ABB ACF-NT Manual de usuario

ACF-NT, ACF-NT V0309

Multicomponent Analyzer Systems for Emission and Process Monitoring

Installation Instructions 42/23571 EN Rev. 5

2 Installation Instructions ACF-NT, ACF-NT V0309 42/23-571 EN Rev. 5

Contents

Page

Foreword 3

Important Safety Information 4

Safety Tips for Handling Electronic Measurement Devices 5

Safety Tips for Handling the FTIR Spectrometer 6

Safety Tips for Handling the VOC Analyzer 7

Safety Tips for Handling Harmful Gases 7

Special Information about the System Design for Measurement of HF 7

Chapter 1 Installation Preparation

Installation Site Requirements 8

Gas Supply Requirements 9

Power Supply Requirements 10

Analyzer System Features Relevant for Installation 11

Items Delivered 12

Materials Needed for Installation (not supplied) 13

Chapter 2 Analyzer System Installation

Installing the Analyzer System 14

Installing the Analyzer Cabinet 15

Installing the Gas Sampling Probe and Filter Unit 16

Installing the Sample Gas Line 18

Installing the Instrument Air and Test Gas Supply 19

Connecting the Electrical Leads 21

Appendix

Analyzer System Components 22

Layout Plan: Exterior View 23

Layout Plan: Interior View 24

Piping Plan 25

Connection Plan: Power Supply 26

Connection Plan: Signal Leads 27

42/23-571 EN Rev. 5 Installation Instructions ACF-NT, ACF-NT V0309 3

Foreword

The Content of this

Manual

This manual contains all the information you will need to safely and efficiently

install the ACF-NT Analyzer System.

This manual contains information on all the functional units in the analyzer system.

Your analyzer system as delivered may differ from the version described in this

documentation.

System

Documentation

The system documentation consists of a set of drawings individually prepared for

each analyzer system as delivered. It includes the following plans:

Layout Plan

Piping Plan

Wiring Plan

Terminal Plan

Connection Plan

The system documentation is supplied as part of the analyzer system.

Title Publication No.

Specification Sheet 10/23-8.11 EN

Supplementary

Documentation

Operator’s Manual 42/23-572 EN

These publications can be ordered from your authorized ABB representative or

from

ABB Automation GmbH,

Analytical, Marketing Communication,

Telefax: +49-(0)69-7930-4566, E-mail: [email protected]

Additional Information

on the Internet

Additional information on ABB Analytical products and services is available on the

Internet at “http://www.abb.com/analytical”.

indicates safety information to be heeded during analyzer system

operation in order to avoid risks to the user.

identifies specific information on operation of the analyzer system as

well as on the use of this manual.

Symbols and Type

Format in this Manual

1, 2, 3, … identifies reference numbers in figures.

This manual is protected by copyright. The right is reserved to pursue civil or criminal penalties if this

publication is translated, reproduced (by electronic or mechanical means, photocopying, recording, etc.),

stored in information retrieval systems or networks or transmitted in any form without the permission of

the copyright holder.

4 Installation Instructions ACF-NT, ACF-NT V0309 42/23-571 EN Rev. 5

Important Safety Information

Proper Operation The ACF-NT analyzer system is designed for continuous measurement of

concentrations of specific components in gases or vapor.

Explosion Protection The analyzer system must not be used to measure combustible gas/air or gas/

oxygen mixtures. The analyzer system must not be installed in hazardous locations.

Requirements for

Safe Operation

In order to operate in a safe and efficient manner, the analyzer system should be

properly handled and stored, correctly installed and set-up, properly operated and

carefully maintained.

Personnel

Qualifications

Only persons familiar with the installation, set-up, operation and maintenance of

comparable analyzer systems and certified as being capable of such work should

work on the system.

Special Information

and Precautions

These include

The content of this manual.

The safety labels affixed to the analyzer system.

The applicable safety precautions for installing and operating electrical devices

Safety precautions for working with gases, acids, condensates, etc.

Observe the safety labels affixed to the analyzer system:Safety Labels

Affixed to the

Analyzer System

Consult

Documentation!

Hot Surface!

(Temperature

> 60 °C)

Risk of

Electric Shock!

