
any fault conditions (Status relay is red) present. Using this control while the
Status relay is red will have no effect.
When a zero calibration cycle is triggered, the zero calibration sequence proceeds in the
following order:
1. The Mode relay output state changes to Calibrate (yellow) and the Control relay output
changes to Manual (yellow)
2. Any analog outputs configured for Hold behaviour will hold the last value they were
outputting prior to the zero calibration cycle being initiated.
3. The Zero / Sample solenoid switches off, allowing zero gas to purge the analyzer’s
sample handling system, including the measurement cell, as well as the sample probe.
This purge continues for the duration specified by the Zero Purge Interval parameter
(refer to Section 4.8).
4. Once the zero purge time has elapsed, the computer collects 10 spectrometer scans
on zero gas and averages them together to calculate a new zero baseline.
5. The Zero / Sample solenoid switches on, allowing sample gas to be drawn back up the
probe and into the analyzer sample handling system and measurement cell by the
aspirator.
6. During this period, any analog outputs configured for Hold behaviour will continue to
hold the last value output prior to the initiation of the calibration cycle The analyzer
waits for the number of seconds specified by the Zero Hold Interval parameter of the
configuration data (Section 4.8.4) to allow the calculated concentration values to
stabilize at on-line values before updating the analog outputs.
7. If no pre-existing fault conditions are present, the Mode relay output changes to Run
(green) and the Control relay output changes to Auto once the Zero Hold Interval time
has elapsed.
4.3.5 Back Purge Indicator and Control
The fail-safe condition of the analyzer is to have instrument air flowing through the
measurement cell, the analyzer sample handling system, and the sample probe. This is a
condition known as back purge. The Back Purge indicator and manual controls are shown
in Figure 25.
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Figure 25: Back Purge Indicator and Manual Controls
The back purge indicator shows the current back purge status. If it is green, this indicates
that the analyzer is currently drawing sample into the measurement cell. If it is red, this
indicates that the analyzer is currently in back purge, either due to the analyzer being
manually placed into back purge OR due to a fault condition causing an automatic back
purge OR because the analyzer is currently carrying out a zero calibration cycle.
Below the Back Purge Indicator are two check boxes which can be used to manually set the
analyzer into back purge or sampling mode. To choose which mode is active, select the
desired mode using the FIELD NEXT / FIELD PREV buttons and press ENTER to choose.
Alternatively, pressing the PURGE button will switch to the currently inactive mode (i.e.
pressing purge while the analyzer is sampling will cause it to switch to back purge mode and
vice versa).
Prior to performing any maintenance, particularly if any sample system tubing is
to be disconnected, the analyzer should be placed into back purge mode and
purged for at least 5 minutes. This will prevent any toxic gases from remaining in
the sample system if tubing is to be disconnected.
If Sample is selected but the back purge indicator remains red, this indicates that a fault
condition likely exists. Once the fault condition(s) are cleared, the analyzer will automatically
return to sampling mode after first performing a zero calibration cycle. If the analyzer is set
to back purge mode while a fault condition exists, the analyzer will NOT automatically return
to sampling mode when the fault condition(s) are cleared.
4.4
Analysis 2 Panel
The Analysis 2 panel shown in Figure 26 displays a variety of analysis information and system
operating parameters.
Figure 26: Analysis 2 Panel
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4.4.1
Online / Offline Control
At the top right of the Analysis 2 panel is the Online / Offline toggle control, as shown in
Figure 27.
Figure 27: Online / Offline Control
This toggle has the same function on the Analysis 2 panel as it does on the Analysis 1 panel.
Refer to Section 4.3.1 for details.
4.4.2
Concentrations, Air Demand, and Trend Graph
Like the Analysis 1 panel, the Analysis 2 panel displays live concentration values for all
monitored parameters, as well as a trend graph showing recent data trends. Refer to Figure
28.
Figure 28: Data Fields and Trend Graph
Unlike the Analysis 1 panel, the Analysis 2 panel does not show the Sulfur Vapour (Svap)
concentration, but it does show all other concentration values (including CS2 if the analyzer
is configured for this measurement). On the Analysis 2 panel, the largest data fields are for
the percentage concentrations of H2S and SO2, with the COS, CS2 (if present) and Air
Demand fields being smaller in size. The trend graph shown below the H2S and SO2
indicators indicates the recent trend in concentration for all measured parameters displayed
on this panel. The colour of each component’s trend line matches the colour of that
component’s data field on this panel. The Air Demand, on this panel indicated as Air, does
not have a line on the trend graph on this panel. The trend graph is updated once per second,
with the most recent result being found on the right side of the graph. The x-axis (time) and
y-axis (concentration) ranges of this graph can be adjusted on the Configuration Panel
Display Sub-panel (refer to Section 4.8.3).
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4.4.3
System Operating Parameters
The Analysis 2 panel also displays several important system operating parameters, as
shown in Figure 29.
Figure 29: System Operating Parameters
The approximate normal operating ranges for these parameters and an explanation of each
parameter is given in Table 8.
Table 8: System Operating Parameters
Parameter
Operating Range
(Typical)
Cell Pressure
670 – 1100 mmHg
Cell Temperature
140 – 160°C
Probe Temperature
Cabinet
Temperature
4.5
110-120°C
5 – 45°C
Explanation
Indicates the measured pressure inside the
measurement cell, in millimetres of mercury (760
mmHg is atmospheric pressure at sea level). The
cell pressure should be observed to drop by
around 50 mmHg (or more) when the analyzer is
switched from back-purge to sampling. If the
pressure does not drop at all, or rises, when the
analyzer is switched from back purge to
sampling, this is an indication of a probe plugging
problem. Refer to section 7.9 for details.
Indicates the measured temperature of the
measurement cell block. If temperature goes
outside user configurable range, analyzer will go
into fault mode.
Measures the temperature of the gas coming out
of the sample probe. If temperature falls outside
user configurable range, analyzer will go into fault
mode.
Indicates the temperature inside the control
cabinet via a temperature sensor on the analyzer
spectrometer. Indicated temperature depends on
ambient
environmental
temperature.
If
temperature falls outside user configurable
range, a warning will be triggered. NOTE: If this
temperature exceeds 45°C for a long period of
time, irreparable damage to the spectrometer
could result.
Indicators Panel
The Indicators panel shown in Figure 30 indicates which fault and warning conditions (if any)
are currently active and a historical record of the last 25 fault / warning events.
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Figure 30: Indicators Panel
The top 6 rows in the historical grid are for fault conditions, while the bottom five rows are for
warning conditions. Every time a fault or warning occurs, an X is placed in the farthest right cell
for that fault or warning (i.e. the current situation). When that fault or warning is cleared, the X
moves one to the left, and a new empty cell appears in the farthest right cell of that fault or
warning. A new column is added to the entire grid any time a fault or warning appears or is
cleared; there is no specific time at which a new column is added, so just by looking at the
historical grid it is not possible to determine the exact time at which a fault or warning appeared
or was cleared.
The column of coloured squares at the right is a column of indicators that indicates current
status. If all these squares are green, there are no active faults or warnings, and the analyzer is
operating normally. If at least one of the fault indicators is red, the analyzer will be in fault
condition and cannot analyze sample; this fault condition cannot clear until ALL of the fault
indicators change to green. The analyzer will continue to operate if any of the warning indicators
are yellow, but maintenance is suggested as soon as is convenient as several warning
conditions could result in fault conditions in the future if not dealt with.
To clear this historical faults and warnings, use the FIELD NEXT or FIELD PREV buttons to
highlight the Clear Fault / Warning History button at the bottom of the panel, then press
ENTER to clear. Note that any faults or warnings which are currently active WILL NOT clear
from the historical grid, and will remain in the right most column.
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4.5.1
Fault Conditions
Table 9 describes each of the fault conditions listed in the fault table on the Indicators panel.
Table 9: Analyzer Faults
Fault
Cell Temperature
High High Sulfur
Measure Range
Reference Range
Dark Range
I/O Board
Explanation
Measurement cell temperature is either below Low Cell
Temperature setpoint or above High Cell Temperature
setpoint.
Measured sulfur vapour content exceeds high sulfur vapour
concentration fault setpoint
Spectrometer signal is out of range while analyzer is
measuring sample (signal either off scale or too low).
Spectrometer signal is out of range while analyzer is in back
purge mode (signal either off scale or too low)
Spectrometer dark level (i.e. signal when no light is present) is
either too low or too high.
System computer is unable to communicate with Input / Output
board and / or spectrometer
Some of these faults may clear by themselves (particularly the cell temperature fault and the
high high sulfur fault) but others may require maintenance or even hardware replacement to
resolve. Refer to Section 7.2 for more detail on how to troubleshoot active faults.
4.5.2
Warning Conditions
Table 10 describes each of the warnings listed in the warning table on the Indicators panel.
Table 10: Analyzer Warnings
Warning
Cabinet Temperature
High Absorbance
High Integration Period
Low Reference Peak
High Sulfur Vapour
Explanation
Control cabinet internal temperature is either below low
cabinet temperature setpoint or above high cabinet
temperature setpoint.
Measured absorbance as shown on the Absorbance spectrum
exceeds 2.0 AU when analyzer is in sampling mode. Typically
indicates that measured concentration of at least one
component is out of range
Integration period required to obtain an in-range spectrometer
signal when analyzer is in back purge mode > 500
milliseconds.
Spectrometer signal peak height when analyzer is in back
purge mode <24000 A/D counts
Measured sulfur vapour content exceeds high sulfur vapour
concentration warning setpoint
Some of these warnings may clear by themselves, particularly the cabinet temperature
warning and the high sulfur vapour warning, but others will not be able to be cleared without
performing maintenance on the analyzer. Refer to section 7.2 for more detail on how to
troubleshoot active warnings.
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4.6
Spectrum Panel
The Spectrum panel shown in Figure 31 shows the current transmission spectrum being
received by the control computer from the analyzer’s spectrometer.
Figure 31: Spectrum Panel
The transmission spectrum shows the intensity of ultraviolet light, in A/D counts, being received
at every pixel of the spectrometer. The spectrometer has a total of 2048 pixels, with an
approximate 0.3nm resolution between the pixels. The x-axis of the spectrum is unlabelled, but
it shows the wavelength range with the shortest wavelengths at the left and the longest
wavelengths on the right. Only a range of 530 of these pixels is actually used for calculating the
concentration values. The higher the A/D counts are for a given wavelength, the greater the
intensity of the light transmitted through the measurement cell to the detector at that specific
wavelength is. In the bottom right corner of the panel are a series of three fields giving data
about spectrometer parameters, shown in Figure 32.
Figure 32: Spectrometer Parameters
These three parameters are described in Table 11.
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Table 11: Spectrometer Parameters
Parameter
Peak Height
First Vector Pixel
Dark Level
Explanation
Displays the peak height of the transmission spectrum, in
A/D counts. Should be approximately 28000-29000 when
analyzer is in back purge mode.
Displays the intensity of light being received at the first
vector pixel, in A/D counts. The first vector pixel is the first
pixel that is used for calculating concentration values.
Displays the intensity of light being received when the
spectrometer is dark (i.e. no light present). This value
should be in a range between 400 and 900 A/D counts.
Below the spectrum are two buttons referring to a parameter called Integration Period, the Set
Integ. Time button and the Optimize Integ. Time button. The integration period is the duration
of time that light is collected by the pixels of the spectrometer before being read by the control
computer. For example, in Figure 31 the integration time is given as 123.69 milliseconds. This
means that the light incident on the spectrometer pixels is allowed to accumulate for 123.69
milliseconds before being read by the control computer; the spectrometer pixels are then zeroed
and allowed to collect light again. The displayed transmission spectrum, then, shows the
intensity of light collected at every pixel in this duration of time. The integration time is a
compromise to optimize the resolution while minimizing noise in the spectrum. A short
integration time will optimize the resolution and show fine detail in the spectrum, but the noise
level may be relatively high. Contrarily, a long integration time will reduce noise, but fine detail
in the spectrum may be lost. The integration time has a maximum value of 1000 milliseconds.
The optimal integration time for the current analyzer conditions can be automatically calculated
by pressing the Optimize Integ. Time button. Use the F4 / F3 keys to highlight this button, then
press ↵ to optimize the integration time. Once pressed, the control computer will adjust the
integration time such that the peak height of the displayed spectrum reads approximately 28000
A/D counts. If this peak height cannot be achieved even with a maximum integration time of
1000 ms, this indicates a problem with the analyzer’s optical system. Refer to section 7.2 for
troubleshooting tips.
Optimizing the Integration Time should ONLY be performed when the analyzer is in
back purge mode. Attempting to optimize the integration time when the analyzer is
in sampling mode may negatively affect the analyzer baseline, and thus the
analyzer’s analytical results.
As an alternative to automatically optimizing the integration period, the operator may choose to
manually adjust the integration period instead. Use the FIELD NEXT / FIELD PREV keys to
highlight the Set Integ. Time Button, then press ENTER. The Integration Period dialog box
shown in Figure 33 will then be presented.
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Figure 33: Integration Period Dialog Box
The current value of the integration time is displayed in the Old Value field. A new integration
period can be entered into the New Value field using the white numerical keys and the decimal
point key. Once the desired value has been entered into the New Value field, press ENTER,
then highlight the Okay button and press ENTER again. To discard changes, highlight the
Cancel button and press ENTER.
After manually editing the integration period, check the indicated Peak Height. If the peak height
displays 32000, this indicates that the peak height is off scale, as the full scale for the
spectrometer reading is 32000 A/D counts. The integration period should be reduced until the
indicated peak height drops below 32000. If the indicated peak height is less than 24000, the
integration period should be increased. If the integration time is already at 1000 ms, this
indicates a problem with the analyzer’s optical system. Refer to Section 7.2 for more details on
troubleshooting analyzer problems.
4.6.1
Factory Reference
The Factory Reference is a zero gas transmission spectrum that was saved at the factory
at the time of analyzer factory calibration. When the Show Factory Reference checkbox is
checked by using the FIELD NEXT / FIELD PREV keys to highlight and then pressing
ENTER to check the box, the factory reference spectrum is shown superimposed on the
same axes as the currently displayed spectrum. The Spectrum panel with the Factory
Reference being displayed is shown in Figure 34.
Figure 34: Factory Reference
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Take note of the following rules-of-thumb when comparing the pink trace of the factory
reference with the red trace of the current transmission spectrum:
• The factory reference should be largely similar to the current transmission spectrum
when the analyzer is in back purge mode. If it is not, there is likely an issue with the
analyzer optical system. Refer to Section 7.2 for troubleshooting techniques.
• The factory reference should be notably different from the current transmission
spectrum, as it is in Figure 34, when the analyzer is in sampling mode. If the sampling
spectrum is the same or very similar to the factory reference, this could indicate an
issue with plugging in the sample probe. Refer to Section 7.9 for details on how to clear
a plugged probe.
The New Reference button is used to make the analyzer use the currently displayed
transmission spectrum to calculate a new zero baseline without carrying out a full zero
calibration cycle. Highlight the New Reference button by using the FIELD NEXT / FIELD
PREV keys, then pressing ENTER.
Pressing New Reference DOES NOT cause the analyzer to automatically go into
back purge mode. Be sure the analyzer is in back purge mode prior to using this
function otherwise the calculated analyzer results after calculating the new
reference WILL NOT BE VALID!
4.7
Absorbance Panel
The Absorbance panel shown in Figure 35 shows the currently calculated absorbance
spectrum as well as the current concentration of all of the analyzed components in the tail gas
stream.
Figure 35: Absorbance Panel
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The absorbance spectrum is calculated by subtracting the current transmission spectrum
from the transmission spectrum that was obtained the last time the analyzer carried out a zero
calibration cycle OR when the New Reference button was pressed on the Spectrum panel,
whichever was most recent. The y-axis of this spectrum is absorbance units (AU). When the
analyzer is in back purge mode, the absorbance spectrum should be a horizontal line at an
absorbance of 0 AU. If it is not, and the analyzer is NOT in a fault condition, first confirm that
the current transmission spectrum in back purge is largely similar to the factory reference
spectrum, then immediately carry out a new zero calibration cycle OR use the New Reference
function on the Spectrum panel. After the zero calibration cycle is complete, confirm that the
absorbance spectrum does become a horizontal line at 0 AU.
The shape of the absorbance spectrum when sampling depends primarily on the concentrations
of H2S and SO2 in the sample. Other components are generally not present in high enough
concentrations to be visibly recognizable on the absorbance spectrum. Figures 36 and 37 show
the typical appearance of absorbance spectra for H2S only and SO2 only.
Figure 36: Absorbance Spectrum for H2S
Figure 37: Absorbance Spectrum for SO2
In most typical operating conditions, the tail gas stream will not contain only H2S or only SO2,
so typically the displayed absorbance spectrum will appear as a combination of the H2S
spectrum and the SO2 spectrum, as shown in the spectrum in Figure 35. The exact magnitude
of the absorbance for a given species will depend on the concentration of that species as well
as the measurement cell length. For a given analyzer, however, the higher the concentration of
the measured species is, the higher the absorbance (i.e. peak height) will be for that species.
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The concentrations shown below the absorbance spectrum are calculated by using a calibration
matrix specific to the analyzer’s spectrometer to mathematically convert the absorbance
spectrum into concentration values. For more information on the calibration matrix, refer to
Section 5.2.2.
4.8
Config Panel
The Configuration panel is used to configure a broad range of analyzer operating parameters.
It has a total of 5 sub-panels, each of which is used to configure a certain type of operating
parameters. To change from one sub-panel to the next, press the PANEL NEXT or PANEL
PREV keys on the keypad. Note that pressing PANEL NEXT from the right most sub-panel
(Network) will return to the Analysis 1 tab and pressing PANEL PREV from the left-most subpanel (Outputs) will go back to the Absorbance panel.
Unauthorized modification of the values of many of the parameters available in the
Config panel could result in the analyzer becoming unable to function correctly. The
parameters on this panel should ONLY be changed by factory-trained personnel or
under the direction of Galvanic Applied Sciences Inc.
4.8.1 Outputs
The Outputs sub-panel shown in Figure 38 is used to configure the four analyzer analog
outputs
Figure 38: Outputs Sub-Panel
There is a total of four analog outputs that can be set up. To access a specific analog output,
use the FIELD NEXT / FIELD PREV keys to highlight the Select Analog Output: button,
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then press ENTER to move to the next analog output. When on Analog Output 4, pressing
this button again will move back to Analog Output 1.
The configuration options available for all four analog outputs are identical. The output
parameters available are listed in Table 12.
Table 12: Analog Output Parameters
Parameter
None
Air Demand
H2S %, SO2 %, COS %,
CS2 %
Sigma S
H2S/SO2 Ratio
H2 / Analog Output 3
H2S ppm, SO2 ppm,
COS ppm, CS2 ppm
Description
No data will be output on the analog output.
The Air Demand value will be output on the analog output. Scale
ranges from negative Full Scale (4 mA) to positive Full Scale
(20mA)
The percentage value of the H2S or SO2 or COS or CS2
concentration will be output on the analog output. Scale ranges
from 0 (4 mA) to Full Scale (20 mA)
The sum of the H2S and SO2 concentrations, in percent, will be
output on the analog output. Scale ranges from 0 (4 mA) to Full
Scale (20 mA)
The ratio of H2S concentration to SO2 concentration will be
output on the analog output. Scale ranges from 0 (4 mA) to Full
Scale (20 mA)
The signal being input into Analog Input 3 (from a hydrogen
sensor or other measurement device that outputs an analog
signal) will be output on the analog output. Scale ranges from 0
(4 mA) to Full Scale (20 mA)
The parts per million value of the H2S or SO2 or COS or CS2
concentration will be output on the analog output. PPM
concentration is obtained by multiplying the percentage
concentration by 10 000, so full scale should be chosen
accordingly. Scale ranges from 0 (4 mA) to Full Scale (20 mA).
The full-scale value for the analog output can be entered into the Full Scale field by
highlighting it using the FIELD NEXT / FIELD PREV keys, then pressing ENTER to enter
data entry mode. Enter in the desired full-scale value, then press ENTER again to save.
Press EXIT to discard any changes.
Above the Full Scale field are two check boxes marked Track and Hold. When Track is
selected, the analog output value will track with the displayed concentration value even when
the analyzer is in back purge mode; hence, when Track is selected, during zero calibration
cycles and any other times when the analyzer is placed into back purge mode, the signal
output to the DCS will be zero. When Hold is selected, the analog output value will hold the
last good process value any time the analyzer switches into back purge mode until the
analyzer is back on line in sampling mode; in this way, the analog output will never drop to
zero even during zero calibration cycles or other times the analyzer is placed into back purge
mode. Highlight the desired analog output behaviour by using the FIELD NEXT / FIELD
PREV keys to highlight the desired choice, then pressing ENTER to select.
After making any changes on this sub-panel, it will be necessary to save them permanently
to the analyzer. Use the FIELD NEXT / FIELD PREV keys to highlight the Save button in the
bottom right-hand corner of the sub-panel, then press ENTER to save changes to the
analyzer. Alternatively, to revert all changes made on this sub-panel, use the FIELD NEXT /
FIELD PREV keys to highlight the Revert button and press ENTER to confirm.
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4.8.2 Calculation Sub-Panel
The Calculation sub-panel shown in Figure 39 is used to set a variety of parameters that
are related to the calculation of analysis results by the control computer.
Figure 39: Calculation Sub-Panel
To edit any parameter on this page, use the FIELD NEXT / FIELD PREV keys to highlight
the desired parameter, then press ENTER to enter the editing dialog. Use the numerical keys
and the decimal point key to enter in the desired value, then press ENTER. Select the Okay
button and press ENTER again. Once all desired edits have been completed, select the
Save button at the bottom right of the screen and press ENTER to save changes
permanently. Alternatively, selecting Revert and pressing ENTER will return all edited values
to their previously saved values.
Unauthorized modification of the values of ANY of the calculation parameters
listed in on this sub-panel could negatively affect the validity of data output by
the analyzer. Calculation-related parameters should ONLY be changed by factorytrained personnel or under the direction of Galvanic Applied Sciences Inc.
4.8.2.1
Calculation Parameters
The calculation parameters outlined in red are explained in Table 13.
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Table 13: Calculation Parameters
Parameter
Normal
Value
Explanation
Plant factor term used in the Air Demand calculation (Section
1.1). Gain term applied to the air demand output to adapt the
process variable (Air Demand) to the plant’s front-end air
adjustment capability. Defined by the equation below:
𝑃𝑃𝑃𝑃 =
Plant
Factor
-3
Operating
Ratio
2
H2S, SO2
Span
≈1
COS,
SVAP, CS2
Span
1 (if used);
0 (if not
used)
4.8.2.2
−𝑄𝑄𝑡𝑡𝑡𝑡 × 100
[𝐻𝐻2 𝑆𝑆]𝑎𝑎𝑎𝑎 × 𝑄𝑄𝑎𝑎𝑎𝑎
Where:
• PF = Plant Factor
• Qtg = Typical tail gas flow rate (moles per unit of time)
• [H2S]ag = Typical molar concentration of H2S in acid
gas feed stream
• Qag = Typical acid gas feed stream flow rate (moles
per unit of time)
Once the plant factor has been established for a given
process, the units of air demand become % Excess Air, so a
positive air demand means that the air input to the furnace
should be reduced and negative air demand means that the
air input to the furnace should be increased.
Stoichiometric ratio of H2S to SO2 at which the air demand
becomes zero (i.e. no change required to input air), regardless
of the numerical value of the plant factor term. In a standard
Claus Process sulfur recovery unit, the optimal ratio is 2:1,
however other sulfur recovery unit processes may use
different ratios.
Span factor applied to the calculated concentration of H2S,
SO2 prior to being displayed on analyzer screen and output on
analyzer outputs. Can be used to make fine adjustments to
analyzer calibration.
Span factor applied to the calculated concentration of COS,
sulfur vapour, CS2 prior to being displayed on analyzer screen
and output on analyzer outputs. If set to zero (default for COS
and CS2) displayed concentrations will be zero.
Cell Length
The Cell Length parameter specifies the length of the measurement cell in centimetres
(cm). The cell length is measured from the inside surface of one cell window to the inside
surface of the other cell window. According to the Beer-Lambert law, the absorbance of
a sample gas is directly proportional to the path length of light passing through that
sample gas, so the cell length is a necessary parameter for calculation of the absorbance
and thus the concentration of the species of interest. The cell length for a given analyzer
is determined by the required measuement range for that analyzer; the higher the
required measurement range, the shorter the cell length will be. Cell lengths can vary
from as short as 1 cm to as long as 15 cm. The specific cell length for a given analyzer is
indicated on the analyzer’s factory QC documentation.
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4.8.2.3
Fixed Temperature and Pressure
The calculated concentrations are compensated for both temperature and pressure.
Typically, this temperature and pressure compensation uses the live values from the
analyzer’s cell temperature and pressure measurement sensors. However, there is also
the capability to use static values of temperature and pressure for this compensation. To
use a Fixed Temperature and / or a Fixed Pressure value for compensation of
concentration values, use the FIELD NEXT / FIELD PREV keys to highlight the checkbox
of the fixed value to be used, then press ENTER to place an X in the box.
4.8.2.4
Sample and Zero Sample Rate
The values shown in the Sample Rate and Zero Sample Rate fields determine how
frequently the analyzer updates the displayed concentrations and air demand when the
analyzer is in sampling mode (Sample Rate) and in back purge mode (Zero Sample rate).
The time values entered in these two fields are in units of milliseconds. The default value
for each sampling rate is 500 ms.
4.8.3
Display
The Display sub-panel, shown in Figure 40, allows the user to configure certain parameters
that affect how data is displayed on the analyzer’s local display screen.
Figure 40: Display Sub-Panel
4.8.3.1
Analysis 1 and 2 Trend Graph Ranges
The displayed x and y axes for the trend graphs shown on the Analysis 1 and Analysis 2
panels can be configured by the user on this panel using the Analysis 1/2 X Range and
Analysis 1/2 Y Range data entry fields. The Y ranges are concentrations, affecting the
displayed vertical ranges on the Air Demand trend on the Analysis 1 panel and the
Component concentration trends on the Analysis 2 panel. These scales can be adjusted
if any of the trend lines are found to be commonly going off of the currently displayed
scale. The X ranges are time, affecting the amount of time represented by the displayed
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trend lines. The maximum time range that can be displayed on the trend graphs on both
panels is fifteen minutes.
Changing the displayed scale on the Analysis 1 / Analysis 2 trend graphs does
NOT change the scale on the analog outputs for these parameters. These
scales are for display purposes ONLY and have no effect on any other aspect
of the analyzer operation.
To edit any of these parameters, simply highlight the field for the parameter to be edited
using the FIELD PREV / FIELD NEXT keys, then use the numerical keys and decimal
point key to enter the desired value and press ENTER again. Alternatively, the up or down
arrows beside the data entry field can be highlighted using the FIELD PREV / FIELD
NEXT keys, and then the ENTER key can be continuously pressed until the desired value
is obtained.
4.8.3.2
Backlight Adjustment
The intensity of the analyzer display’s backlight can be adjusted on this sub-panel. Simply
use the FIELD NEXT / FIELD PREV keys to highlight either the More (brighter) or Less
(dimmer) buttons, then press the ENTER Key continually until the display brightness is
adjusted the desired level. When the slider is at the left-most position, the display
backlight is completely off, and when at the right-most position the backlight is turned on
to 100% power.
Once all desired changes have been made on the Display sub-panel, use the FIELD
NEXT / FIELD PREV keys to highlight the Save button, then press ENTER to save all
changes permanently to the analyzer. Alternatively, select the Revert button and press
ENTER to revert all changes made since the last time the Save button was pressed.
4.8.4
Timers/Alarms Sub-Panel
The Timers/Alarms sub-panel shown in Figure 41 is used to configure a variety of
parameters related to timers, temperature control, and alarm setpoints.
Figure 41: Timers / Alarms Sub-Panel
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To edit a parameter on this sub-panel, use the FIELD NEXT / FIELD PREV keys to highlight
the parameter to be edited, then press ENTER to bring up the data entry dialog box. Enter
the desired value for the parameter using the numerical keys and the decimal point key, then
press ENTER to save. When all desired changes have been made, use the FIELD NEXT /
FIELD PREV keys to highlight Save, then press ENTER to save all changes permanently to
the analyzer. Alternatively, highlight Revert, and press ENTER to revert all changes made
since the last time the Save button was pressed.
4.8.4.1
Timers
The parameters in the orange Timers box are described in Table 14.
Table 14: Timers Parameters
Parameter
Normal
Value
Auto Cal
Interval
240 (min)
Zero Purge
Interval
≥15 (sec)
Zero Hold
Interval
≥30 (sec)
4.8.4.2
Explanation
The time period that elapses between subsequent zerocalibration cycles. The interval is timed from the completion of
the previous calibration cycle, regardless of whether that
calibration cycle was automatically or manually initiated. The
maximum value is 16666.7 min. The minimum value is zero,
in which case the automatic zero calibration function is
disabled. The automatic zero calibration will NOT run when
there are any fault conditions present.
The time period that elapses after the analyzer is placed into
back purge mode for a zero calibration cycle (either manual or
automatic) prior to the initiation of the zero calibration cycle.
This value should be at least 10 seconds longer than the
minimum amount of time required to completely purge the
measurement cell of all sample gas and fill it completely with
zero gas. The final 10 seconds of this interval are used to
collect zero data used in the calculation of the new zero
baseline. The exact value of this parameter will depend on a
variety of analyzer conditions, including but not limited to
probe length and zero gas pressure / flow rate.
The amount of time the analog outputs and relay outputs are
held in the calibration state after the completion of the new
zero baseline calculation. During this time period, sample gas
is drawn through the measurement cell by the aspirator, and
measured concentration values climb up to normal process
values. At the completion of this interval, the analog outputs
are begin to update as normal, and the relay outputs are
returned to normal on-line state. The exact value of this
parameter will depend on a variety of analyzer conditions,
including but not limited to probe length and aspirator drive air
pressure / flow rate.
Temperature Control
The parameters in the green Temp. Control box are described in Table 15.
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Table 15: Temperature Control Parameters
Parameter
Normal
Value
Cell
Setpoint
150°C
Cell Prop
Band
1.0%
Cabinet
Setpoint
35°C
Cabinet
Deadband
≥3°C
Probe
Setpoint
≈110°C
Probe
Deadband
≥3°C
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Explanation
Temperature control setpoint for the measurement cell. The
setpoint for the cell MUST be set well above the condensation
point of sulfur vapour (≈120°C) to avoid plugging due to
accumulation of liquid sulfur inside the analyzer sample
handling system.
Proportional term of the measurement cell electric heater PID
temperature control algorithm.
Temperature control setpoint for the interior of the analyzer
control cabinet. If the control setpoint is exceeded, the cabinet
cooling air solenoid energizes, providing air flow to the control
cabinet vortex cooler.
Control cabinet temperature set point deadband. Indicates the
number of degrees BELOW the control cabinet temperature
setpoint the temperature must drop before switching off the
cabinet cooler cooling air flow. A larger number will reduce the
number of actuation cycles for the cabinet cooler solenoid,
potentially extending its useful life.
Temperature control setpoint for the sample gas exiting the
probe. If the temperature of the gas exiting the probe into the
analyzer sample system exceeds this temperature, the probe
cooler solenoid activates and the probe cooler switches on.
NOTE: This parameter is only active when the Control
with RTD function is selected in the Web GUI (refer to
section 5.4).
Probe temperature setpoint deadband. Indicates the number
of degrees BELOW the probe setpoint the probe gas
temperature must drop before switching off the probe cooler
air flow. A larger number will reduce the number of actuation
cycles for the probe cooler solenoid, potentially extending its
useful life.
NOTE: This parameter is only active when the Control
with RTD function is selected in the Web GUI (refer to
section 5.4).
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4.8.4.3
Alarms
The parameters in the red Alarms box are described in Table 16.
Table 16: Alarms Parameters
Parameter
Normal
Value
Low Cell
≈135°C
Low Probe
≈100°C
High S8
Warn
0.5%
High S8
Fault
0.75%
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Explanation
Measurement cell fault temperature setpoint. If the cell
temperature falls below this setpoint, a cell temperature fault
will be activated, causing the Status relay to switch to Fault
state and the Control relay to switch to Manual state. The low
cell temperature fault setpoint should be set below the cell
temperature setpoint but still well above the sulfur vapour
condensation temperature of ≈120°C to ensure that the
analyzer will go into fault before the temperature is low enough
to cause sulfur vapour to condense in the analyzer sample
system. There is a 3°C deadband on this setpoint. If the cell
temperature rises to more than 3°C above this setpoint, and
no other fault conditions exist, the analyzer will then perform a
zero calibration cycle and then return to normal operation.
Probe temperature fault temperature setpoint. If the probe
temperature falls below this setpoint, a probe temperature fault
will be activated, causing the Status relay to switch to Fault
state and the Control relay to switch to Manual state. There is
a 3°C deadband on this setpoint. If the probe temperature
rises to more than 3°C above this setpoint, and no other fault
conditions exist, the analyzer will then perform a zero
calibration cycle and then return to normal operation.
NOTE: This alarm is only active the Control with RTD
function is selected in the Web GUI (refer to section 5.4).
Sulfur vapour concentration warning setpoint. If the sulfur
vapour rises above this concentration, a sulfur vapour warning
will be triggered in the analyzer and the Service relay will
switch to the Warning state. Sulfur vapour above this
concentration could start to interfere with the measurement of
H2S and SO2, causing a decrease in sensitivity.
Sulfur vapour concentration fault setpoint. If the sulfur vapour
rises above this concentration, a sulfur vapour fault will be
triggered in the analyzer and the Status relay will switch to
Fault and the Control relay will switch to Manual. This fault can
only be cleared once the sulfur vapour content in the sample
gas drops below the setpoint. Sulfur vapour concentrations
exceeding this setpoint are likely to result in sulfur plugging the
probe and/or analyzer sampling system.
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4.8.5 Network Sub Panel
The Network sub-panel shown in Figure 42 is used to view the network settings for the local
Ethernet connection and view/edit the network settings for the remote Ethernet connection.
Figure 42: Network Sub-Panel
4.8.5.1 Direct Connect
The Direct Connect box shows the network parameters for the local Ethernet port on the
front door of the analyzer’s control cabinet, below the display screen. The Ethernet port
on the analyzer’s door is used for connecting a laptop computer to the analyzer with an
Ethernet cable locally. The IP Address field shows the analyzer’s IP address for use
when the analyzer is connected to a local PC, and is not editable by the user. This value
is entered into the navigation bar of a web browser running on the local PC and is used
to access the analyzer’s web-based graphical user interface (GUI). Refer to Section 5 for
more details. The Netmask and MAC Address fields show other network related
parameters. The Status field shows the current status of the network connection. If there
is no computer connected to the analyzer, it will read Inactive. If there is a computer
connected to the analyzer, it will read Active and one of the two green Ethernet Speed
LEDs below the display (either 1000Mb/s or 100Mb/s depending on the connected
computer’s hardware) will illuminate.
4.8.5.2
Network
The Network box shows the network parameters for the analyzer when it is not directly
connected to a local PC but rather connected to a remote PC via the plant’s local area
network (LAN). The Ethernet port used for LAN connections, either via the web GUI
(Section 5) or Modbus TCP/IP, is on the right side of the analyzer’s controller board
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mounted on the inside of the control cabinet door, behind the analyzer display. The
location of the Ethernet port on the controller board is shown in Figure 43.
Figure 43: Controller Board
The Ethernet cable connecting from the analyzer to the plant’s LAN can be connected to
the indicated port (the other port is used to connect from the controller board to the
Ethernet port on the analyzer control cabinet door). When the connection is established
between the analyzer and the LAN, a solid green LED will illuminate inside the port below
the cable, and a blinking orange LED will illuminate inside the port above the cable
indicating data transfer is occurring. One of the two Ethernet Speed LEDs below the
analyzer display (either 1000Mb/s or 100Mb/s depending on LAN hardware) will also
illuminate, and the Status field in the Network box will show Active.
If the plant’s LAN can automatically assign an IP Address, Netmask, Gateway, and
Name Servers to the analyzer when it is connected to the LAN, the type of network
chosen should be DHCP. Use the FIELD NEXT / FIELD PREV keys to highlight DHCP,
then press ENTER to place an X in the checkbox. The analyzer will then automatically be
assigned the relevant network parameters and the fields will then populate.
If the plant’s LAN cannot automatically assign the necessary network parameters when
the analyzer is connected to the LAN, it will be necessary to input them manually. Use
the FIELD NEXT / FIELD PREV keys to highlight Manual, then press ENTER to place an
X in the checkbox. The IP Address, Netmask, Gateway, and Name Servers fields will
then become editable. Obtain the correct values for these parameters from the plant’s IT
department, then use the numerical keys and decimal point key to enter these parameters
into the analyzer. Once all changes have been made, use the FIELD NEXT / FIELD PREV
keys to highlight the Apply button, then press ENTER to save changes.
Once the analyzer has a correct IP address and other parameters assigned, it will be
possible to connect to the analyzer from anywhere within the plant’s LAN by using the IP
address.
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Section 5
5.1
Web-based Graphical User Interface (GUI)
Overview
The Model 943-TGXeNA Tail Gas Analyzer can be monitored, configured and controlled by use
of a web-based GUI on a personal computer connected to the analyzer via an ethernet
connection, either as a direct local connection or remotely through the plant’s local area network
(LAN). The necessary IP address for each type of connection is indicated in the Config panel’s
Network sub-panel as described in Section 4.8.5. Once the PC is physically connected to the
analyzer via an Ethernet connection, and either the remote or local connection is shown on the
analyzer display as Active, simply type in the IP address of the active connection into the
navigation bar of a web browser running on the connected computer.
While other browsers may also be able to succesfully access the web GUI, for best
results Galvanic Applied Sciences recommends the use of Mozilla Firefox.
Any changes that are made to the analyzer configuration via the web GUI and saved
to the analyzer will be displayed on the analyzer’s local display.
After entering in the IP address to the web browser navigation bar and pressing Enter, the web
GUI splash screen shown in Figure 44 will be displayed.
Figure 44: Brimstone Web GUI Splash Screen
Once the web GUI has finished loading, the Analysis page described in Section 5.2.1 is shown.
The Brimstone web GUI is divided into two sections – a Navigation menu shown in Figure 45
on the left and an information page on the right. The Navigation menu is used to navigate
through the various available information pages.
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Figure 45: Navigation Menu and Tips
The Navigation menu is divided into four sections: Analysis, Configuration, Factory, and
Help. Each of these sections may have several data display pages. The information pages for
a given section can be displayed by pressing the (+) sign to the right of the section name. Note
that only one section can be expanded at a time; expanding a different section of the Navigation
menu will collapse any previously expanded sections.
After clicking on a specific information page to access it, a list of tips associated with the
displayed information page will be displayed on the left side of the window, below the navigation
window. These tips will provide information on how to interpret, interact with, and/or modify the
data displayed in the information window.
5.2
5.2.1
Analysis Section
Analysis Page
The Analysis page shown in Figure 46 displays information and controls that mirror the data
and controls shown on the analyzer’s local display Analysis 1 and Analysis 2 panels.
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Figure 46: Analysis Section - Analysis Page
The Analysis page is divided into 5 sections, each displaying different information.