National Regulations The regulations, standards and guidelines cited in this operator’s manual are

applicable in the Federal Republic of Germany. The applicable national regulations

should be followed when the analyzer system is used in other countries.

Analyzer System

Safety and Safe

Operation

The analyzer system is designed and tested in accordance with EN 61010 Part 1/

IEC 1010-1, “Safety Provisions for Electrical Measuring, Control, Regulation and

Laboratory Instruments” and has been shipped ready for safe operation.

To maintain this condition and to assure safe operation, read and follow the safety

information identified with the symbol in this manual. Failure to do so can put

persons at risk and can damage the analyzer system as well as other systems and

instruments.

Additional

Information

If the information in this manual does not cover a particular situation, ABB Service

is prepared to supply additional information as needed.

Please contact your local service representative. For emergencies, please contact

ABB Service

Telephone: +49-(0)180-5-222580, Telefax: +49-(0)621-38193129031,

E-mail: [email protected]

42/23-571 EN Rev. 5 Installation Instructions ACF-NT, ACF-NT V0309 5

Safety Tips for Handling Electronic Measurement Devices

Protective Lead

Connection

The protective lead should be attached to the protective lead connector before

any other connection is made.

Risks of a

Disconnected

Protective Lead

The analyzer system can be hazardous if the protective lead is interrupted inside

or outside the system or if the protective lead is disconnected.

Correct Operating

Voltage

Be sure the analyzer system voltage setting matches the line voltage before

connecting the power supply.

Risks Involved in

Opening the Covers

Current-bearing components can be exposed when covers or parts are removed,

even if this can be done without tools. Current can be present at some connection

points.

Risks Involved in

Working with an

Open Analyzer

System

The analyzer system must be disconnected from all power sources before being

opened for any work. All work on an analyzer system that is open and connected

to power should only be performed by trained personnel who are familiar with the

risks involved.

Charged Capacitors The capacitors in the analyzer system can retain their charge even when it is

disconnected from all power sources.

Use of Proper Fuses Only fuses of the specified type and rated current should be used as replace-

ments. Never use patched fuses. Do not short-circuit the fuse holder contacts.

When safe operation

can no longer be

assured …

If it is apparent that safe operation is no longer possible, the analyzer system

should be taken out of operation and secured against unauthorized use.

The possibility of safe operation is excluded:

If the analyzer system is visibly damaged

If the analyzer system no longer operates

after prolonged storage under adverse conditions

after severe transport stresses

6 Installation Instructions ACF-NT, ACF-NT V0309 42/23-571 EN Rev. 5

Safety Tips for Handling the FTIR Spectrometer

Electrical Safety The FTIR Spectrometer consists of an exposed metal chassis that is connected

directly to earth via a power supply cord and is therefore classified as “Safety

Class I” equipment.

WARNING!

When used to analyze flammable gases, the equipment is subject to

acceptance by the local inspection authorities having jurisdiction.

For continued fire protection use specified line fuse only. Disconnect power

cord before replacing fuse.

To avoid electrical shock, the power cord protective conductor must be

connected to earth.

To avoid electrical shock, do not operate this equipment if it bears any sign

of damage to any portion of its exterior surface.

Do not expose this equipment to any source of excessive moisture.

Do not use this equipment in an explosive atmosphere.

Laser and

High Voltage

Under normal operating conditions, the FTIR spectrometer can be operated in

complete safety (Class 1 Laser Product – see rating plate).

Do not open the spectrometer enclosure during normal operation – no user-

serviceable parts inside.

However, since the instrument contains a laser and uses high voltages (accessible

only when the spectrometer enclosure is open), observe the following warnings.

WARNING!

The enclosure of the spectrometer is to be opened only by authorized ABB

Service Personnel.

Opening the enclosure may result in exposure to laser radiation and high

voltages.

Laser type: He-Ne Laser Class 3B as per IEC-60825-1

Class 111a as per 21 C F R 1040.10

Output power: max. 3.2 mW

Wavelength: 632.8 nm

Avoid eye exposure to direct to direct or mirrored laser radiation. It is

recommended to wear laser safety goggles when working on the open

spectrometer.

High voltage is present at the red wire connected to the laser tube inside the

enclosure.

The voltage is approximately 7 kV at startup, and between 1200 V and 1400 V

under normal operating conditions.