5.2.1.1
Value Display
The Value Display section displays concentration data, calculated analysis data, and
analyzer parameter as described in Table 17.
Table 17: Value Display Parameters
Parameter
Air Demand
H2S
SO2
COS
CS2
Sulfur Vapour
Cell Pressure
Cell Temperature
Probe Temperature
Cabinet Temperature
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Description
Present air demand, in % excess air based on currently measured H2S and SO2
concentrations, calculated as per equation in Section 1.1.
Present calculated concentration of H2S in percent
Present calculated concentration of SO2 in percent
Present calculated concentration of COS in percent
Present calculated concentration of CS2 in percent
NOTE: CS2 is an optional measurement. Only analyzers configured with this
option will be capable of measuring CS2
Present calculated concentration of sulfur vapour in percent
Present measured pressure inside the sample measurement cell in mmHg
Present measured concentration of the measurement cell block assembly in °C
Present measured temperature of the sample gas exiting the probe in °C
The present measured temperature of the interior of the analyzer’s control cabinet
in °C.
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The values displayed in this section are live values and cannot be edited. The associated
setpoints and alarm setpoints for the pressure and temperature values can be edited in the
Configuration section’s Parameters page. Refer to Section 5.3.1.
5.2.1.2
Status and Control
This section displays indicators indicating general status of the analyzer as well as
controls that can be used to manually control certain aspects of the analyzer operation.
The status indicators and controls shown in this section are described in Table 18.
Table 18: Status and Control
Indicator / Control
Online Status
Sample / Backpurge
Sample
Backpurge
Manual Zero
5.2.1.3
Description
Shows the current online status of the analyzer.
• Solid Green – Online: Analyzer is online. Analyzer
considers output values to be valid.
• Flashing Red – Offline: Analyzer is offline. Analyzer
considers output values to be invalid, as during analyzer
maintenance. Control relay is set to Manual.
Online status does not affect operation of analyzer, but rather exists
as a convenience to operator as a remote indication that the
analyzer data is valid or invalid.
NOTE: Online status can ONLY be changed locally using the
keypad. Refer to Section 4.3.1
Shows the current sampling status of the analyzer:
• Solid Green – Sample: Analyzer is in sampling mode
analyzing process sample gas
• Flashing Red – Back purge: Analyzer sample system is
being purged with zero gas, as during zero calibration
cycle, manual back purge, or fault state back-purge.
Pressing this button will place the analyzer in sampling mode if
currently in back-purge mode.
NOTE: Analyzer can only be placed into sampling mode if no
fault conditions are present.
Pressing this button will place the analyzer in back purge mode if
currently sampling.
NOTE: Analyzer should be placed into back-purge mode prior
to carrying out any maintenance on the analyzer itself OR on
the sulfur recovery unit in which it is installed.
Pressing this button will switch the analyzer automatically to back
purge mode (if currently sampling) and carry out a zero calibration
cycle as described in Section 4.3.4.
NOTE: Analyzer can only carry out a zero calibration cycle if
there are no fault conditions currently present.
Relay Indicators
This section displays the current status of the analyzer’s four digital (relay) outputs, which
are used to provide an indication of the status of various aspects of the analyzer
operation. A basic overview of the four relay indicators is given in Table 19; for a more
complete discussion of the function of these four relay outputs refer to Section 3.3.2.
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Table 19: Relay Indicators
Relay Indicator
Status
Service
Mode
Control
5.2.1.4
Description
Shows the current state of the Status relay.
• Solid Green – Normal: No fault conditions noted in any of
the parameters monitored by the analyzer. Analyzer can
analyze process sample.
• Flashing Red – Fault: At least one fault condition is noted
in the parameters monitored by the analyzer. Analyzer is
incapable of analyzing process sample until all current fault
conditions are cleared.
Shows the current state of the Service relay
• Solid Green – Normal: No warning conditions noted in any
of the parameters monitored by the analyzer. If Status relay
is also green, no maintenance is currently required, and
analyzer condition is completely normal.
• Flashing Red – Warning: At least one warning condition
noted in parameters monitored by the analyzer. If Status
relay is green, analyzer is still capable of analyzing process
ample, but maintenance should be scheduled as soon as
possible to resolve warning condition.
Shows the current state of the Mode relay
• Solid Green – Run: Analyzer is not carrying out a zerocalibration cycle. If Status relay is also green, analyzer is
currently monitoring process sample.
• Flashing Red – Calibrate: Analyzer is currently carrying out
a zero-calibration cycle, either automatically initiated by
timed schedule, or manually initiated from keypad or web
GUI.
Shows the current state of the Control relay
• Solid Green – Auto: Analyzer is currently in automatic
control, which means that analyzer output signals can be
considered valid values and can be used for plant control
purposes if required.
• Flashing Red – Manual: Analyzer is currently in manual
control, either as a result of fault condition(s) being present,
the analyzer being placed into Offline mode, or due to a
zero-calibration cycle (manual or automatic) being in
progress. Analyzer output signals should be deemed to be
invalid and NOT used for plant control purposes.
Air Demand and H2S/SO2 Trends
The Air Demand Trend and H2S/SO2 Trend displays show the graphical trend in these
results over the past 17 minutes. They are updated once ever second, and the latest
reading is at the extreme right of the each of the trend lines. The shaded areas shown
above and below the trend lines in Figure 46 indicates the distance between the current
trend line and the zero baseline. The colour code of the trend lines is the same as the
colour code of the numerical data fields in the Value Display section.
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The X-axis (time) for these trend graphs cannot be changed. However, should the data
be found to be often off the scale, it is possible to change the y-axis (concentration) scale
to ensure that all data is on the scale. To change the Y-axis scale, right click on the graph
for which the scale is to be changed, then select Y-axis Range. The dialog box shown in
Figure 47 will then appear.
Figure 47: Trend Graph Y-Axis Range Change Dialog Box
When the trend graph y-axis range is changed, the concentration range given in the trend
header will change to reflect the new range.
Changing the displayed scale on the Air Demand or H2S/SO2 trend graphs
does NOT change the scale on the analog outputs for these parameters. These
scales are for display purposes ONLY and have no effect on any other aspect
of the analyzer operation.
5.2.2
Calibration Matrix Page
The Model 943-TGXeNA uses a spectrometer that connects to the control computer via a
USB connection for the collection of the spectrum data needed for the calculation of
concentration values and the air demand value. The spectrometer is shown in Figure 48.
Figure 48: Spectrometer
Every spectrometer has a uniquely determined Calibration Matrix which allows the control
computer to convert the spectrum data it reads from the spectrometer into measured
concentration values for every measured component. The Calibration Matrix is a 12-column
x 530 row (older versions of the analyzer firmware use a 9 column by 530 row) matrix that is
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used in the linear algebraic calculations that produce the displayed concentration values.
The Calibration Matrix page of the Analysis section in the web GUI, shown in Figure 49,
allows the user to look at the calibration matrix being used by the analyzer.
Figure 49: Calibration Matrix
Each spectrometer’s unique calibration matrix is determined by Galvanic Applied Sciences
Inc. during the production of the analyzer in which it is incorporated. The calibration matrix
is determined by incorporating the molar absorptivity data of the gases to be measured with
the specific spectral resolution and sensitivity characteristics of that spectrometer. The
Calibration Matrix page allows the user to determine whether the installed calibration matrix
is correct for the installed spectrometer by comparing the displayed calibration matrix with
the calibration matrix file that is associated with the spectrometer’s unique serial number.
The serial number of each spectrometer is found on the body of the spectrometer, as visible
in Figure 48.
As the calibration matrix is unique to a given spectrometer, if at any time an
analyzer’s spectrometer requires replacment, a new calibration matrix for that
spectrometer must be installed onto the analyzer’s computer. Refer to Section
7.10 for the procedure to upload a calibration matrix to the analyzer.
5.2.3
Indicators Page
The Indicators page shown in Figure 50 shows almost the same information as the
Indicators panel on the analyzer’s local display, with the addition of two additional faults and
one additional warning.
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Figure 50: Indicators Page
The specific faults shown on the Indicators page are listed in Table 20.
Table 20: Analyzer Faults
Fault
Measure Out of Range
Reference Out of Range
Dark Out of Range
Low Cell Temperature
High Cell Temperature
Low Probe Temperature
High Probe Temperature
IO Board
Explanation
Spectrometer signal is out of range while analyzer is
measuring sample (signal either off scale or too low)
Spectrometer signal is out of range while analyzer is in back
purge mode (signal either off scale or too low)
Spectrometer dark level (i.e. signal when no light is present) is
either too low or too high
Measurement cell temperature is below low cell temperature
fault setpoint
Measurement cell temperature is above high cell temperature
fault setpoint
Temperature of gas exiting the probe is below the low probe
temperature setpoint
Temperature of gas exiting the probe is above the high probe
temperature setpoint
Control computer is unable to communicate with the IO board
or spectrometer
Some of these faults may clear by themselves but others may require maintenance or even
hardware replacement to resolve. Refer to Section 7.2 for more detail on how to troubleshoot
active faults.
Table 21 describes each of the warnings listed int the warning table on the Indicators page.
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Table 21: Analyzer Warnings
Warning
Low Cabinet
Temperature
High Cabinet
Temperature
Low Reference
Peak
High Integration
Period
High Absorbance
High Sulfur
Vapour
Explanation
Control cabinet internal temperature is below low cabinet temperature
setpoint
Control cabinet internal temperature is above high cabinet temperature
setpoint
Spectrometer signal peak height when analyzer is in back purge mode
<24000 A/D counts
Integration period required to obtain an in-range spectrometer signal
when analyzer is in back purge mode > 500 milliseconds.
Measured absorbance >2.0AU when analyzer is in sampling mode.
Measured sulfur vapour content exceeds high sulfur vapour
concentration warning setpoint
Some of these warnings may clear by themselves but others will not be able to be cleared
without performing maintenance on the analyzer. Refer to section 7.2 for more detail on how
to troubleshoot active warnings.
5.2.4
Spectrum Page
The Spectrum page shown in Figure 51 shows identical information to the Spectrum panel
on the analyzer’s local display.
Figure 51: Spectrum Page
The Spectrum Curve, or transmission spectrum, displayed on this page shows the intensity
of light measured at each of the 2048 pixels of the spectrometer. The exact X (pixel number)
and Y (A/D counts) coordinates of each data point on the curve can be determined by placing
the mouse cursor over the data point of interest. The Y-axis scale can be adjusted by clicking
on the Change Spectrum Curve Display Y Axis button. The Y-Axis Maximum Value
dialog box shown in Figure 52 will then appear.
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Figure 52: Spectrum Curve Y-Axis Maximum Value Dialog Box
Enter in the desired maximum value for the Y-Axis scale (the minimum will always be zero)
and click on Save. Note that the normal maximum peak height for the spectrum curve is
around 28000-29000 A/D counts when the analyzer is in back-purge mode. The displayed
spectrum is updated once per second; to change to a static spectrum simply place a
checkbox into the Stop Polling checkbox. Once changed to a static spectrum, a specific
section of the X-axis can be zoomed into by left clicking and holding on the desired starting
pixel then dragging the green highlight that appears to the desired end pixel. After releasing
the left mouse button, the selected pixel range will expand to fill the whole graph field. The
zoomed in section will also be shown in green the Panorama View field, which shows an
overview of the entire collected spectrum. To return to the full spectrum, left click and hold
at the left side of the Panorama View field and drag the green area all the way the right side,
and the Spectrum Curve view will return to the full spectrum. To save the displayed
spectrum to a CSV file on the connected PC, click on the Save Spectrum button and saving
to the desired filename.
There are four numerical parameters displayed at the bottom of the Spectrum Page. These
parameters are described in Table 22.
Table 22: Spectrum Parameters
Parameter
Spectrum
Peak
First Vector
Pixel Level
Dark Level
Integration
Time
Explanation
Displays the peak height of the spectrum, in A/D counts. Should be
approximately 28000-29000 when analyzer is in back purge mode.
Displays the intensity of light being received at the first vector pixel, in A/D
counts. The first vector pixel is the first pixel that is used for calculating
concentration values.
Displays the intensity of light being received when the spectrometer is dark
(i.e. no light present). This value should be in a range between 400 and 900
A/D counts.
The integration time, or integration period, is the duration of time that light is
collected by the pixels of the spectrometer before being read by the control
computer. For example, in Figure 50 the integration time is given as 123.69
milliseconds. This means that the light incident on the spectrometer pixels
can accumulate for 123.69 milliseconds before being read by the control
computer; the spectrometer pixels are then zeroed and allowed to collect light
again. The displayed transmission spectrum, then, shows the intensity of light
collected at every pixel in this time period. Maximum value 1000ms.
The optimal integration time for the current analyzer conditions can be automatically
calculated by clicking the Optimize Integration Time button. Once clicked, the control
computer will adjust the integration time such that the peak height of the displayed spectrum
reads approximately 28000 A/D counts. If this peak height cannot be achieved even with a
maximum integration time of 1000 ms, this indicates a problem with the analyzer’s optical
system. Refer to section 7.2 for details on how to troubleshoot analyzer problems.
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Optimizing the Integration Time should ONLY be performed when the analyzer is
in back purge mode. Attempting to optimize the integration time when the
analyzer is in sampling mode may negatively affect the analyzer baseline, and
thus the analyzer’s analytical results.
As an alternative to automatically optimizing the integration time, the operator may choose
to manually adjust the integration time instead. Click on the Set Integration Time button,
and the Set Integration Time dialog box shown in Figure 53 will appear.
Figure 53: Set Integration Time Dialog Box
Enter the desired integration time (range between 1 and 1000ms) into the field, then press
OK.
After manually editing the Integration Time, check the indicated Spectrum Peak. If the
spectrum peak displays 32000, this indicates that the peak height is off scale, as the full
scale for the spectrometer reading is 32000 A/D counts. The integration time should be
reduced until the indicated peak height drops below 32000. If the indicated spectrum peak
is less than 24000, the integration time should be increased. If the integration time is already
at 1000 ms, this indicates a problem with the analyzer’s optical system. Refer to Section 7.2
for more details on troubleshooting the analyzer’s optical system.
When the Display Factory Reference checkbox is checked by clicking on it, the factory
reference spectrum is shown superimposed on the same axes as the currently displayed
spectrum. Take note of the following rules-of-thumb when comparing the pink trace of the
factory reference with the red trace of the current transmission spectrum:
• The factory reference should be largely similar to the current transmission spectrum
when the analyzer is in back purge mode. If it is not, there is likely an issue with the
analyzer optical system. Refer to Section 7.2 for troubleshooting techniques.
• The factory reference should be notably different from the current transmission
spectrum when the analyzer is in sampling mode. If the sampling spectrum is the same
or very similar to the factory reference, this could indicate an issue with plugging in the
sample probe. Refer to Section 7.9 for troubleshooting of sampling problems.
The New Reference button is used to make the analyzer use the currently displayed
transmission spectrum to calculate a new zero baseline without carrying out a full zero
calibration cycle.
Clicking New Reference DOES NOT cause the analyzer to automatically go into
back purge mode. Be sure the analyzer is in back purge mode prior to using this
function otherwise the calculated analyzer results after calculating the new
reference WILL NOT BE VALID!
5.2.5
Absorbance Page
The Absorbance page shown in Figure 54 shows identical information to the Absorbance
panel on the analyzer’s local display.
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Figure 54: Absorbance Page
The Absorbance Curve, or absorbance spectrum, shown on this page shows the
absorbance of the gas in the measurement cell, in absorbance units (AU) across the range
of 530 spectrometer pixels that are used by the analyzer for analysis. The exact X (pixel
number) and Y (AU) coordinates of each data point on the curve can be determined by
placing the mouse cursor over the data point of interest. The Y-axis scale can be adjusted
by clicking on the Change Absorbance Curve Display Y Axis button. The Y-Axis
Maximum Value dialog box shown in Figure 55 will then appear.
Figure 55: Absorbance Curve Y-Axis Maximum Value Dialog Box
Enter in the desired minimum and maximum values for the Y-Axis scale and click on Save.
Note that the normal absorbance curve will rarely go above 1.5 AU or drop below 0 AU. The
displayed spectrum is updated once per second; to change to a static spectrum simply place
a checkbox into the Stop Polling checkbox. Once changed to a static spectrum, a specific
section of the X-axis can be zoomed into by left clicking and holding on the desired starting
pixel then dragging the green highlight that appears to the desired end pixel. After releasing
the left mouse button, the selected pixel range will expand to fill the whole graph field. The
zoomed in section will also be shown in green the Panorama View field, which shows an
overview of the entire collected spectrum. To return to the full spectrum, left click and hold
at the left side of the Panorama View field and drag the green area all the way the right side,
and the Absorbance Curve view will return to the full absorbance spectrum.
The absorbance spectrum is calculated by subtracting the current transmission spectrum
from the transmission spectrum that was obtained the last time the analyzer carried out a
zero calibration cycle OR when the New Reference button was pressed on the Spectrum
panel, whichever was most recent. The y-axis of this spectrum is absorbance units (AU).
When the analyzer is in back purge mode, the absorbance spectrum should be a horizontal
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line at an absorbance of 0 AU. If it is not, and the analyzer is NOT in a fault condition, first
confirm that the current transmission spectrum in back purge is largely similar to the factory
reference spectrum, then immediately carry out a new zero calibration cycle OR use the New
Reference function on the Spectrum panel. After the zero-calibration cycle is complete,
confirm that the absorbance spectrum does become a horizontal line at 0 AU.
The shape of the absorbance spectrum when sampling depends primarily on the
concentrations of H2S and SO2 in the sample. Other components are generally not present
in high enough concentrations to be visibly recognizable on the absorbance spectrum.
Figures 56 and 57 show the typical appearance of absorbance spectra for H2S only and SO2
only.
Figure 56: Absorbance Spectrum for H2S
Figure 57: Absorbance Spectrum for SO2
In most typical operating conditions, the tail gas stream will not contain only H2S or only SO2,
so typically the displayed absorbance spectrum will appear as a combination of the H2S
spectrum and the SO2 spectrum. The exact magnitude of the absorbance for a given species
will depend on the concentration of that species as well as the measurement cell length. For
a given analyzer, however, the higher the concentration of the measured species is, the
higher the absorbance (i.e. peak height) will be for that species.
The concentrations shown below the absorbance spectrum are calculated by using a
calibration matrix specific to the analyzer’s spectrometer to mathematically convert the
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absorbance spectrum into concentration values. For more information on the calibration
matrix, refer to Section 5.2.2.
5.3
Configuration Section
The Configuration section consists of two pages that allow the user to configure many of the
analyzer’s basic operating parameters as well as the Modbus output if required.
5.3.1
Parameters Page
The Parameters page shown in Figure 58 shows a list of operational parameters that can
be viewed or edited.
Figure 58: Configuration Parameters Page
The parameters given on this page are grouped together by colours which indicate the type
of parameter they are. The colour grouping for the various parameters is given in Table 23.
Table 23: Parameters Page Colour Code
Background Colour
Pink
Blue
Grey
Green
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Type of Parameter
Temperature-related parameters, including both control and
fault / warning setpoints
Parameters related to the analyzer’s analytical results
Calibration cycle timing and spectrometer related parameters
All other parameters that do not fit in any of the other groups.
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Many of the parameters on this page are also available for editing on the analyzer’s local
display using the analyzer keypad, though not all of them are. Table 24 gives an overview of
the parameters available for editing on this page.
Table 24: Configuration Parameters
Parameter
Editable
via
Keypad
Local Display
Editing Location
Y
Config – Timers/Alarms
Y
Config – Timers/Alarms
N
N/A
Y
Config – Timers/Alarms
Cell temperature PID control parameter
N
N/A
Cell temperature PID control parameter
Probe Temperature Set
Point
Y
Config – Timers/Alarms
Probe Temperature
Dead Band
Y
Config – Timers/Alarms
Y
Config – Timers/Alarms
Y
Config – Timers/Alarms
Y
Config – Timers/Alarms
Cabinet Temperature
Dead Band
Y
Config – Timers/Alarms
Low Cabinet
Temperature Alarm
N
N/A
High Cabinet
Temperature Alarm
N
N/A
High SVAP Warning
Y
Config – Timers/Alarms
High SVAP Alarm
Y
Config – Timers/Alarms
Cell Temperature Set
Point
Low Cell Temperature
Alarm
High Cell Temperature
Alarm
Cell Temperature
Proportional Band
Cell Temperature Reset
Time
Low Probe Temperature
Alarm
High Probe Temperature
Alarm
Cabinet Temperature Set
Point
SVAP Set Point
N
N/A
SVAP Dead Band
N
N/A
Filter Points
N
N/A
Auto Cal Intervall (min)
Y
Config – Timers/Alarms
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Explanation
Control setpoint for analyzer’s measurement
cell heaters.
Cell temperature below which a cell
temperature fault will be triggered
Cell temperature above which a cell
temperature fault will be triggered
Control setpoint for probe cooler solenoid
actuation
NOTE: Only if probe control is set to RTD
Number
of
degrees
below
probe
temperature setpoint measured probe gas
temperature must drop prior to probe cooler
solenoid turning off
NOTE: Only if probe control is set to RTD
Probe gas temperature below which low
probe temperature fault will be triggered
Probe gas temperature above which high
probe temperature fault will be triggered
Control cabinet temperature above which
the cabinet cooler will be turned on
Number of degrees below cabinet
temperature
setpoint
the
cabinet
temperature must drop prior to the cabinet
cooler switching off
Control cabinet temperature below which a
cabinet temperature warning will be
triggered
Control cabinet temperature above which a
cabinet temperature warning will be
triggered.
Sulfur vapour concentration above which a
High Sulfur Vapour warning will be triggered
Sulfur vapour concentration above which a
high sulfur vapour fault will be triggered
Sulfur vapour concentration above which the
probe cooler will be turned on
NOTE: Only if probe control is set to
SVAP
Amount the sulfur vapour concentration
must drop below the set point before the
probe cooler switches off
NOTE: Only if probe control is set to
SVAP
Number of data points averaged together to
produce the displayed concentration values
Time interval from last zero calibration cycle
(manual or automatic) to next scheduled
auto zero calibration cycle.
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Zero Purge (sec)
Y
Config – Timers/Alarms
Zero Hold (sec)
Y
Config – Timers/Alarms
Integration Time (ms)
Y
Spectrum
Fixed Temperature
(Enable)
Y
Config – Calculation
Fixed Pressure (Enable)
Y
Config – Calculation
Measure Analog Input 3
N
N/A
Analog Input 3 is
Hydrogen
N
N/A
Sample Rate
Y
Config – Calculation
Zero Sample Rate
Y
Config – Calculation
Time interval during a zero calibration cycle
after switching to back purge and before
calculating the new zero baseline
Time interval during a zero calibration cycle
after the analyzer has switched back to
sampling mode and prior to the analyzer
concentration outputs configured for Hold
being updated again.
Amount of time light is collected by
spectrometer before the intensity is read to
produce a spectrum
Enable and select a fixed temperature value
for temperature compensation of results
NOTE: Live cell temperature value will be
used for temperature compensation if
this is not enabled.
Enable and select a fixed pressure value for
pressure compensation of results
Note: Live cell pressure value will be
used for pressure compensation if this is
not enabled.
Enable the measurement of a concentration
sensor connected to Analog Input 3 on the
IO Board. If enabled, this measurement will
be displayed on the Analysis 2 panel of the
local display.
Enable the measurement of Hydrogen via a
sensor connected to Analog Input 3 on the
IO board. If this option and the previous
option are enabled, this measurement will be
displayed on the Analysis 2 panel of the
local display.
Rate at which the displays and output data
are updated when the analyzer is in
sampling mode
Rate at which the displays and output data
are updated when the analyzer is in back
purge mode.
When the page is first opened, it is opened in Read Only mode, which means that the values
for the displayed parameters can only be viewed, not edited. To edit the parameters, first
click on Change to Update Mode ( at the top right of the screen. The LOGIN dialog box
shown in Figure 59 will then appear.
Figure 59: Login Dialog Box
Enter in the correct password, then click Login. To change a parameter:
1. Click on the parameter to be edited. The data entry field for that parameter will change
to a white background.
2. Edit the parameter by typing in a new value. Some parameters such as Fixed
Temperature Enable are non-numerical and can be edited by using the pull-down
selection menu.
3. Once editing of the selected field is complete, press Enter on the keyboard.
4. Change any other parameters to be edited using the procedure in steps 1 to 3.
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5. Once all necessary changes have been made, click on the Save to Unit button at the
bottom of the screen to save all changes permanently to the analyzer.
If it is necessary to cancel all changes made on this page, clicking Revert before clicking on
Save to Unit will undo all changes made during that editing session.
5.3.2
Modbus Page
The Modbus page shown in Figure 60 allows the user to configure Modbus output in one
of three Modbus formats – Enron, Modicon-16, or Modicon-32.
Figure 60: Modbus Page
As there are many possible configurations for Modbus communication, this manual will only
cover the basics. If the user requires assistance in configuring the Modbus for their specific
application, the Service Department of Galvanic Applied Sciences Inc. will be able to assist.
Contact the Service Department at [email protected] for more information.
The bottom two lines of the Modbus page include several items that relate to
communications parameters and numerical formats. The exact selection for each of these
parameters will depend on the type of communication being used (RS485 or TCP/IP) as well
as the specific DCS being used. These parameters are explained in Table 25.
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Table 25: Modbus Communication Parameters
Parameter
IP Port Number
Modbus Address
32 Bit Register Swap
Mode
Endian
Baud Rate
Data Bits
Parity
Stop Bits
Explanation
Port number to be used if the communication protocol being
used is Modbus TCP/IP.
Modbus address of the analyzer. This address needs to be
entered into the DCS to allow the DCS to communicate
correctly with the analyzer.
If register swap is selected, the portion of the 32-bit register
that follows the decimal point is transmitted in the first 16-bit
word, and the portion that precedes the decimal point is
transmitted in the second 16-bit word. If register swap is not
selected, the portion that precedes the decimal point is
transmitted first.
NOTE: Only used if Modicon-32 format is chosen
Sets the mode for beginning and ending messages. ASCII
mode uses ASCII characters to mark the beginning and
ending of messages, whereas RTU uses time gaps to mark
the beginning and ending of messages. Choice will depend
on the DCS being used.
Selects between Big Endian and Little Endian. In Big
Endian, the most significant bit is transmitted first, whereas
in Little Endian, the least significant bit is transmitted first.
Note: Only used if Modicon-32 format is chosen
Selects the Baud Rate to be used for communication
between the analyzer and the DCS. Usually 9600 but may
differ depending on the DCS being used.
Note: Only used if RS485 serial communication is used
for Modbus
Number of data bits transmitted at a time. Usually 8, but 7
may be used under some circumstances
Note: Only used if RS485 serial communication is used
for Modbus
Type of parity checking used for data transmission. Usually
None, but Even or Odd may be used under some
circumstances.
Note: Only used if RS485 serial communication is used
for Modbus
Number of bits marking the end of a transmitted byte. Usually
1 but may be 2 under some circumstances.
Note: Only used if RS485 serial communication is used
for Modbus
The various items in the Available Points listing on the left side of the Modbus page can be
accessed by clicking on the + sign. The items in this listing can be used to populate the
Modbus Items list on the right side of the Modbus page by dragging and dropping them into
the Modbus list. The general types of data in each folder in the Available Points list is given
in Table 26.
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Table 26: Available Modbus Points
Folder Name
Relay Status
Fault Status
Warning Status{XE
“Available Points:Warning
Status}
Concentration Status{XE
“Available
Points:Concentration
Status}
Control Command{XE
“Available Points: Control
Command}
Explanation
Contains relay status points for each of the analyzer’s four
relay outputs – Status, Service, Mode, and Control. This data
is output in the Modbus list as either 0 (off) or 1 (on).
Allows for the output of the status of all possible analyzer
faults. This data is output in the Modbus list as either 0 (no
fault) or 1 (fault)
Note: Peripheral Fault point is the same as the IO Board
fault displayed the Indicators panel on the analyzer local
display.
Allows for the output of the status of all possible analyzer
warnings. This data is output in the Modbus list as either 0
(no warning) or 1 (warning).
Allows for the output of all measured concentration data in
both percentage and parts per million (PPM) as well as
calculated values of Air Demand, H2S/SO2 Ratio, and
Sigma S. This data is output in the Modbus list as either 16bit numerical data (Enron and Modicon-16) or floating point
numerical data (Modicon-32).
Allows for remote control of the analyzer via Modbus. If a 1
is placed into the register for any of these points, that will
force that command to be performed. Available remote
commands are Go Online, Go Offline, Force Zero (forces
analyzer into back-purge mode), Manual Zero (performs a
Zero Calibration Cycle), and Sample Mode (switches
analyzer into Sampling mode if currently in back-purge mode
and no faults are present.
To set up a new Modbus list, click on Change to Update Mode. A LOGIN dialog box like
the one shown in Figure 58 will appear. The default password is 2222. Press Login. Once
the password has been correctly entered, the New, Load, and Save buttons will be activated.
Click on New to set up a new Modbus list. The Modbus Type dialog box shown in Figure
61 will then appear.
Figure 61: Modbus Type Dialog Box
Select the desired Modbus type and click on OK. A new Modbus List the desired format will
appear and can then be populated with items from the Available Points list. Clicking on the
Save button will store a currently configured Modbus list to the analyzer memory. If a new
Modbus list is then opened, pressing Load during the editing of this new list will reload the
original Modbus list; pressing Save during the editing of this new list will overwrite the original
Modbus list.
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Regardless of the format chosen, a Modbus list consists of three columns that are described
in Table 27.
Table 27: Modbus List Columns
Column
Modbus Items
Register
Value
Explanation
Contains a series of “nodes” (folders) which are used to hold
data in different numerical formats depending on the specific
data being output. Points from the Available Points list can
be dragged and dropped into the appropriate node.
Shows the Modbus register number for each data point.
Used for DCS programming to ensure that the DCS is
reading the correct registers.
Shows the real time value of each register. Useful for
troubleshooting to ensure that the DCS is reading each
register correctly.
To add items to a Modbus list, left click on the desired point in the Available Points list and
drag it over to the Modbus list. Once the node name of the node to which the point is to be
added is highlighted in blue, release the left mouse button. The point will then be added to
the list in that note. When additional data points are added to a node, they are added at the
bottom of the list. Once data points have been added to a Modbus list, the Modbus list can
then be further edited by right clicking on a specific data point. A menu like the one shown
in Figure 62 will appear.
Figure 62: Editing a Modbus List
There are three options available. Clicking on Up will move the selected data point up in the
Modbus list, unless the data point is already at the top of the list in the node, in which case
this option will not have any effect. Clicking on Down will move the selected data point down
in the Modbus list, unless the data point is already at the bottom of the list in the node, in
which case this option will not have any effect. Clicking on Delete will remove the data point
from the list.
5.3.2.1
Enron Modbus Format
If Enron is chosen as the Modbus format, the Modbus list will contain 4 nodes as shown
in Figure 63.
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Figure 63: Enron Modbus Format
The Enron Modbus format contains 4 nodes on the Modbus tree: Coils, Short Integers,
Long Integers, and Floating Point. Coils are Boolean (i.e. ON or OFF) data points
which have a value of either 0 or 1. Thus, points placed into the Coils should be points
that have only an ON or an OFF state, such as Relay Status points, Fault Status points,
or Warning Status points. Control Command points can also be placed into the Coils
node for remote initiation of different commands. Short Integers are 16-bit whole
numbers with either a positive or a negative sign. Long Integers are 32-bit whole
numbers with either a positive or a negative sign. Floating Point values are also 32-bit
numbers, but unlike the integers they do not have a sign, but they do have decimal points.
Because the Floating Point node can display data that includes decimal points, it is the
most suitable node to use for the output of concentration data and other calculated
results.
5.3.2.2
Modicon 16 Format
If Modicon 16 is chosen as the Modbus format , the Modbus list will contain 4 nodes as
shown in Figure 64.
Figure 64: Modicon 16 Format
The Modicon 16 Modbus format contains 4 nodes on the Modbus tree: Output “Coils”
Status, Input Status, Input Register, and Output “Holding” Register. The Input
Status and Output “Coils” Status nodes contain Boolean data points. Data points in
the Input Status node can be written to, so if any Control Command points are required,
they should be placed into the Input Status node. Data points in the Output “Coils”
Status node are read-only, so points placed into this node should include any data points
from the Relay Status, Fault Status, or Warning Status nodes, as data points in these
nodes are all read-only. Output “Holding” Registers are data points that are read-only
outputs of analyzer data, such as concentration values and calculated values like Air
Demand. The Input Register node is used for non-Boolean (i.e. numerical) data points
that can be written to.
The Modicon 16 format only outputs numerical data as 16-bit numbers. Thus,
the ouptut of decimal point data in this format is not possible – all numerical
data output in Modicon 16 is whole number only.
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5.3.2.3
Modicon with Floating Point Format
If Modicon 32 (Modicon with Floating Point) format is chosen as the Modbus format, the
Modbus list will contain 4 main nodes on the Modbus tree, as in Modicon 16 format.
However, the Input Register and Output “Holding” Register nodes contain sub-nodes,
as shown in Figure 65.
Figure 65: Modicon 32 Format
These sub-nodes are the same in both the Input Register node and the Output
“Holding” Register node, and are Register Short, Register Long, and Register Float.
Thus, the input and output registers can output data in 16-bit (short), 32-bit (long), or 32bit with floating point (float) in the Modicon with Floating Point Modbus list. Long and Short
registers can contain whole number integer data, while Floating Point registers can
contain integer data with decimal points. The Output “Coil” Status and Input Status
nodes are identical to Modicon 16 format.
5.4
Factory Section
The Factory section in the Navigation menu consists of only a single page, the Factory
Parameters page, which is shown in Figure 66.
Figure 66: Factory Parameters Page
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The parameters on this page are configured at the factory and in general should not require
changing once the analyzer is in operation. When this page is first opened, it is opened in readonly mode. In order to make changes on this page, click on Change to Update Mode at the top
right corner of the screen. A LOGIN dialog box like the one shown in Figure 59 will appear. After
entering the correct password (default is 9713) the page will change to Update mode and these
parameters can then be edited.
The parameters displayed on this page are colour-coded as described in Table 28.
Table 28: Factory Parameters Colour Code
Background Colour
Blue
Grey
Green
Type of Parameter
Parameters related to the analyzer’s analog outputs
Parameters related to the analyzer’s spectrometer
Parameters related to calculation of analytical results
Most of the parameters that are available for editing on this page can be edited at the analyzer
local display using the keypad, though a few cannot. The available parameters are described
briefly in Table 29.
Table 29: Factory Parameters
Parameter
Editable
via
Keypad
Local Display
Editing
Location
Air Demand Full Scale (/+)
Y
Config – Outputs
Dark Start Pixel
N
N/A
First Vector Pixel
N
N/A
H2S, SO2, COS, CS2
SVAP span factor
Y
Config – Calculation
Cell Length
Y
Config – Calculation
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Explanation
In previous software versions, AO1 was
hardcoded to output Air Demand, and this
parameter was used to set the range of the air
demand output. In current software version, all
AOs can be configured individually, so this
parameter has no real use.
Pixel number (out of 2048) where the
spectrometer starts looking at the dark level.
The displayed dark level is an average of the
dark level on all pixels between this pixel and
the first vector pixel.
NOTE: This parameter is unique to each
spectrometer and should ONLY be changed
if the spectrometer is changed.
Pixel number (out of 2048) on the spectrometer
that is used as the first pixel out of the 530
consecutive pixels that are used for analysis.
NOTE: This parameter is unique to each
spectrometer and should ONLY be changed
if the spectrometer is changed.
Span factors used for each measured
component. The concentration of each
component calculated from the absorbance
spectrum and the calibration matrix are
multiplied by these span factors to produce the
displayed and output concentration value.
Should be close to 1 for each component.
Setting to 0 will make the analyzer unable to
measure that component.
Measurement cell length as measured from
inside of one cell window to the inside of the
other cell window. Should only be changed if
the measurement cell block is replaced with a
block with a longer or shorter measurement cell
length.
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Plant Factor
Y
Config – Calculation
Operating Ratio
Y
Config – Calculation
Probe Control
N
N/A
Analog Output 1, 2, 3, 4
Setup
Y
Config – Outputs
Analog Output 1, 2 ,3 4
Full scale
Y
Config – Outputs
Analog Output 1, 2, 3, 4
Track or Hold
Y
Config – Outputs
Plant factor in the Air Demand equation (refer
to Section 1.1). Plant factor is calculated as per
the equation shown in Table 13, Section
4.8.2.1. In most cases, this will be -3.
Optimal ratio of H2S to SO2 for the sulfur
recovery unit in which the analyzer is installed.
In most cases, this will be 2.
Indicates which control point is used for the
actuation of the probe cooler solenoid. Three
options are available:
•
Control with SVP No RTD
Attached – probe cooler is actuated
when sulfur vapour level rises above
set
point
value.
No
probe
temperature measurement RTD
present, so probe temperature
warning / fault are disabled.
•
Control with SVP (RTD is still
attached) – probe cooler is actuated
when sulfur vapour level rises above
set point value. Probe temperature
measurement RTD is present, so
probe temperature warning / fault are
active.
•
Control with RTD – probe cooler is
actuated when measured probe
temperature exceeds set point value.
Probe temperature warning / fault
active.
Configures the parameter output on each of the
analyzer’s four analog outputs. Available output
parameters for each output as per Table 12,
Section 4.8.1.
Concentration value corresponding to an output
of 20mA for each output.
NOTE: For all parameters but air demand, 4
mA corresponds to a concentration of 0. For Air
Demand, 4 mA corresponds to negative full
scale.
Configures each output for either track or hold
behaviour. Refer to section 3.3.1 for more
details.
To change a parameter:
1. Click on the parameter to be edited. The data entry field for that parameter will change
to a white background.
2. Edit the parameter by typing in a new value. Some parameters such as Probe Control
are non-numerical and can be edited by using the pull-down selection menu.
3. Once editing of the selected field is complete, press Enter on the keyboard.
4. Change any other parameters to be edited using the procedure in steps a to c.
5. Once all necessary changes have been made, click on the Save to Unit button at the
bottom of the screen to save all changes permanently to the analyzer.
If it is necessary to cancel all changes made on this page, clicking Revert before clicking on
Save to Unit will undo all changes made during that editing session.
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5.4.1
Changing the Passwords
When logged into Update mode on the Factory Parameters page, there is a button marked
Change Password on the bottom of the page. When clicked, the Change Password dialog
box shown in Figure 67 appears.
Figure 67: Change Password Dialog Box
There are two passwords for the web GUI: the Operator password, which allows the user to
change parameters in the Configuration section of the analyzer (configuration parameters,
Modbus), and the Factory password, which is used to make changes to the factory
parameters. The Change Password dialog box can be used to change either of these
passwords according to the procedure below:
1. To change the factory password, place a checkmark in the Factory Password
checkbox. To change the operator password, leave this checkbox unchecked.
2. Enter in the current password in the Enter Old Password.
3. Enter the desired new password twice in the Enter New Password (twice) fields.
4. Click on OK
5. If the current password is entered correctly, and the new password entered twice
matches, the dialog box will disappear, and the new password is now valid.
If the current password is entered incorrectly, or the new passwords entered twice don’t
match, the error messages shown in Figure 68 will appear.