Because of the capacitors in the laser power supply, the high voltage may be

present even when the power is off.

42/23-571 EN Rev. 5 Installation Instructions ACF-NT, ACF-NT V0309 7

Safety Tips for Handling the VOC Analyzer

DANGER!

Do not open any threaded connections in the VOC analyzer gas paths. Doing

so will damage gas path seal integrity.

Combustion gas flowing out of the leak points thus formed in the internal gas

paths can cause fire and explosions (even outside the VOC analyzer itself).

If device-internal gas path threaded connections are opened, a seal integrity

check must be performed with a leak detector (thermal conductivity) when

the device is reassembled.

CAUTION!

The combustion gas path inside the VOC analyzer is checked for leaks at the

factory. No seal integrity testing is required during normal operation.

Safety Tips for Handling Harmful Gases

WARNING!

Some of the gases measured with the analyzer system are harmful to health.

Therefore, the sample gas must not escape from the gas path during normal

operation and maintenance works.

A seal integrity check of the analyzer system has to be performed at regular

intervals.

The diluted exhaust gas must be drained out of the installation room of the

analyzer cabinet.

Special Information about the System Design for Measurement of HF

Type Designation ACF-NT V0309

Design of the

Analyzer System

The analyzer system is equipped with a cooling unit which ensures the reliable

operation of the analyzer in a temperature range from 20 °C to 25 °C. The cooling

device guarantees these conditions in an ambient temperature range between

+5 °C and +40 °C.

Operating System

and Software

Versions

The analyzer system must be operated with the following software versions:

FTIR Controller: WindowsXP Professional operating system

FTSW 100: Software version 2.61

AO2000 System Controller: Software version 3.0.6

8 Installation Instructions ACF-NT, ACF-NT V0309 42/23-571 EN Rev. 5

Chapter 1 Installation Preparation

Installation Site Requirements

Short Gas Paths The analyzer cabinet should be installed as close as possible to the sampling site.

A short sample gas line results in brief lead times. The sample gas line length is

limited to 60 meters with 230 VAC power supply and to 40 meters with 120 VAC

power supply on account of pressure drop build-up in the line and the required

electrical fusing. The air purifier and the test gas cylinders should be installed as

close as possible to the analyzer cabinet.

Protection from

Adverse Conditions

Protect the analyzer cabinet against

Water spray

Contact with chemicals

Strong sunlight and heat radiation

Strong air currents

Heavy dust

Corrosive atmospheres

Vibration

The analyzer system is intended for indoor use only.

Ambient temperature for storage and shipping –25 to +65 °C

Ambient temperature during operation

In air conditioned rooms +20 to +25 °C

With air conditioning unit (optional) +5 to +40 °C

Relative humidity

Year-round average max. 75 %

Short-term max. 95 %

Environmental

Conditions

Occasional slight condensation is permitted, provided the

analyzer system is turned on and the FTIR spectrometer is purged

Installation Location

Altitude

The maximum installation altitude is 800 m above sea level (for sample gas line

length with probe = 10 m).

Remark: The minimum inlet pressure at the analyzer cabinet is defined to 900 hPa.

This results in a maximum altitude above 800 m; however, the pressure drop along

the probe (15 hPa for a new, dust-free probe) and the heated line must be consid-

ered. Higher altitudes would result in no gas flow through the system. Lowering

the pressure set points of the ACF-NT is not allowed as this directly reduces the

sensitivity of the FTIR spectrometer. Thus, the measurement accuracy according

to QAL1 and QAL2 for components with low concentrations cannot be warranted.

Right side 1 m for gas lines, air purifier and air conditioning unit (optional)

Left side 0.5 m for electrical lines

Front 1 m to open the door (hinged at left)

Space Requirement

Top 0.5 m with air conditioning unit (optional) to prevent heat buildup

Floor The installation site floor must be plane and capable of supporting the cabinets

weight (approx. 300 kg).