Figure 68: Password Entry Error Messages
In either case, click on OK, then repeat the procedure taking care not to make the same
mistake.
5.5
Help Section
The Help section contains information that may be useful to the user for installation, operation,
and troubleshooting of the Model 943-TGXeNA analyzer.
5.5.1
Drawing Page
When the Drawing page is opened, a PDF showing generic drawings of the analyzer
exterior, interior, and electronic schematics is downloaded from the analyzer and displayed.
These drawings are also included in Section 9 of this manual.
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5.5.2
User Manual Page
When the User Manual page is opened, a PDF copy of this operator manual is downloaded
from the analyzer and displayed.
5.5.3
Revision History Page
When the Revision History page is opened, the revision number of the web GUI software
installed on the analyzer is displayed, as shown in Figure 69. Please refer to this revision
number when making inquiries about the analyzer software.
Figure 69: Revision History
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Section 6
6.1
Maintenance
Overview
The Model 943-TGXeNA is designed for automatic trouble-free operation under the continuous
supervision and control of the analyzer’s control computer. However, periodic maintenance is
required to keep the analyzer performing at optimal levels. Maintenance requirements include:
•
•
Routine preventative maintenance (Section 6.2)
Periodic operations to optimize performance (Section 6.3)
In addition, a list of recommended spare parts to be kept on hand for reduced down-time is
provided in Section 11.
6.2
Routine Preventative Maintenance
Routine preventative maintenance of the 943-TGXeNA analyzer is used to ensure that the
analyzer is continuing to operate in an optimal manner and all operating parameters are within
a normal range. It consists of:
•
•
•
Visual Inspection of the Key Operating Parameters displayed on analyzer’s local
display (Section 6.2.1)
Verification of analyzer’s response time, both sample to zero and zero to sample
(Section 6.2.2).
Weekly completion of the Maintenance Check-out Procedure (Section 6.2.2). The
operator should complete the Maintenance Record Sheet included in this section and
maintain a file of record sheets to provide a time-based record of system operation.
6.2.1
Parameters
Visual
Inspection
of
Key
Operating
Table 30 shows the normal conditions of a variety of analyzer operational parameters and
indicators. If the conditions and indicators displayed on the analyzer’s local display are
indicating as shown in the table, the system is operating normally, and no further
maintenance is required at this time.
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Table 30: Normal Operating Parameter and Indicator Conditions
Indicator /
Parameter
Online / Offline
Backpurge
Panel Location
Normal Condition
Analysis 2
Analysis 1
Relay Indicators
Analysis 1
Fault Indicators
Indicators
Warning Indicators
Indicators
Cell Temperature
Probe Temperature
Cabinet Temperature
Analysis 2
Analysis 2
Analysis 2
Air Demand Output
Analysis 1
H2S and SO2
Analysis 2
Absorbance
Absorbance
Online (green)
Off (green)
• Status “Normal” (green)
• Service “Normal” (green)
• Mode “Run” (green)
• Control “Auto” (green)
• Cell Temperature (Green)
• Probe Temperature (Green)
• Measure Range (Green)
• Reference Range (Green)
• Dark Range (Green)
• I/O Board (green)
• Cabinet Temperature (green)
• High Absorbance (green)
• High Integration Period (green)
• Low Reference Peak (green)
• High Sulfur Vapour (green)
Within normal range (140°C to 160°C)
Within normal range (100°C to 120°C)
Within normal range (10°C to 40°C)
Depends on process, should be within -5%
to +5%, change in air demand should be
gradual and not sudden
Depends on process, should not be off
scale, ratio should be reasonably close to
2:1 H2S to SO2, any indicated changes on
trend lines should be gradual and not
sudden
Peak absorbance given on absorbance
graph should not exceed 2 AU
6.2.2
Maintenance Check Out Procedure
It is recommended that this maintenance check be performed once per week and
the Maintenance Record Sheet (Table 31) be completed at the same time. It is
recommended that the completed record sheets are saved in a secure location.
The information on the sheets can provide a time based record of system
operation and may be useful for troubleshooting.
The following procedure should be performed on a periodic basis and the Maintenance
Record Sheet should be completed (Table 31):
1. Observe the present status of the analyzer indicated on the Analysis 1 and Analysis
2 panels. Record any fault conditions or abnormal values. Record the displayed values
for the cell / probe temperatures as well as the cell pressure.
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2. Place the analyzer in Offline mode using the Online / Offline control on the Analysis
2 panel. (Refer to Section 4.3.1)
3. Place the analyzer in back-purge by clicking the Back Purge check box on the
Analysis 1 panel OR by pressing the PURGE key on the keypad. The displayed
concentration and air demand outputs should stabilize to a near zero readings within
seconds. Use a stopwatch to measure the time required for the readings to drop from
stable process values to stable zero values. Record the stabilized zero concentration
output values.
The offset from zero will vary based on length of time since the last zero
calibration cycle (manually initiated or automatic).
4. On the Spectrum panel, observe the raw scan signal and compare the shape of the
scan trace to the Factory Reference. Note any extreme deviations from the factory
referene. Record the value in the Peak Height field in approximate A/D counts
(±1,000).
5. If the value in the Peak Height field is less than 16,000, the signal peak height should
be optimized using the Optimize Integ. Time button. Refer to Section 4.6.
6. Return to the Analysis 1 panel. Ensure that the Status indicator is green (Normal) and
the Service indicator is also green (Normal). Check the displayed concentration values.
If they are not very close to zero (±0.02% for all indicated values) a Manual Zero
should be performed. Refer to Section 4.3.4.
7. Return the analyzer to Sample mode by clicking on the Sample checkbox on the
Analysis 1 panel OR by pressing the PURGE key on the keypad. Observe and record
how long it takes for the concentration readings to stabilize at the process value.
Record the stabilized process values. A long response time to a stabilized sample
reading may indicate plugging of the sample system or filter, or inadequate aspirator
drive air flow. Record any observed anomalies and/or valve position adjustments
made.
The response time from back purge to stabilized sample values should be
>30 seconds, but the exact value depends on a variety of factors, including
probe length and instrument air pressure.
8. Return the analyzer to Online by toggling the Online / Offline control back to the green
Online state.
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Table 31: Maintenance Record Sheet
Processing Unit Number
Analyzer Tag Number
Analyzer Serial Number
Date
Time
Instrument Technician
As Found
Forced Zero On
Spectrum
Configuration
Forced Zero Off
As Left
Fault Condition
Cell Temperature
Cabinet Temperature
Cell Pressure
Integration Period
Air Demand
H2S
SO2
Time to Stabilize
Air Demand
H2S
SO2
Spectrum Peak Height
Standard Spectrum Shape
Optimize Integration Time
New Integration Time
Configuration Changed
New Configuration Saved
Time to Stabilize
Fault Condition
Cell Temperature
Cabinet Temperature
Cell Pressure
Integration Period
Air Demand
H2S
SO2
Yes/No
Yes/No
Yes/No
Yes/No
Notes:
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6.3
Changing the Anti-Solarant Solution
Radiation generated by the analyzer’s broadband UV Source Lamp in the short wavelength UV
region (wavelength <200 nm) may degrade the transparency of the optical fibres to ultraviolet
radiation in the measurement region over a period of time. An optical fibre directly exposed to
the broadband source will eventually develop an absorption band that reduces fibre
transmittance at wavelengths below 250 nm.
The degree of fibre degradation is a function of accumulated exposure time. The Anti-Solarant
Solution incorporated into the analyzer provides a high-pass liquid optical filter with a sharp cutoff region. The Anti-Solarant Solution filters out the short wavelength UV radiation which is the
cause of the fibre degradation and prevents it from entering the fibre where it can cause
damage. RUNNING A BRIMSTONE-943 ANALYZER WITHOUT ANTI-SOLARANT
SOLUTION WILL NOT AFFECT THE ANALYSIS RESULTS. HOWEVER, OPERATING IN
THIS MANNER COULD CAUSE IRREVERSIBLE DAMAGE TO THE ANALYZER’S OPTICAL
FIBRES, AND SIGNIFICANTLY SHORTEN THEIR LIFESPAN.
The Anti-Solarant Solution will eventually degrade to the point where it absorbs too much energy
causing the integration period to approach the maximum of 1000 ms. When the analyzer is
exhibiting a loss of spectrometer signal level (a high integration period >500ms required to reach
28,000 A/D counts), and all other potential causes of loss of spectrometer signal have been
ruled out (dirty cell windows, lamp near the end of its lifespan, damaged optical fibres), the
cause of the low response is likely expired anti-solarant solution. Under these circumstances,
the anti-solarant solution will need to be replaced.
Wear protective UV eye glasses at all times if the optical fibres are removed while
the UV Source Lamp is powered up.
The control cabinet door should NOT be opened while the analyzer is energized
UNLESS the area is known to be non-hazardous.
The anti-solarant solution should only be changed only by authorized personnel. It
is not necessary to turn the UV source lamp off to perform this procedure. The UV
lamp lifespan can be reduced by additional ON/ OFF cycles.
The fluid holder may be warm. Wear Gloves when handling the fluid holder.
Always handle optical fibres carefully and avoid any contact with the end of the fibre.
Before proceeding with the following procedure, ensure that the analyzer is Off Line
and purged with zero gas.
Always handle optical fibres carefully and avoid any contact with the end of the fibre
when it is disconnected. Before proceeding with the following procedure, ensure
that the analyzer is Off Line and purged with zero gas.
Refer to Figure 70 while performing the following procedure.
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3
2
4
1
Figure 70: Replacing the Anti-Solarant Solution
1. Disconnect the source optical fibre from the fluid holder bracket on the UV Lamp
Supply (Item #1 in Figure 70). Let the fibre hang freely and ensure that the end does
not contact anything.
It is suggested that a protective plastic cap is placed onto the end of the
fibre. This fibre is removed from the light path to protect it from unfiltered
exposure to the UV Source Lamp).
2. Loosen the light shield retaining screw on the bottom right-side of the fluid holder and
remove the light shield. (#4 in Figure 70)
3. Loosen the fluid holder locking screw (s) on the left-side of the fluid holder using a
7/64" ball driver.(#2 in Figure 70)
4. Lift the fluid holder from the base by grasping the fluid holder filler plug (#3 in Figure
70).
5. Remove the filler plug from the top of the fluid holder.
6. Dump out the old anti-solarant solution.
The Anti-Solarant Solution is not hazardous to the environment.
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7. Rinse the chamber with a small amount of new anti-solarant solution. Shake and
empty. Ensure that there are no solid deposits and the chamber windows are
completely clear.
8. Fill the fluid holder with new anti-solarant solution. Tilt and tap the fluid holder to
remove any air bubbles that may form. Leave a small amount of air space at the top of
the fluid holder to allow for thermal expansion.
Take care not to touch the Anti-Solarant Solution directly as the oils from
your hands will contaminate the solution.
9. Replace the fluid holder filler plug.
10. Replace the fluid holder into the bracket. Orient the fluid holder so that the face with
the word LAMP engraved on it faces the UV Source Lamp.
DO NOT touch the fluid holder windows as dirt, grease and human skin oil
will reduce their transparency to UV radiation.
11. Tighten the fluid holder locking screw (s) on the left-side of the fluid holder (#2 in Figure
70). Unless the analyzer is installed in a high-vibration environment, hand tight is
enough for these screws.
12. Reinstall the light shield and tighten the light shield retaining screws on the bottom
right-side of the fluid holder.(#4 in Figure 70).
13. Remove the protective plastic cap from the disconnected source fibre and reconnect it
to the fluid holder bracket (#1 in Figure 70). Hand tight is sufficient for this connection.
14. Reoptimize the spectrometer energy level as described in Section 6.4
6.4
Optimizing the Spectrometer Signal
Optimization of the Spectrometer signal is periodically required to maintain a sufficient signal to
noise ratio on the spectrometer output signal as the spectral output signal from the spectrometer
will degrade over time. Commonly seen causes of this degradation include:
•
•
•
•
•
Degraded Anti-Solarant Solution
Aging UV Source Lamp (output reduces over time)
Dirty measurement cell windows
Dirty optics
Optical fibre problem
For convenience, the energy level of the spectrometer output signal is gauged by observing the
Peak Height as displayed on the Spectrum panel of the analyzer or the Spectrum page on the
Web GUI. When optimizing the spectrometer signal, the normal target value for the peak height
is 28000 counts (+/- 500).
The spectrometer energy level can be optimized manually (for special cases), or automatically
as a function of the analyzer. The automatic function will always target 28000 counts.
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Prior to carrying out spectrometer signal optimization, the analyzer MUST be in back
purge and offline mode.
6.4.1
Automated Optimization
1. Place the analyzer in back purge mode. This can be done by selecting the Back Purge
field on the Analysis 1 panel and pressing the ↵ key to place an X in the box OR by
pressing the PURGE key on the keypad.
2. Access the Spectrum panel, navigate to the Optimize Integ Time button and press
ENTER. Make sure that the peak height after completion of this operation is ≈28000
A/D counts.
3. Return to the Analysis 1 Panel.
4. Request a Manual Zero by navigating to the Manual Zero button and pressing ENTER.
5. After the Manual Zero is completed, place the analyzer back in Sampling mode by
selecting the Sample field and then pressing ENTER to put an x in the box OR pressing
PURGE on the analyzer keypad.
6. Place the analyzer back into ONLINE mode by toggling the button on the Analysis 2
panel.
6.4.2
Manual Optimization
1. Place the analyzer in back purge mode. This can be done by selecting the Back Purge
field on the Analysis 1 panel and pressing the ENTER key to place an X in the box
OR by pressing the PURGE key on the keypad.
2. Access the Spectrum panel.
3. If the peak level is between 25,000 and 28,000 then no adjustment is required at this
time.
4. If adjustment is necessary, optimize the peak signal height to ≈28,000 counts. Navigate
to the Set Integ. TIme and press ENTER to display the Integration Period dialog box
(Section 4.6). Enter a new integration period in the New Value field and press ENTER.
After several seconds, the new raw signal will be displayed. New values for the
Integration Period can be entered until the peak height is 28 000 counts +/- 1000
counts.
5. Once the peak height has been optimized, record the peak height value and the
resulting integration period.
7. Return to the Analysis 1 Panel.
8. Request a Manual Zero by navigating to the Manual Zero button and pressing ENTER.
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9. After the Manual Zero is completed, place the analyzer back in Sampling mode by
selecting the Sample field and then pressing ENTER to put an x in the box OR pressing
PURGE on the analyzer keypad.
10. Place the analyzer back into ONLINE mode by toggling the button on the Analysis 2
panel
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Section 7
7.1
Servicewhat is going on here...
Overview
The Service section consists of procedures for determining the cause of a problem and includes
a series of procedures to replace certain components.
A major component failure should be handled by contacting Galvanic Applied Sciences, Inc.
Galvanic Applied Sciences, Inc. offers service on a call-out basis and/or factory assistance on
the 943-TGXeNA analyzer.
For Service and/or Assistance Contact:
Galvanic Applied Sciences Inc.
7000 Fisher Road SE
Calgary, Alberta T2H 0W3
Canada
Tel: 403-252-8470
TOLL FREE (CANADA/US): 1 (800) 458 4544
INTERNATIONAL +1 978 848 2708
Fax: 403-255-6287
Email: [email protected]
7.2
Indicators Panel Troubleshooting
The Indicators panel shown in Figure 71 shows a historical record the most recent 25 fault /
warning events. Refer to Section 4.5 for a full description of the information presented on this
panel.
Figure 71: Indicators Panel
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Table 32 shows potential troubleshooting solutions for all displayed active faults and warnings
on the Indicators panel.
Table 32: Analyzer Fault / Warning Troubleshooting
Fault / Warning
Cell Temperature
High High Sulfur
Measure Range
Reference Range
Dark Range
I/O Board
Cabinet
Temperature
High Absorbance
High Integration
Period
Low Reference
Peak
High Sulfur Vapor
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Troubleshooting Tips
•
Oven heater fuse is blown (ACTS:25)
•
Cell assembly is not securely clamped to the heaters
•
Oven heater(s) inoperative
•
Steam lines, sample probe nozzle, and analyzer flange are not sufficiently insulated
•
Set point for low temperature alarm is incorrect
NOTE: If this fault is active but the temperature is above the low temperature set point,
this indicates that the High Cell Temperature setpoint is set too low. This setpoint can
only be set through the web GUI. Refer to Section 5.3.1
•
The sulfur vapor concentration in the sample has risen to unacceptable levels. This
usually indicates that the probe’s condenser tip is not cool enough to condense
sulfur in the process pipe.
•
Probe cooler solenoid is not functioning
•
Probe cooler instrument air flow rate is not high enough
•
Check probe cooler air outlet on left side of analyzer for air flow
•
UV lamp is nearing the end of its useful life and requires changing
•
UV lamp is not operating
•
Fuse on UV power supply is blown (integral with the power switch on the bottom
side of the UV lamp supply enclosure inside the control cabinet)
•
Fuse on ACTS28 is blown
•
Anti-Solarant solution transmissivity has degraded.
•
Cell windows are dirty
•
Optical Fibres have become damaged
•
Spectrometer problem, consult factory.
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
The I/O board is not communicating with the controller board.
The spectrometer is not communicating with the controller board
Check ArcNet wiring.
Check USB connection at spectrometer and at top of controller board
Cabinet cooler air solenoid not functioning
Air supply to Vortec cooler is turned off
Analyzer is installed in direct sunshine and requires a sun shade .
The H2S and or SO2 concentration is out of range (process issue)
The analyzer is not zeroed.
Switch analyzer to backpurge and ensure that the spectrum displayed on the
Absorbance panel goes to zero; if it does not, immediately perform a Manual Zero
UV lamp is nearing the end of its useful life
UV lamp is not operating (only in conjunction with Measure / Reference range fault)
Anti-Solarant solution transmissivity has degraded.
Cell windows are dirty
Optical fibres have been damaged
ACTS 28 fuse or lamp power supply fuse blown (only in conjunction with Measure /
Reference range fault)
UV lamp is nearing the end of its useful life
UV lamp is not operating (only in conjunction with Measure / Reference range fault)
Anti-Solarant solution transmissivity has degraded.
Cell windows are dirty
Optical fibres have been damaged
ACTS 28 fuse or lamp power supply fuse blown (only in conjunction with Measure /
Reference range fault)
Sulfur vapour concentration approaching fault set point
Confirm probe cooler is operating by checking for air flow from probe vent on left
side of analyzer cabinet.
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7.3
Testing and Replacement of the Optical Fibres
When a High Integration Period warning is present, one of the possible causes of this warning
is that one or both of the optical fibres have been damaged and are not able to transmit
ultraviolet radiation normally. To eliminate or confirm the fibres as the source of the high
integration period, they can be tested as a pair or, if necessary, individually to observe their
transmission characteristics .
The fibre optic cables will generally only require change-out if they suffer from mechanical
damage or if they have been exposed directly to short wavelength ultraviolet radiation for
prolonged time periods, as when the analyzer has been operated for prolonged periods without
anti-solarant solution present.
The fibre optic cable ends terminate into SMA type connectors and are intended to be installed
with the seal body installed in the inter-cabinet seal fittings that connect the oven cabinet and
the control cabinet. There are two cables. The shorter of the two fibres connects the UV Source
Lamp in the control cabinet to the top side of the measurement cell in the oven cabinet. The
longer of the two fibres connects the Spectrometer in the control cabinet to the bottom side of
the measurement cell in the oven cabinet.
The SMA connectors only need to be finger-tight. Do not overtighten the connectors
as this may damage the cable.
Remove the anti-solarant fluid holder and check if the High Integration Period warning is still
present when operating without anti-solarant solution BEFORE proceeding with the fibre test
procedure. If the High Integration Period warning clears when the anti-solarant fluid holder is
removed, this indicates that the anti-solarant solution has degraded to a non-usable level and
needs to be replaced as per the procedure described in section 6.3. Perform this replacement
prior to testing the optical fibres. To test the optical fibres, and replace if necessary, follow the
procedure below.
1. Place the analyzer in Offline mode by toggling the Online / Offline control toggle
(Section 4.3.1) on the Analysis 2 panel to Offline (red).
2. Place the analyzer in back purge mode by pressing the PURGE key on the keypad OR
by placing the X in the Back Purge check box on the Analysis 1 panel.
3. Access the purged control cabinet following proper user company and/or regulatory
agency procedure.
The control cabinet door may NOT be opened while the analyzer is
energized UNLESS the area is known to be non-hazardous. Observe all the
warning labels on the analyzer enclosures.
DO NOT look at the end of disconnected fibres connected to the UV lamp or
place them in contact with skin. The intense UV radiation transmitted
through these fibres can cause eye and skin damage. Fibres should be
capped immediately after disconnection to prevent acidental exposure to
UV radiation.
4. Turn the oven heaters off by locating the Heater AC Power fuse terminal on terminal
block ACTS:25. Lift the fuse terminal tab opening the terminal block and thus
disconnecting the Heater AC Power fuse, as shown in Figure 72.
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Figure 72: Location of Cell Heater Fuse on ACTS
5. Open the oven cabinet door and remove the black cover on the oven enclosure.
The oven enclosure and all of its components are HOT (150°C). Wear
appropriate personal protective equipment (gloves, eye wear, clothing etc)
if working with hot surfaces or wait until surface have cooled to safe
temperatures before performing maintenance tasks.
6. Disconnect the fibres from both the top right and the bottom right of the measurement
cell block by unscrewing the nut and pulling out.
7. Joint the two loose ends of the optical fibres together by cutting the end off of one of
the orange fibre caps and connecting both fibres into the same cap. Press the fibres
into the cap so that both ends are in contact with one another.
8. Using the PANEL NEXT / PANEL PREV keys on the keypad, navigate to the Spectrum
panel.
9. Use the FIELD NEXT / FIELD PREV keys to select Optimize Integ. Time and press
ENTER to optimize the integration period. It may be necessary to press ENTER more
than once to get a peak height ≈28000 A/D counts.
10. Use the FIELD NEXT / FIELD PREV keys to select Show Factory Reference and
press ENTER to display the factory reference spectrum.
11. Observe the indicated integration time. If the observed integration period is <100
milliseconds AND the shape of the red current spectrum has no major differences from
the factory spectrum, both fibres are undamaged and will not require replacement. If
the lamp was replaced <6 months ago, the High Integration Period warning is likely
due to dirty cell windows. Refer to Section 7.5 for cleaning / replacement procedure.
Do not reinstall the fibres at the measurement cell at this time. However, if the
integration period is >100 milliseconds OR the shape of indicated spectrum is
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significantly different from the factory reference spectrum, it will be necessary to test
the fibres individually. Continue to Step 12.
12. Loosen the two inter-cabinet seal fittings through which the fibres pass from the oven
cabinet into the control cabinet and unscrew the retaining caps. Lift out the plastic
retainers and pull gently outward on the cable and rubber seal plug until free from the
fitting.
Be careful that the ends of the Fibre Optic Cables do not become abraded
by contact with other surfaces. Installing a protective plastic cap onto the
end of the fibre is recommended.
13. Disconnect the fibre optic cables from the UV Lamp enclosure and the spectrometer
by unscrewing the nuts and pulling the fibre optic cables out. The cables can then be
pulled out through the cabinet seal fittings.
14. Connect one cable directly from the UV lamp enclosure to the spectrometer. Repeat
steps 9 and 10 for this cable. Observe the integration time and the shape of the
spectrum. If the integration time <50 milliseconds AND the peak shape is similar to the
factory reference, the cable is good and does not require replacement. If the integration
time >100 milliseconds OR the peak shape is significantly different from the factory
reference spectrum, the cable should be replaced.
15. Repeat step 15 for the other fibre optic cable.
16. If both fibre optic cables are found to be good, and the UV lamp was last replaced <6
months ago, the High Integration Period warning is likely due to dirty measurement
cell windows. Refer to Section 7.5 for cleaning / replacement procedure. If at least one
cable is found to require replacement, obtain the necessary replacement(s) and then
continue with this procedure.
17. Slide the short (source) fibre optic cable through the seal retaining cap, the rubber seal,
and the fitting for the bottom inter-cabinet seal fitting, ensuring that the seal body on
the fibre optic cable is closer to the control cabinet end. Connect the end of the fibre to
the SMA fitting on the UV Lamp power supply and hand tighten the nut. Tighten the
seal fitting.
18. Slide the long (detector) fibre optic cable through the seal retaining cap, the rubber
seal, and the fitting for the top inter-cabinet seal fitting, ensuring that the seal body on
the fibre optic cable is closer to the control cabinet end. Connect the end of the fibre to
the SMA fitting on the spectrometer and hand tighten the nut. Tighten the seal fitting.
19. Route the fibres into the oven, making sure that the fibres are routed in the indents to
avoid damage when the oven enclosure cover is secure.
20. Connect the short fibre to the SMA fitting on the top of the measurement cell. Connect
the long fibre to the SMA fitting on the bottom of the measurement cell. Hand tighten
the nuts.
21. Loosen the set screw holding the SMA Fittings into the measurement cell slightly so
that the SMA fitting can rotate and slide in and out.
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22. Use the PANEL NEXT / PANEL PREV keys to navigate to the Spectrum panel. Adjust
the position of each SMA fitting in the measurement cell by rotating it slightly left and
right and sliding it in and out to find the position that gives the greatest Peak Height.
Once the optimal position is found for each fibre, re-tighten the set screw.
The SMA connectors only need to be finger-tight. Do not overtighten the
connectors as this may damage the cable.
23. Optimize the integration period by using the FIELD NEXT / FIELD PREV keys to
highlight Optimize Integ. Time, then press ENTER.
24. Observe the optimized integration time. If the High Integration Period warning has
cleared, no further work is required at this time. Proceed to the next step in this
procedure. If the High Integration Period warning is still present, however, it is likely
that the cell windows are dirty and/or damaged. Proceed to Section 7.5.
25. Make sure that both fibre optic cables are in their correct indent in the oven enclosure
frame, then replace the oven enclosure cover and securely fasten both latches.
26. Reconnect the AC Power to the oven heaters by pushing down and snapping closed
the oven heater fuse terminal cover (ACTS:25). The oven will begin heating to the set
point temperature.
27. Close and latch the oven cover.
28. Close and latch the control cabinet and oven cabinet doors.
29. Confirm that the High Integration Period warning has not returned.
30. Once the measurement cell temperature rises to >140°C, and the Cell Temperature
fault has cleared, use the PANEL NEXT / PANEL PREV keys to navigate to the
Analysis 1 panel. Perform a manual zero calibration cycle by using the FIELD NEXT
/ FIELD PREV keys to highlight Manual Zero, then press ENTER..
31. Once the manual zero calibration cycle is complete, place the analyzer into sampling
mode by highlighting the Sample checkbox using the FIELD NEXT / FIELD PREV
keys, then press ENTER. Alternatively, press the PURGE key
32. Once normal operation has been confirmed, return the Online / Offline control toggle
on the Analysis 2 panel back to Online (green).
7.4
Troubleshooting the UV Source Lamp
The UV Source Lamp requires replacement when either the lamp will not start, or when the
energy output of the lamp has diminished to a point where a Peak Height of >20,000 A/D counts
as displayed on the Spectrum panel cannot be achieved even with the maximum 1000
millisecond integration period.
Before replacing the UV Source Lamp, it is advisable to eliminate all other potential sources of
the problem, unless the time since the last replacement is >8 months (if using standard lifespan
lamp, Galvanic part number BA7195) or >16 months (if using long life lamp, Galvanic part
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number BA7532). Refer to the spectrum displayed on the Spectrum page and the lamp
troubleshooting tips shown in Table 33.
Table 33: Lamp Troubleshooting
Spectrum Appearance
•
•
Horizontal line, no peak observed
•
•
Peak present, but peak height <20,000 with
integration time 1000ms
•
•
•
Potential Cause
Lamp supply fuse on ACTS burned
out
Lamp supply fuse in switch on
bottom of black UV lamp enclosure
burned out
Lamp burned out
Anti-solarant degraded and requires
replacement
Dirty / broken cell windows
Damaged optical fibres
Lamp degraded to beyond useful life
Once the lamp has been switched off, it will not restart for a period of time as ignition of a hot
lamp can cause serious problems. If the lamp is turned off or is no longer lit, it may be worthwhile
to wait for 15-20 minutes before restarting it. If the lamp does not start after the cool down period,
and it has been more than six months since the lamp has been replaced, then it should be
replaced. The normal lifespan of a UV Source Lamp is about six months, but longer life spans
are possible in circumstances where the restart count is low.
If the lamp was replaced <8 months ago (standard lifespan lamp) or <16 months ago (long
lifespan lamp) , it is advisable to investigate the other potential causes listed in Table 33 prior
to replacing the lamp.
The lamp life is inversely proportional to the number of restarts on a particular lamp.
The lamp should ONLY be turned off when absolutely necessary to preserve lamp
lifespan.
An iris is installed on the lamp holder between the lamp and the fluid holder. The iris is preset
at the factory with clean optics and a new lamp to obtain 28,000 counts at a <100 ms integration
period. The setting of the iris is only to be changed in extreme situations. Please contact
Galvanic Applied Sciences Inc. prior to making any changes to the iris position.
To change the UV Source Lamp, follow the procedure below.
1. Place the analyzer in Offline mode by toggling the Online / Offline control toggle
(Section 4.3.1) on the Analysis 2 panel to Offline (red).
2. Place the analyzer in back purge mode by pressing the PURGE key on the keypad OR
by placing the X in the Back Purge check box on the Analysis 1 panel.
3. Access the purged control cabinet following proper user company and/or regulatory
agency procedure.
The control cabinet door may NOT be opened while the analyzer is
energized UNLESS the area is known to be non-hazardous. Observe all the
warning labels on the analyzer enclosures.
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4. Lift the fuse terminal tab opening the terminal block and disconnect the UV Lamp
Power Supply fuse, located at ACTS:28, next to the cell heater fuse tab indicated in
Figure 72. Alternatively, place the UV Lamp power switch to the Off position. The
location of the lamp power switch is indicated in Figure 73.
Socket Head Cap Screw
Figure 73: UV Lamp Enclosure
5. Remove the UV Lamp Enclosure lid by removing the four (4) socket head cap screws
and pulling the cabinet lid outwards.
The lamp enclosure lid has a safety cutoff switch underneath it that will
automatically cut off power to the lamp supply enclosure when the lid is
removed. However, for safety reasons the power supply should ALWAYS be
shut off as described in Step 4 prior to removal of the lid.
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Figure 74 shows the internal layout of the UV lamp enclosure. Refer to this picture
while performing the next steps of this procedure.
1
3
2
Figure 74: UV Lamp Enclosure Internal Layout
6. Remove the two plastic hole plugs from the top of the UV Lamp Enclosure to gain
access to the lamp retaining screws. The location of these two hole plugs is indicated
in Figure 74 by the red circle (#1).
7. Disconnect the three (3) lamp connection wires from the terminal strip, circled in yellow
in Figure 74 (#2).
8. Remove the two lamp retaining screws (5-40 x 3/8") from the lamp retaining ring using
a 3/32" ball driver passed through the removed hole plugs. The location of the front
retraining screw is marked by the blue circle (#3) in Figure 74.
9. Remove the lamp.
10. Place the new lamp in the lamp retainer on the lamp mount assembly. Ensure the lamp
is facing the correct direction. Refer to Figure 75 for the correct UV source lamp
orientation.
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This side faces
towards
the
anti-solarant
fluid holder.
Figure 75: UV Lamp Orientation
DO NOT touch the front face (light emitting side) of the lamp. Dirt, grease,
and human skin oils can affect the lamp spectral performance. Always
handle the lamp by the metal base.
DO NOT apply power to the lamp with the cover removed. Intense UV
radiation can cause severe eye damage.
11. Replace the two lamp retaining screws (5-40 x 3/8") and tighten using a 3/32" ball
driver passed though the holes on the top of the lamp enclosure.
12. Replace the two plastic plugs on the top of the lamp enclosure.
13. Reconnect the three wires from the lamp to the terminal strip. The wires are colour
coded on the terminal strip. Connect the lamp’s blue wire to the blue terminal, the red
wire to the red terminal, and the black wire to the black terminal. If the lamp has two
black wires instead of a blue and a black, connect one of the black wires to the blue
terminal and the other to the black terminal.
14. Reinstall the UV lamp enclosure cover. Tighten the cover cap screws.
15. Reconnect the AC terminal block fuse terminal on terminal block ACTS:28 by pressing
down and snapping it into place. Place the UV Lamp power switch to the ON position.
16. Close and latch the control cabinet door.
17. Ensure that the analyzer is still in backpurge mode.
18. Using the keypad, navigate to the Spectrum panel.
33. Optimize the integration period by using the FIELD NEXT / FIELD PREV keys to
highlight Optimize Integ. Time, then press ENTER.
34. Observe the optimized integration time. If the High Integration Period warning has
cleared, no further work is required at this time. Proceed to the next step in this
procedure. If the High Integration Period warning is still present and the fibres have
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already been tested as described in Section 7.3, however, it is likely that the cell
windows are dirty and/or damaged. Proceed to Section 7.5 – 7.6
35. Use the PANEL NEXT / PANEL PREV keys to navigate to the Analysis 1 panel.
Perform a manual zero calibration cycle by using the FIELD NEXT / FIELD PREV keys
to highlight Manual Zero, then press ENTER.
36. Place the analyzer into sampling mode by highlighting the Sample checkbox using the
FIELD NEXT / FIELD PREV keys, then press ENTER. Alternatively, press the PURGE
key.
37. Once normal operation has been confirmed, return the Online / Offline control toggle
on the Analysis 2 panel back to Online (green).
7.5
Measurement Cell Block Removal
The measurement cell block will require removal only when there is a suspected sampling
problem or if it becomes necessary to clean or change the cell windows and/or O-Rings. A
sampling problem could be due to system plugging or collection of nongaseous material in the
measurement cell.
The measurement cell is to be removed by trained and authorized personnel only.
Follow the procedure to remove the measurement cell block from the analyzer.
1. Place the analyzer in Offline mode by toggling the Online / Offline control toggle
(Section 4.3.1) on the Analysis 2 panel to Offline (red).
2. Place the analyzer in back purge mode by pressing the PURGE key on the keypad OR
by placing the X in the Back Purge check box on the Analysis 1 panel.
3. Access the purged control cabinet following proper user company and/or regulatory
agency procedure.
The control cabinet door may NOT be opened while the analyzer is
energized UNLESS the area is known to be non-hazardous. Observe all the
warning labels on the analyzer enclosures.
DO NOT look at the end of disconnected fibres connected to the UV lamp or
place them in contact with skin. The intense UV radiation transmitted
through these fibres can cause eye and skin damage. Fibres should be
capped immediately after disconnection to prevent acidental exposure to
UV radiation.
4. Turn the oven heaters off by locating the Heater AC Power fuse terminal on terminal
block ACTS:25. Lift the fuse terminal tab opening the terminal block and thus
disconnecting the Heater AC Power fuse, as shown in Figure 72.
5. Open the oven cabinet door and remove the black cover on the oven enclosure.
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The oven enclosure and all of its components are HOT (150°C). Wear
appropriate personal protective equipment (gloves, eye wear, clothing etc)
if working with hot surfaces or wait until surface have cooled to safe
temperatures before performing maintenance tasks.
6. Allow zero gas to flow for approximately five (5) minutes to remove all toxic gases from
the sample system.
7. Ensure all five block valves in the oven enclosure are in the closed position. Fully close
the Zero Air Flow Adjust valve.
8. Remove the Fibre Optic Cables from both ends of the measurement cell. Carefully
hang the cables in a location where the ends of the cables cannot not contact anything.
Cap the ends of the two fibres with the orange protective caps.
9. Loosen one of the cell tubing fittings to vent positive pressure zero gas that may be
trapped in the sample system.
10. To remove the measurement cell block, tubing connected to the measurement cell
block assembly must first be removed. Disconnect the fittings circled in Figure 76.
Figure 76: Oven Enclosure
Process gas is still present at
the probe side of these
valves. To prevent the
release of toxic gases, ONLY
disconnect tubing from the
cell side of these valves, NOT
the probe side.
11. Using a 7/64” ball driver, remove the 6-32 x 3/8” screw securing the cell RTD to the
cell block Carefully place the cell RTD behind the cell block where it will be out of the
way. Place the screw in the storage box in the control cabinet to prevent it from getting
lost.
12. Loosen the four ¼-20 x 2” heater bracket mounting screws from the cell block face
using a 3/16” ball driver. Before removing the last screw entirely, place your fingers
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under the cell block to catch the plate as you release the last screw. Place the screws
in the storage box in the control cabinet.
13. Carefully remove the measurement cell block from the analyzer. Disconnect any
additional tubing as required to remove the measurement cell block, bearing in mind
the warning displayed in Figure 76.
7.6
Cell Windows Cleaning / Replacement
Under normal operating conditions, cell window replacement is necessary only when the
particular window becomes cracked, chipped, etched or stained to a non-cleanable degree.
However, under normal operating conditions, it is possible for the cell windows to become
sufficiently dirty to reduce their transparency to ultraviolet radiation, which can lead to a High
Integration Period warning.
Cleaning or changing the cell windows is most easily accomplished by removing the entire
measurement cell assembly from the oven enclosure, as described in Section 7.6. It is
recommended that the measurement cell assembly is opened in a clean environment such as
a bench top.
Follow the procedure below to open up the measurement cell and clean / replace the cell
windows and their associated O-rings. Refer to Figure 77 while performing this procedure.
Figure 77: Measurement Cell Block (Exploded VIew)
1. Remove the cell as described in Section 7.5.
2. With the measurement cell in a vertical position, remove the top cell end fitting. Leave
the SMA fibre connector in place in the cell end fitting body.
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3. Remove the top O-ring. If it is not on the cell window, then it will be in the end cap Oring groove. Discard if there is any sign of damage or deformation. A fine tipped tool
may be required to remove the O-Ring from the groove in the cell end fitting. The cell
window may also stick to the cell end fitting when it is removed.
4. If the cell window did not come out with the cell end fitting, turn the measurement cell
over, holding your hand over the open end, and gently shake until the cell window
drops into your hand. Set the window aside on a clean surface. Remove the bottom ORing (if it didn’t drop into your hand with the window). A fine tipped tool may be required.
Discard the O-ring if there is any sign of damage or deformation.
The cell window may stick to the inner O-Ring and be difficult to remove. If
it is, cap all but one port on the top of the measurement cell and blow into
the open port, holding a hand under the cell end to catch the cell window.
The air pressure should be sufficient to loosen the cell window and allow it
to be removed.
5. Repeat Steps 1-4 for the other cell window. If the other cell window sticks to the inner
O-Ring, it may be removed by passing a soft tipped tool through the measurement cell
and pushing on it gently from the inside until it comes loose.
6. Inspect both windows for damage and/or contaminants. If the windows are damaged
(chipped, cracked, discoloured, etc.) discard and replace them with new ones. If the
windows are not damaged, they should be cleaned with isopropyl alcohol, using a nonabrasive lint free tissue such as KimWipes® or a cotton swab. Thoroughly rinse the
cleaned surface with pharmaceutical grade distilled water. They should be wiped dry
using a soft, lint free cloth or tissue.
Commercially available lens or window cleaning solutions or prepackaged
lens cleaning wipes ARE NOT to be used. These products may contain a
compound which leaves an UV absorbing coating on the cell window, which
could lead to continued High Integration Period warnings.