42/23-571 EN Rev. 5 Installation Instructions ACF-NT, ACF-NT V0309 9

Gas Supply Requirements

Characteristic Inlet Pressure Flow

Analyzer System

Sample gas 6) Temperature controlled at 180 2 °C

by means of the heated sample gas

line

pabs = 900 to 1100 hPa

(0.9 t o 1.1 b a r )

approx. 250 l/h

Instrument air 2) Based on ISO 8573-1 Class 2

(max. particle size 1 μm,

max. particle density 1 mg/m3,

max. oil content 0.1 mg/m3,

max. pressure dew point –20 °C)

pe= 5000 to 7000 hPa

(5.0 to 7.0 bar)

approx. 1700 l/h

for FTIR and

approx. 1500 l/h

for VOC

FTIR Analyzer

Zero gas for the

FTIR spectrometer

Clean air from air purifier pe= 1100 100 hPa

(1.1 0.1 bar)

500 l/h

Span gas for the

FTIR spectrometer 4)

Measurement component in N2

70 to 80 % of measuring range

(accuracy 2 %)

pe= 1100 100 hPa

(1.1 0.1 bar)

500 l/h

VOC Analyzer 1)

Combustion gas H2, quality 5.0 pe= 1200 100 hPa

(1.2 0.1 bar)

3 l/h 3)

Zero gas N2, quality 5.0

or zero gas for the oxygen analyzer

pe= 1100 100 hPa

(1.1 0.1 bar)

120 l/h

Span gas 5) n-Propane C3H8in N2

70 to 80 % of measuring range

(accuracy 2 %)

pe= 1000 100 hPa

(1.0 0.1 bar)

80 to 120 l/h

O2Analyzer 1)

Zero gas 1 to 4 Vo l % O 2in N2 (accuracy 2 %) pe= 1100 100 hPa

(1.1 0.1 bar)

500 l/h

Span gas Clean air from the air purifier

(20.96 Vol% O2)

pe= 1100 100 hPa

(1.1 0.1 bar)

500 l/h

1) Option

2) Provide a pressure gauge and a shut-off valve.

3) Provide a flow limiter. Recommendation: Provide two 40 l cylinders and a

switchover station.

4) H2O, HCl, HF and NH3test gases for calibration are produced with a vapor

generator by vaporizing either distilled water or HCl, HF or NH3solutions with

known concentrations.

5) As the VOC analyzer only measures the number of carbons the concentration

of the span gas has to be calculated from ppm or mg/m3CnHmto ppm or

mg/m3C

6) For information regarding sample components and measuring ranges refer to

ACF-NT operator’s manual, “Operating Specifications” section in the Appendix

Definition pe= pabs – pamb

with pe= positive pressure, pabs = absolute pressure, pamb = atmospheric pressure

10 Installation Instructions ACF-NT, ACF-NT V0309 42/23-571 EN Rev. 5

Power Supply Requirements

Voltage Fuse (external) Power consumption

Power Supply

230/400 V AC or

120/208 V AC,

10 %,

48 to 62 Hz

3 x 20 A or

3 x 25 A

approx. 2400 VA on activation,

approx. 1800 VA in operation

approx. 600 VA for heated probe tube

approx. 250 VA for heated filter

approx. 90 VA/m for heated sample gas line

approx. 1400 VA for air conditioning unit

Voltage Fuse (external) Power consumption

Uninterruptible

Power Supply 230/120 V AC,

48 to 62 Hz

20 A approx. 600 VA (included in above values)

Service Socket 230 V AC or 120 V AC, 48 to 62 Hz, max. 5 A.

The service socket is located in the cabinet light (–E02).

Function Rated Value

–F10 Power supply – residual current-operated circuit breakers 30 A/30 mA

–F10.1 UPS – residual current-operated circuit breakers 25 A/30 mA

–F01 Fan or

Air condition (optional)

2 A or

16 A

–F02 Cabinet light, socket 6 A

–F03 Heated probe tube type 42 6 A

–F04 Heated filter unit type PFE2 2 A (230 V)

6 A (120 V)

–F05 Heated sample gas line 16 A (230 V)

20 A (120 V)

–F06 RGM11 module, FTIR spectrometer/heated sampling cell 6 A (230 V)

10 A (120 V)

–F07 MultiFID14 module, catalyst 6 A

–F08 FTIR purge gas generator, FTIR spectrometer, flow monitor,

system controller, PC FTIR, power supply 24 V/5 A

16 A

–F09 Sample probe cleaning 6 A

Fuses

–F11

–F12

–F13

Temperature controller T 2 A

CAUTION!

High leakage current: 6 mA!

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