7. Inspect the measurement cell body. Clean with isopropyl alcohol, using a nonabrasive
lint free tissue such as KimWipes® or a cotton swab. Thoroughly rinse the cleaned
surface with pharmaceutical grade distilled water and dry completely before
reassembly.
8. Hold the measurement cell vertically and install the new bottom O-Ring in the top
window recess, ensuring that it is centred and sitting in the O-Ring seat.
9. Insert the cell window. Handle the window by its edges to prevent fingerprints on the
transparent surfaces of the window.
10. Place the top O-ring onto the window and replace the cell end fitting. The O-Ring will
self-align as the end fitting is tightened. Tighten the end fitting to hand-tight only.
Do not overtighten the cell end fittings. Overtightening these fittings could
cause damage or break the windows. Also ensure that there is no crossthreading to avoid damaging the interior threads on the sample cell
block.The cell end fitting should screw on smoothly. DO NOT FORCE!
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11. Repeat steps 8 to 10 to install the O-rings and window for the other window. Look
through the cell and verify that there is an unobstructed light path, with no dirt or other
visible contaminants on the cell windows. It may be necessary to remove one or both
of the SMA connectors to check the light path. Replace the connectors to hand-tight
when done.
12. When both windows are installed, the measurement cell assembly is ready for
reinstallation as described in Section 7.8.
7.8
Measurement Cell Installation
Once the cell windows have been cleaned or replaced, the measurement cell can be reinstalled
in the oven enclosure by following the procedure below.
1. Place the measurement cell in its approximate position focusing on the engagement of
the 3/8” elbow Swagelok® fitting connection on the bottom left of the measurement cell
block. Once this fitting is engaged, the aspirator drive air inlet fitting on the top left of
the measurement cell can also be reconnected to finger tight.
2. Hold the heater bracket plate in place behind the measurement cell block with fingers.
Install one (1) of the four (4) ¼-20 x 2" heater bracket screws with a 3/16" ball driver.
Do not fully tighten at this point. A small screwdriver or awl may be used to align the
tapped holes in the bracket with the screw holes in the measurement cell.
3. Install the remaining screws. Once all four screws have been partly screwed in, they
can all be tightened.
4. Install any remaining removed tubing that has yet to be re-installed.
5. Tighten all the Swagelok® fitting connections that were opened during the
measurement cell removal process.
6. Open the Zero Air Flow Control valve to about 2 turns. This will pressurize the
measurement cell and related plumbing to about 20 psig.
7. Open all the sample flow control valves (V1, V3, V5). Leak check all fittings with Snoop
or similar liquid leak detector. Tighten any loose fittings.
8. Connect the short fibre to the SMA fibre connector on the top of the measurement cell.
Connect the long fibre to the SMA fibre connector on the bottom of the measurement
cell. Hand tighten the nuts.
9. Loosen the set screw holding the SMA fibre connector into the measurement cell
slightly so that the SMA fibre connector can rotate and slide in and out.
10. Use the PANEL NEXT / PANEL PREV keys to navigate to the Spectrum panel. Adjust
the position of each SMA fibre connector in the measurement cell by rotating it slightly
left and right and sliding it in and out to find the position that gives the greatest Peak
Height. Once the optimal position is found for each fibre, re-tighten the set screw.
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The SMA fibre connector set screws only need to be finger-tight. Do not
overtighten the set screws as this may damage the SMA fibre connector.
11. Optimize the integration period by using the FIELD NEXT / FIELD PREV keys to
highlight Optimize Integ. Time, then press ENTER.
12. Reinstall the cell RTD with the 6-32 x 3/8" screw using a 7/64" ball driver.
13. Make sure that both fibre optic cables are in their correct indent in the oven enclosure
frame, then replace the oven enclosure cover and securely fasten both latches.
14. Reconnect the AC Power to the oven heaters by pushing down and snapping closed
the oven heater fuse terminal cover (ACTS:25). The oven will begin heating to the set
point temperature.
15. Close and latch the oven enclosure cover.
16. Close and latch the control cabinet and oven cabinet doors.
17. Once the measurement cell temperature rises to >140°C, and the Cell Temperature
fault has cleared, use the PANEL NEXT / PANEL PREV keys to navigate to the
Analysis 1 panel. Perform a manual zero calibration cycle by using the FIELD NEXT
/ FIELD PREV keys to highlight Manual Zero, then press ENTER.
18. Once the manual zero calibration cycle is complete, place the analyzer into sampling
mode by highlighting the Sample checkbox using the FIELD NEXT / FIELD PREV
keys, then press ENTER. Alternatively, press the PURGE key.
19. Once normal operation has been confirmed, return the Online / Offline control toggle
on the Analysis 2 panel back to Online (green).
The oven can take up to two hours to reach operating temperature. While
the cell temperature is below the Low Cell Temperature fault set point, the
system will continue to back purge and maintain a fault indication to the
control room.
7.9
Steam Purging the Sample Probe
Steam Purging the Sample Probe is recommended only when a plug in the probe is suspected
and should only be performed as a last resort to avoid the possibility of steam or condensate
contamination in the sample cell, particularly on the cell windows. The residue of some boiler
water chemicals on the cell windows will cause a loss of spectrometer energy, potentially
resulting in High Integration Period warnings or even a fault condition in a worst-case scenario.
There are some indications potential warning signs that may indicate the potential need to
perform a steam purge of the probe. These include but are not limited to:
•
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Absorbance spectrum and concentration readings remaining at zero even when the
analyzer is switched to sampling mode – this indicates that there may be a blockage
on the sample inlet side of the probe that is preventing sample from being drawn up
the probe and into the measurement cell.
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•
•
Cell pressure increasing dramatically when analyzer is switched to sampling mode –
this indicates that there may be a blockage on the vent side of the probe that prevents
the aspirator drive air from entering the process pipe; this will cause a high sample cell
pressure.
Response time from zero to sample increases for a set aspirator drive air flow rate –
this indicates a partial blockage in the sample probe that is restricting the flow rate in
the probe and thus increasing the response time.
Prior to performing a steam purge, the method described in Section 3.2.1 using adjustments in
the zero air flow to clear obstructions in the probe and analyzer sampling system should be
attempted. Only if this method is unsuccessful should the steam purge procedure be performed.
Steam Purging the Sample Probe is to be performed by trained and authorized
personnel only.
To perform the a steam purge of the sample probe assembly, follow the procedure below: :
1. Place the analyzer in Offline mode by toggling the Online / Offline control toggle
(Section 4.3.1) on the Analysis 2 panel to Offline (red).
2. Place the analyzer in back purge mode by pressing the PURGE key on the keypad OR
by placing the X in the Back Purge check box on the Analysis 1 panel.
3. Open the oven cabinet door and remove the black lid on the oven enclosure.
The control cabinet door may NOT be opened while the analyzer is
energized UNLESS the area is known to be non-hazardous. Observe all the
warning labels on the analyzer enclosures.
The oven enclosure and all of its components are HOT (150ºC/300ºF). Wear
appropriate personal protective equipment (gloves, eye wear, clothing etc)
if you are working with hot surfaces or wait until surface have cooled to safe
temperatures before performing maintenance tasks.
4. Close valves V1, V3, and V5. Prior to performing a steam purge, Galvanic Applied
Sciences also recommends disconnecting the measurement cell side fittings on valves
V1 and V3 and install plugs on these valves. This will prevent steam or condensate
from entering the measurement cell.
5. Blow down the steam supply lines to be used for steam purging the sample probe
assembly prior to connecting to the analyzer to clear the line of any condensate.
6. Connect steam supply lines to the Sample Side Access and/or Vent Side Access ports
on the left side of the analyzer cabinet.
7. Switch valves V2 and V4 to the ON position. This will begin the steam purge process.
Zero gas will be venting into the oven when the tubing is removed.
8. Re-install the oven enclosure cover. Ensure that the fibre optic cables are still routed
in the indent in the oven enclosure frame to avoid damage when the oven enclosure
cover is installed.
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9. Steam Purge the Sample Probe for between 15 and 30 minutes.
10. When purging is complete, remove the oven enclosure cover.
11. Switch valves V2 and V4 to the OFF position.
12. Disconnect the steam supply lines from the Probe Access ports on the left side of the
analyzer cabinet. Replace any sections of tubing that connect the measurement cell to
valves V1 and V3 that may have been disconnected prior to the steam purge to allow
the back purge air to begin flowing through the probe.
13. Re-install the oven enclosure cover. Ensure that the fibre optic cables are still routed
in the indent in the oven enclosure frame to avoid damage when the oven enclosure
cover is installed.
14. Close and latch the oven cabinet door.
15. Allow the back purge to continue for five to ten minutes.
20. Once the measurement cell temperature rises to >140°C, and the Cell Temperature
fault has cleared, use the PANEL NEXT / PANEL PREV keys to navigate to the
Analysis 1 panel. Perform a manual zero calibration cycle by using the FIELD NEXT
/ FIELD PREV keys to highlight Manual Zero, then press ENTER..
21. Once the manual zero calibration cycle is complete, place the analyzer into sampling
mode by highlighting the Sample checkbox using the FIELD NEXT / FIELD PREV
keys, then press ENTER. Alternatively, press the PURGE key.
22. Once normal operation has been confirmed, return the Online / Offline control toggle
on the Analysis 2 panel back to Online (green).
The oven can take up to two hours to reach operating temperature. While
the cell temperature is below the Low Cell Temperature fault set point, the
system will continue to back purge and maintain a fault indication to the
control room.
7.10
Spectrometer Replacement
In very rare cases it may be necessary to replace the analyzer spectrometer. To replace the
analyzer spectrometer, refer to Figure 78 while following the procedure below.
Replacing the spectrometer is to be performed by trained and authorized personnel
only.
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2
1
3
4
Figure 78: Spectrometer
1. Place the analyzer in Offline mode by toggling the Online / Offline control toggle
(Section 4.3.1) on the Analysis 2 panel to Offline (red).
2. Place the analyzer in back purge mode by pressing the PURGE key on the keypad OR
by placing the X in the Back Purge check box on the Analysis 1 panel.
3. Access the purged control cabinet following proper user company and/or regulatory
agency procedure.
The control cabinet door may NOT be opened while the analyzer is
energized UNLESS the area is known to be non-hazardous. Observe all the
warning labels on the analyzer enclosures.
DO NOT look at the end of disconnected fibres connected to the UV lamp or
place them in contact with skin. The intense UV radiation transmitted
through these fibres can cause eye and skin damage. Fibres should be
capped immediately after disconnection to prevent acidental exposure to
UV radiation.
4. Disconnect the USB cable from the front of the spectrometer (#1).
5. Disconnect the air trickle purge line connected to the bottom left corner of the
spectrometer (if present) (#3)
6. Disconnect the detector fibre connected to the top of the spectrometer by unscrewing
the nut and gently pulling it out of the SMA connector. (#2) Place an orange protective
cap over the end of the fibre to prevent damage.
7. Remove the retaining screws that hold the spectrometer to the mounting bracket. (#4).
Hold a hand under the spectrometer while removing it to prevent it from falling when
the last screw is removed.
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8. Mount the new spectrometer on the mounting bracket. It should be oriented with the
USB port and serial number label facing forward. Reinstall and tighten fully all mounting
screws.
9. Remove the protective cap from the detector fibre optic cable and connect it to the
SMA connector on the top of the spectrometer. The nut only needs to be tightened to
hand tight.
10. Connect the trickle purge line to the purge port on the spectrometer’s left side.
11. Connect the USB cable to the USB port on the front of the spectrometer.
Once the new spectrometer has been installed in the analyzer, it will be necessary to install the
new spectrometer matrix file associated with the new spectrometer into the analyzer. Follow
the procedure below to update the spectrometer calibration matrix file.
1. Connect a laptop computer to the local Ethernet port. Ensure that the local Ethernet
connection displayed in the Config panel Network sub-panel displays as Active.
2. In a web browser program on the connected PC, enter in the IP address of the analyzer
followed by /Utility.html (for the local Ethernet port, this would be
http://192.9.200.16/Utility.html) to access the Utility page shown in Figure 79.
Figure 79: Utility Page
3. Under the Calibration Matrix Upload to Analyzer heading, click on the Browse button.
Select the CSV format calibration matrix file with the file name indicated in the one-page
PDF document provided along with the spectrometer. The folder in which this file and the
calibration matrix will be found will have the spectrometer’s serial number (indicated on a
label on the front of the spectrometer) as the folder name. For an example, refer to Figure
80.
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Dark
Start
Pixel and First
Vector Pixel to
be input via web
GUI.
Spectrometer
Serial Number –
Make sure this
matches
spectrometer
serial number
label!
File name of the
spectrometer
calibration
matrix to be
loaded
Figure 80: Spectrometer Calibration Matrix PDF Example
Select the file indicated by the Load File Named heading at the bottom right of this page,
then press OK. Once the file has been selected, click on Calibration Matrix Upload to
Analyzer to upload the file.
Uploading an incorrect calibration matrix file may render the analyzer
unusable. Be absolutely CERTAIN that the matrix file being uploaded is the
correct file. If uncertain, contact Galvanic Applied Sciences Inc. for
assistance.
4. Once the Calibration Matrix file has successfully uploaded to the analyzer, click on Reboot
Analyzer to reboot the analzyer. The analyzer must be rebooted before it will start to use
the new calibration matrix file.
5. Once the analyzer has rebooted, navigate to the Calibration Matrix page in the web GUI
(refer to Section 5.2.2) and confirm that the first several rows of the displayed calibration
matrix match the first several rows of the calibration matrix printed in the PDF file supplied
with the spectrometer.
6. Navigate to the Factory Parameters section in the web GUI (refer to section 5.4). Switch
to Update mode, then change the Dark Start Pixel value to the Dark value indicated at
the bottom of the PDF file. Change the First Vector Pixel to the Start pixel indicated in
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the PDF file. Once both parameters have been edited, click on Save to save the changes
to the analyzer.
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Section 8
8.1
The Product Quality Assurance Program
Overview
The Galvanic Applied Sciences product quality assurance program is designed to ensure that
the system meets all manufacturing specifications and is built to meet the customer’s specific
requirements. This chapter consists of a number of forms which provide the overall QA
procedure and should be retained.
8.2
Overall System Identification
Proposal
Purchase Order Number
Sales Order Reference
Serial Number
Customer Name
Facility Address
Primary Contact Name
Primary Contact Telephone Number
Primary Contact e-mail
Inspection
Software Revision
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8.3
QA Document Package Check List and Requirements
Table 34 is completed during the manufacturing process and QA inspection to ensure that the
all relevant operations are performed.
Table 34: Document Package Checklist
Serial Number: _______________
Description
Sample System Pressure Checked - System Heaters
Sample System Pressure Checked – Sample System
Purge System Checked
Aspirator Performance Tested
Gas Runs Complete (Calibration Data Sheet)
Temperature Sensor Inputs Checked and Calibrated
Analog Output Calibration Checked
Digital Output Checked
System 24VDC Supply Checked
Span Factor Set
Condenser Solenoid Function Checked
Zero Solenoid Function Checked
Control Cabinet Air Solenoid Function Checked
Operation of Cell Heaters Checked
Burn Oven for three (3) weeks
Cell Pressure Transducer Checked.
Dielectric Strength Test Certificate Completed
Matrix and Cal Documents Completed
Serial Numbers Recorded
Oven Lid Latches Adjusted and Locked
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Section 9
Drawings
Several generic analyzer drawings and schematics are provided in this section. These drawings
are also available in PDF format via the Help section Drawing page in the web GUI. For serial
number-specific drawings refer to the USB key that is shipped with the analyzer.
Figure 81: Mounting and Service Connections
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Figure 82: Oven Cabinet Door Removed
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Figure 83: Control Cabinet Door Removed
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Figure 84: Power, Steam, Air, Signals Connection Details
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Figure 85: AC Wiring Schematic
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Figure 86: DC Signals and Wiring Diagram
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Figure 87: Flow Diagram
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Section 10
Specifications
Performance Specifications
Auto Calibration
Zero Drift
User Selectable Frequency
< 0.25% of full scale per day (based on
autozero frequency of once/hour
+/- 1%
of Full Scale with pressure
compensation (with all species present)
+/- 1.0 % of Full Scale
Better than 0.5% of full scale (with all species
present)
Analyzer – Near Instantaneous
Total System – typically less than 30 seconds
(depends on probe length)
Accuracy
Sensitivity
Repeatability
Response Time
Physical Specifications
Size - Outside Dimensions
(including Mounting Frame)
Analyzer cabinets
Weight (Total System on Frame
57” W x 41.25” H x16” D
(145 cm x 105 cm x 41 cm)
Two cabinets, each 24” W x 30” H x 12” D
(61 cm x 76.2 cm x 30 cm)
Approximately 275 lbs (125 kg),varies with
options
Services Required
Electrical
Instrument Air
Steam
100-240 Vac, 1 phase, 50/60 Hz, 800 W
17 SCFM at 80 psi (maximum case with Vortec
Cooler)
Nozzle – 50 psi
Area Classification
943-TGXeNAHy
Class I, Division 2, Groups C and D, Temperature Code T3, Type Z Purge
IP Protection:
NEMA 4
All specifications are subject to change as part of our ongoing product
improvement program.
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Section 11
Recommended Spare Parts
It is recommended that the purchaser have the spare parts indicated in Table 35 (one year of
spares) or Table 36 (two years of spares) at the plant site to expedite maintenance and service
procedures.
Spare Parts can be obtained from:
Galvanic Applied Sciences Inc.
7000 Fisher Road SE
Calgary, Alberta T2H 0W3
Canada
Tel: 403-252-8470
TOLL FREE (CANADA/US): 1 (800) 458 4544
INTERNATIONAL +1 978 848 2708
Fax: 403-255-6287
Email: [email protected]
Alternatively, local Galvanic gas products distributors in many countries and regions around the
world may be contacted for spare parts assistance. Refer to the distributor list found at the following
website: https://www.galvanic.com/service-support/representatives
.
Table 35: Recommended Spare Parts - 1 Year Kit
Item Description
Cell Window
O Rings for Cell Windows
UV Source Lamp
Anti-Solarant Solution
Fuse, 1.5 Amp
Fuse, 2 Amp
Fuse, 5 Amp, Slo-Blo
Part Number
BA7118
CO7134
BA7195 (standard
lifespan)
OR
BA7532
(long
lifespan)
CO7312
PC7090
PC7089
PC7087
Quantity
2
20
1
Unit of Measurement
each
each
each
1
1
1
1
Bottle
Pkg of 5
Pkg of 5
Pkg of 5
Table 36: Recommended Spare Parts - 2 Year Kit
Item Description
Cell Window
O Rings for Cell Windows
UV Source Lamp
Anti-Solarant Solution
Fuse, 1.5 Amp
Fuse, 2 Amp
Fuse, 5 Amp, Slo-Blo
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Part Number
BA7118
CO7134
BA7195 (standard
lifespan)
OR
BA7532
(long
lifespan)
CO7312
PC7090
PC7089
PC7087
137
Quantity
4
32
2 (BA7195) OR
1 (BA7523)
Unit of Measurement
each
each
each
2
1
1
1
Bottle
Pkg of 5
Pkg of 5
Pkg of 5
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Section 12
12.1
Input / Output (IO) Board Configuration
IO Board Web GUI
To access the web GUI used to configure the IO board, connect a PC to one of the Ethernet
ports on the analyzer’s control board inside the control cabinet, and ensure that the local
connection status displayed on the Config panel Network sub panel is showing as Active.
The control cabinet door may NOT be opened while the analyzer is energized
UNLESS the area is known to be non-hazardous. Observe all the warning labels
on the analyzer enclosures.
Enter the IP address of the analyzer followed by /io.html (i.e. for a locally connected computer
the address would be http://192.9.200.16/io.html) into the address bar of a web browser running
on the connected computer and press Enter. The IO board web GUI is shown in Figure 88.
Figure 88: IO Board web GUI
The Peripheral Board menu on the left side of the screen has four pages, as described in Table
37.
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Table 37: IO Board Web GUI Pages
Page Title
Manual Section
Status
12.2
Manual
Override
12.3
Analog Inputs
N/A
Firmware
N/A
12.2
Purpose
Presents the current status of all inputs and outputs
(analog and digital) on the IO board; all data is read
only.
Used for testing of digital outputs (solenoids and
relays) as well as for calibration of the four analog
outputs
Used for calibration of the analog inputs used for
pressure, temperature, and other analog signal
measurement inputs to the IO board.
NOTE: This section is for factory engineers only.
Used for upgrading the IO board firmware.
NOTE: This section is for factory engineers only.
Status Page
The Status page shown in Figure 89 shows the current status of the inputs and outputs that are
under the supervision and control of the IO board. The information on this page is read-only and
cannot be edited by the user.
Figure 89: Status Page
At the top of the page is an Online indicator which indicates whether the board is under the
control of the analyzer’s control computer. In normal operation, this will always be green. The
indicator will be red (Direct Board Control) only when the IO board has been switched to Direct
Peripheral Board Control for calibration and/or testing of the board’s inputs and outputs. Refer
to Section 12.3 for more information. The Firmware Revision field shows the current firmware
version installed on the IO board, which may be useful for troubleshooting purposes. The On
Board Temperature field shows the current temperature measured by the IO board’s on board
temperature sensor.
The remaining five boxes on this page are explained in Table 38.
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Table 38: Status Page Sections
Section
Purpose
Calculated
Analog Outputs
Shows the current calibrated value being received at each of the IO board’s four analog
inputs. Displayed measurement units are based on the factory calibration of these inputs.
Pressure is the measurement cell pressure input, RTD1 is the measurement cell
temperature input, and RTD2 is the probe temperature input (if present).
Shows the present expected current output, in milliamps, from each of the four analog
outputs on the IO board. These current outputs are based on the analog output’s configured
parameter and range.
Relays (P4
Connector) Test
Shows the current status of the IO board’s four digital (relay) outputs. A grey indicator
indicates the relay is in the deenergized (alarm) condition, while a red indicator indicates
that the relay is in the energized (normal) condition. P4 Connector indicates that the relay
connections are made to the P4 terminal block on the IO board.
Analog Inputs
Solenoids (P6
Connector) Test
Digital Input
12.3
Shows the current status of the IO board’s four solenoid control relays. A grey indicator
indicates the solenoid is deenergized, while a red indicator indicates the solenoid is
energized. P6 Connector indicates that the solenoid connections are made to the P6
terminal block on the IO board.
•
Solenoid 1 = cabinet cooler solenoid
•
Solenoid 2 = Sampling / Backpurge solenoid (energized = sample, deenergized
= backpurge)
•
Solenoid 3 = probe cooler solenoid
•
Solenoid 4 = oven heater control relay
Shows the current status of the IO board’s single digital input. Red indicates the digital input
is receiving a signal, while grey indicates it is not receiving a signal. This input can be used
for remote triggering of a zero calibration cycle.
Manual Override Page
The Manual Override page shown in Figure 90 allows the user to take control of the IO board
for the purpose of calibrating and testing all available outputs, both analog and digital.
This page allows the user to take control of and make changes to the configuration
of the IO board of the analyzer. Any change made to the analog output calibration
will permanently delete the present value. Access to this page should be limited to
qualified users who understand the consequences of making changes on this page.
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Figure 90: Manual Override Page
In order to make any changes on this page, Direct Peripheral Board Control must first be
enabled by placing an X in the checkbox. Once this is enabled, the IO board will be under
manual control of the user and the analyzer’s control computer will have no control of this board
until this direct board control is manually disabled.
The analyzer should be placed into back purge mode and set to Offline state prior to
performing any operations under Direct Board Control.
When work is complete on this page, the Direct Board Control Enable checkbox
must be unchecked manually to return the IO board to automatic control, otherwise
the analyzer will be unable to function normally.
12.3.1 Analog Output Calibration and Testing
Each Analog Output box allows the user to configure, calibrate, and test an analog output.
To configure/calibrate/test an Analog Output, follow the procedure below. This procedure is
identical for all four analog outputs:
1. Place a check mark in the Calibrate Analog Output x check box. The fields within the
box will become active.
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2. The value in the Zero field must be set to 4, and the value in the Span field must be
set to 20.
3. Connect a multimeter set to milliamp measurement to the analog output to be
calibrated. The analog outputs are all on terminal block P3 of the IO board. The
terminals for each analog output are clearly marked on the board. Refer to Figure 91.
Loop power available, current
loop
complete
indicator
LEDs, one per analog output.
Figure 91: Analog Output Terminal Block P3
The analog outputs on the IO board are loop powered, so an external power
supply must be provided. The multimeter must be placed in SERIES with the
current loop. When the multimeter is connected correctly, a green LED
above the analog output wiring connection on the IO board will illuminate
to show that the current loop is closed and loop power is being provided,
as indicated in Figure 91.
4. Press the Output Zero button. The output current from the analog output will change
to approximately 4 mA.
5. Enter the reading from the meter in the Meter Reading field under the Zero heading
and press the Auto Cal button. This will adjust the Zero output to exactly 4 mA. If the
meter reading is still not exactly 4 mA, repeat the process.
6. Press the Output Span button. The output current from the analog output will change
to approximately 20 mA.
7. Enter the reading from the meter in the Meter Reading field under the Span heading
and press the Auto Cal button. This will adjust the Span output to exactly 20 mA. If
the meter reading is still not exactly 20 mA, repeat the process.
8. The analog output is now calibrated. Press Capture to save the calibration to the
board.
9. Test the output by entering the desired mA output in the Test(mA) field and then
pressing the Output Test button. This will force the analog output to generate the
entered value. In this way the analog output loop can be tested at several readings
such as 0, 25, 50, 75 and 100 % of scale (4, 8, 12, 16 and 20 mA). It is advisable that
this test be done in conjunction with control room staff to ensure the correct readings
are being received not only at a multimeter connected to the analyzer but also at the
DCS.
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10. If there are any issues with the calibration discovered while performing the test
procedure in Step 9, repeat the calibration process in steps 4-8 and test again.
11. Repeat the calibration process steps 1-10 for each additional analog output that needs
to be calibrated.
12. When all analog outputs have been calibrated and tested, press Permanent Save to
save all changes permanently to the analyzer. This process will take approximately 30
seconds to complete.
Below the calibration and test fields for each analog are three read-only fields giving information
about the analog output. The Description field shows the analog output number (AO1 – AO4),
the Unit field shows the output measurement units (milliamps for all analog outputs), and the
Calculated Value field shows the current output current, in milliamps, being output from that
analog output. The intensity of the green indicator LED on the IO board for each analog output
is directly proportional to the magnitude of the output current. That is to say, the LED will be
brighter when outputting 20 mA than when outputting 4 mA.
12.3.2 Testing the Digital Input
The IO board has a single digital input at terminal block P5 that is used for remote initiation of
a zero calibration cycle. This digital input can be tested using the procedure below.
1. Ensure that Direct Board Control Enable is selected on the Manual Override page.
2. Switch to the Status page.
3. Connect a switch with a 12-24VDC power supply to the digital input terminal block to
create an open circuit connected to the digital input terminal block. ‘
The digital input terminal is polarity insensitive.
4. When the switch is open and the circuit is not complete, the Digital Input indicator on
the Status page will be grey (inactive).
5. When the switch is closed and the circuit is complete so that 12-24VDC is being
received at P5, the Digital Input indicator on the Status page will be red (active).
12.3.3 Testing Digital Outputs
There are four digital (relay) outputs available at P4 of the IO board, as shown in Figure 92.
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Figure 92: Relay Connection Terminal Block P4
Each relay connection is clearly marked. Relay 1 is Status, Relay 2 is Service, Relay 3 is
Mode, and Relay 4 is Control. The relays can be connected either as normally open (NO)
whereby the circuit is only complete when the relay is energized or as normally closed (NC)
whereby the circuit is complete when the relay is deenergized. There are also 4 solenoid
connections at terminal block P6 on the IO board.
To test the digital outputs, follow the procedure below.
1. Ensure that Direct Board Control Enable is selected on the Manual Override page.
2. Test each relay. If the relay is currently deenergized, the circle will be grey, and the
checkbox will be empty. If the relay is currently energized, the circle will be red, and
the checkbox will have a checkmark in it. To energize a deenergized relay, simply
place a checkmark in the checkbox by clicking on it. To deenergize an energized relay,
remove the checkmark in the checkbox by clicking on it. Confirm with the control room
that the signals are being received correctly. If the install location is not too loud, it
should also be possible to hear an audible ‘click’ when a relay is energized and
deenergized.
3. Test each solenoid if necessary. If the solenoid is currently deenergized, the circle will
be grey, and the checkbox will be empty. If the relay is currently energized, the circle
will be red, and the checkbox will have a checkmark in it. To energize a deenergized
solenoid, simply place a checkmark in the checkbox by clicking on it. To deenergize
an energized solenoid, remove the checkmark in the checkbox by clicking on it.
Solenoid energization and deenergization should produce audible clicks as the
solenoid actuates.
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Index
Baud Rate, 87
Beer-Lambert Law, 62
Big Endian, 87
3
32 Bit Register Swap, 87
C
A
Cabinet Cooler Air Valve, 34
Cabinet Deadband, 66
Cabinet Purge Air Flow Adjust Valve, 33
Cabinet Setpoint, 66
Cabinet Temperature, 34, 51
Cabinet Temperature Dead Band, 84
Cabinet Temperature Set Point, 84
Calibration Matrix, 15, 75, 82
Calibration Matrix Page (Web Based GUI), 75
Calibratoin Matrix
Absorbance, 62, 81
Absorbance Page (Web Based GUI), 80
Absorbance Panel, 57
Absorbance Spectrum, 81
Appearance in Back Purge, 58, 82
Appearance when Sampling, 58, 82
Calculation, 81
AC Power
Connection Procedure, 27
AC Terminal Strip (ACTS), 27
Air Demand, 14, 46
Ambient Temperature Range, 19
Analog Input 3 is Hydrogen, 85
Analog Outputs, 17, 38, 59
Upload to Analyzer, 123
Cell Length, 62, 92
Cell O-Rings, 117
Cell Pressure, 51
Cell Prop Band, 66
Cell Setpoint, 66
Cell Temperature, 51
Calibration and Testing Procedure, 140
Configuration Parameters, 60
Hold, 38, 41, 60, 93
Signal Cable Connection, 27
Track, 38, 60, 93
Effect of Aspirator Drive Air Flow, 37
Cell Temperature Proportional Band, 84
Cell Temperature Reset Time, 84
Cell Temperature Set Point, 84
Cell Windows, 116
Analysis 1 Panel, 45
Manual Zero Control. See Manual Zero
Relay Indicators, 47
Analysis 2 Panel, 49
Analysis Page (Web Based GUI), 71
Cleaning, 117
Cleaning / Replacement Procedure, 117
Cell WIndows
Air Demand Trend, 74
H2S/SO2 Trend, 74
Relay Indicators, 73
Status and Control, 73
Value Display, 72
Replacement, 116
Condenser Cooling Air Adjust Valve, 36
Configuration Page
Configurable Parameters, 84
Analysis Section, 71
Analyzer Dimensions, 19
Analyzer Support Structure, 22
Anti-Solarant Solution, 100
Configuration Panel, 59
Aspirator, 16, 37
Aspirator Drive Air Flow Adjust Valve, 37
Auto Cal Interval, 65, 84
Available Points, 87
Configuration Section, 83
Control Board, 17
Control Cabinet, 15
Control Output, 41, 74
Calculation Sub-Panel, 61
Display Sub-Panel, 63
Network Sub-Panel, 68
Outputs Sub-Panel, 59
Timers/Alarms Sub-Panel, 64
Changing Frequency, 100
Procedure for Changing, 100
Fault Status, 88
Relay Status, 88
D
B
Dark Level, 55, 79
Dark Start Pixel, 92
Data Bits, 87
Back Purge, 17, 36, 48, 73
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I
Digital Input
Testing, 142
Digital Outputs. See Relay Outputs
Direct Connect, 68
Display Board, 17
Drawing Page (Web Based GUI), 94
Drawings
Indicators Page (Web Based GUI), 76
Indicators Panel, 51
Ingress Protection (IP) Rating, 20
Installation Procedure, 21
Instrument Air
AC Wiring Schematic, 132
Control Cabinet Door Removed, 130
DC Signals and Wiring Diagram, 133
Flow Diagram, 134
Mounting and Service Connections, 128
Oven Cabinet Door Removed, 129
Power, Steam, Air, Signals Connection Details, 131
Clearing Sample Handling System
Blockages, 36
Flow Control Settings, 33
Pressure and Flow Requirements, 20
Pressure Regulator, 38
Pressure Regulator, 29
Supply Connection, 29
Probe
Integration Period, 55, 85
E
Automatic Optimization Procedure, 103
Manual Optimization Procedure, 103
Optimization, 55, 79
Enron Modbus Format, 89
Ethernet Port, 17
Integration Time. See Integration Period, See
Integration Period
IO Board, 17, 27, 28
Configuration Settings, 68
Local Connection. See Direct Connect
Remote Connection. See Network
Web Based GUI. See IO Board Web GUI
IO Board Web GUI, 137
F
Direct Peripheral Board Control, 138, 140
Manual Override Page, 139
Peripheral Board Menu, 137
Status Page, 138
Factory Parameters Page (Web Based GUI),
91
IP Port Number, 87
Available Parameters, 92
Factory Reference, 56
Factory Section, 91
Fault Condition, 16, 40, 52
K
Keypad, 15, 44
Description of Each Type, 53, 77
Key Functions, 44
Fibre Optic Cables, 14, 100
Replacement, 107
SMA Connector, 107
Testing, 107
Testing / Replacment Procedure, 107
L
Little Endian, 87
Local Display
Filter Points, 84
First Vector Pixel, 55, 92
First Vector Pixel Level, 79
Fixed Pressure, 63, 85
Fixed Temperature, 63, 85
Absorbance panel. See Absorbance Panel
Analysis 1 Panel. See Analysis 1 Panel
Analysis 2 panel. See Analysis 2 Panel
Config panel. See Configuration Panel
Indicators panel. See Indicators Panel
Spectrum panel. See Spectrum Panel
User Interface, 43
H
Loss of Purge Signal, 31, 41
Low Cabinet Temperature Alarm, 84
Low Cell Alarm Setpoint, 67
Low Cell Temperature Alarm, 84
Low Probe Alarm Setpoint, 67
Low Probe Temperature Alarm, 84
Hazardous Area Certification, 20
Help Section, 94
High Cabinet Temperature Alarm, 84
High Cell Temperature Alarm, 84
High Probe Temperature Alarm, 84
High S8 Fault Setpoint, 67
High S8 Warn Setpoint, 67
High SVAP Alarm, 84
High SVAP Warning, 84
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M
Maintenance Check Out Procedure, 97
Manual Zero, 47, 73
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Manufacturer’s Warranty, 12
Mating of the Process and Analyzer System
Flanges, 23
Measure Analog Input, 85
Measurement Cell
Changing the Passwords, 94
Factory Password, 92
Peak Height, 55, 56
Plant Factor, 14, 62, 93
Probe Control, 93
Probe Deadband, 66
Probe Setpoint, 66
Probe Temperature, 51
Probe Temperature Dead Band, 84
Probe Temperature Set Point, 84
Product Quality Assurance Program, 126
Purge Control Box, 30, 33
Purge Flow Control Valve, 30
Purge Indicator, 31, 33
Installation, 118
Removal, 115
Modbus Address, 87
Modbus Items, 87
Modbus List
Adding Items, 89
Loading a List, 88
Making a New List, 88
Rearranging Items, 89
Saving a List, 88
Modbus Page
Q
Available Points. See Available Points
Communication Parameters, 86
Modbus Items. See Modbus Items
QA Inspection, 127
Modbus Page (Web Based GUI), 86
Mode Output, 40, 74
Modicon with Floating Point Format, 91
Modicon-16 Modbus Format, 90
Modicon-32 Modbus Format. See Modbus
with Floating Point Format
Mounting Dimensions, 22
R
Read Only mode (Web Based GUI), 85
Relay Outputs, 17, 39
Control. See Control Output
Loss of Purge. See Loss of Purge Signal
Mode. See Mode Output
Service. See Service Output
Signal Cable Connection, 28
Status. See Status Output
Testing, 143
N
Navigation Menu, 71
Network, 68
Response Time
Sample, 37
Zero, 36
Automatic Configuration via DHCP, 69
Manual Configuration, 69
Revision History Page (Web Based GUI), 95
Routine preventative maintenance, 96
New Reference Function, 57, 80
Normal Operating Parameter and Indicator
Conditions, 97
S
O
Safety Guidelines, 10
Safety Symbols, 9
Sample Handling System, 16
Sample Probe, 16
Offline Mode, 45, 73
Online / Offline Mode Toggle, 41, 45, 50
Effect on Control Relay, 41
Condenser, 16, 35
Installation Procedure, 24
Steam Purge, 17, 120
Steam Purge Procedure, 120
Online Mode, 45, 73
Operating Ratio, 14, 46, 62, 93
Operating Voltage, 19
Oven Cabinet, 15
Oven Enclosure, 17
Oven Heaters
Sample Probe Nozzle, 17, 31
Sample Rate, 63, 85
Sampling Mode, 73
Serial Port, 17
Service Output, 40, 74
Solenoids
Powering Off, 107
P
Testing, 143
Parameters Page (Web Based GUI), 83
Parity, 87
Password (Web Based GUI), 85, 88
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Span Factor, 62, 92
Spare Parts, 136
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Specifications
Enclosure Layout, 112
Lifespan, 111
Mounting Orientation, 113
Power Off Switch, 112
Replacement Procedure, 111
Troubleshooting, 110
Hazardous Area Classification, 135
Performance, 135
Physical, 135
Required Services, 135
Spectrometer, 14, 54, 75, 78
Parameters, 54, 79
Replacement Procedure, 122
V
Spectrum, 54, 78
Vortex Cooler, 34
Absorbance. See Absorbance Spectrum
Comparison with Factory Reference, 57, 80
W
Spectrum Page (Web Based GUI), 78
Spectrum Panel, 54
Spectrum Peak. See Peak Height
Status Output, 39, 74
Steam
Warning Condition, 40, 52
Description of Each Type, 53, 77
Web Based GUI
Analysis Section. See Analysis Section
Configuration Section. See Configuration Section
Factory Section. See Factory Section
Help Section. See Help Section
Navigation Menu. See Navigation Menu
Overview, 70
Utility Page, 123
Pressure and Temperature Requirements, 20
Supply Connections, 31
Steam Heater, 17
Steam Jacketed Ball Valve, 22
Stop Bits, 87
SVAP Dead Band, 84
SVAP Set Point, 84
Z
T
Zero Air Flow Adjust Valve, 36
Zero Calibration, 16, 36, 47
Transmission Spectrum. See Spectrum
Troubleshooting
Remote Trigger by DIgital Input, 142
Sequence of Events, 48
Potential Solutions, 106
Zero Gas, 16
Zero Hold Interval, 41, 48, 65, 85
Zero Purge Interval, 48, 65, 85
Zero Sample Rate, 63, 85
U
Update Mode, 94
Update Mode (Web Based GUI), 85, 88, 92
User Manual Page (Web Based GUI), 95
UV Source Lamp, 14, 100
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Reason for Revision
The changes incorporated in Revision 4 of the Operation Manual are in the addition of the level of
detail for clarity only and do not affect product, processes or methods of protection used for
approval.
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