ABB ACX Manual de instalación y operación

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ABB MEASUREMENT & AN

ALYTICS | COMMISSIONING INSTRUCTION | CI/ACX-EN REV. D

ACX

Advanced CGA Solutions

—

BB Automation GmbH

Measurement & Analytics

Stierstädter Str. 5

60488 Frankfurt am Main

Germany

Tel:

+49 69 7930-4666

Email:

[email protected]

abb.com/analytical

Analyzer System for Emission

Monitoring, Cement Applications

and Process Measurement

Measurement made eas

CI/ACX

-EN Rev. D 02.2020

—

ACX

Introduction

ACX is a complete system solution for continuous

gas analysis

The ACX system includes everything from probe,

heated lines, sample conditioning to reliable and

time

-tested analyzers of the Advance Optima

series. It can be operated from the ou

tside.

The system is available in various variants tailored

to your measuring tasks

- emission monitoring,

cement applications and process gas

measurements.

It is especially designed for easy service and

maintenance.

Additional Information

Additional d

ocumentation on ACX is available for

download free of charge at www.abb.com/

analytical.

Alternatively simply scan this code:

—

We reserve the right to make technical changes or

modify the contents of this document

without prior

notice. With regard to purchase orders, the agreed particulars shall prevail.

ABB does not accept any

responsibility whatsoever for potential errors or possible lack of

information in this document.

We reserve all rights in this document and in the

subject matter and illustrations contained

therein.

Any reproduction, disclosure to third parties or utilization of its contents – in whole

or in parts

– is forbidden without prior written consent of ABB.

=== Ende der Liste f ürT extmarke Cover ===

Advanced CGA Solutions

ACX

Analyzer System for Emission Monitoring, Cement Applications and

Process Measurement

Commissioning Instruction

Publication No. CI/ACX-EN

Revision D

Edition: February 2020

This operator’s manual

is protected by copyright. The translation, duplication and distribution in any form, even in a

revised edition or

in extracts, in particular as a reprint, by photomechanical or electronic reproduction or in the form of

storage in data processing systems o

r data networks are prohibited without the consent of the copyright holder and

will be prosecuted under civil and

criminal law.

4 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D

Table of Contents

Page

Foreword 6

Safety Information 7

Important Safety Information 7

Safety Tips for Handling Electronic Measurement Devices 8

Safety Tips for Handling the Analyzer System 9

Additional Safety Tips for Handling the Analyzer System with

Integrated VOC Analyzer 9

Safety Tips for Handling Corrosive and Acidic Substances 10

Safety Tips for Handling Harmful Gases 10

Notes on data safety 11

Installation Preparation 12

"Hydrogen Monitoring of the Analyzer Cabinet" option 12

Installing the Analyzer System 14

Choosing the Extraction Point, Wall Tube Installation 15

Analyzer System Installation Site Requirements 16

Sample Gas Inlet Conditions (at the Extraction Point) 17

Test Gas Connection at the Gas Sampling Probe or upstream of the Sample Gas

Cooler: Test Gas Inlet Conditions 17

AO2000-Magnos27: Test Gas Inlet Conditions 18

AO2000-Fidas24: Supply Gas and Test Gas Inlet Conditions 18

Back-Purging Unit: Installation Site and Air Supply Requirements 19

Power Supply Requirements 20

Weight, Sound Level 22

Items Delivered 23

Materials Needed for Installation (not supplied) 24

Sampling System Installation 25

Type 40 Probe Tube and Filter Unit Installation 25

Type 42 Probe Tube and Filter Unit Installation 26

Type 40W Probe Tube and Filter Unit Installation 27

PFE2 Filter Unit: Installation 29

PFE2 Filter Unit: Gas Connection 30

PFE3 Filter Unit: Installation 31

PFE3 Filter Unit: Gas Connection 32

Probe 2 Installation 33

Sample Gas Line Installation 35

Back-Purging Unit Installation 39

Gas Sampling with Automatic Back-Purging 40

In General 40

Components for Automatic Back-Purging Procedure 40

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 5

Start of the Back-Purging Procedure 41

Program Sequence 42

Cycle Time 44

Post-Purge Time 45

Adjustment of Cycle Time and Post-Purge Time 46

Analyzer Cabinet Installation 47

Installing the Analyzer Cabinet 47

Mounting Plate and Electrical Distribution Cabinet: Installation 48

Analyzer System with Integrated VOC Analyzer: Installing the Supply Gases

and Test Gases 49

AO2000-Fidas24: Connecting the Sample Gas Line 51

Analyzer Cabinet: Connecting the Electrical Leads 52

Analyzer System Start-Up 53

Prior to Analyzer System Start-Up 53

Transportation Restraints Release 54

Reagent Fill 55

Analyzer System Start-Up 56

AO2000-Fidas24: VOC Analyzer Start-Up 57

Warm-Up Phase 61

Analyzer System: Seal Integrity Check 62

AO2000: Air Pressure Correction 64

AO2000: Air Pressure Value Correction 65

Dynamic QR Code 66

Analyzer System Operation 68

Display/Control Unit 68

“Measured Values” Screen 69

“Control Panel” Screen 70

Menu Tree 72

Setting the Time Zone, Date and Time 74

Selecting User Interface Language 75

Changing the Password 76

Password Protection 77

Inhibit Operation 79

Release of communication via port 8001/tcp 80

Release of communication via Modbus® TCP/IP 82

Inspection and Maintenance 84

Safety Information 84

Analyzer System Shut-Down 85

Packing the Analyzer Cabinet or System Components 86

6 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D

Foreword

The Content of this

Operator’s Manual

This operator’s manual contains all the information you will need to safely and

efficiently install, operate and maintain the ACX Analyzer System.

This operator’s 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

operator’s manual.

System documentation

The system documentation includes the following:

•Device Data Sheet

•Instructions in brief for installation, commissioning and operation

•Certificates

•Project-relevant CD-ROM with

•Set of drawings (arrangement diagram, piping diagram, interface diagram) as well

•Information on function block configuration as needed

•System CD-ROM ‘Continuous Gas Analysis – Software Tools and Technical

Documentation’

•CD-ROM ‘Spare Parts Catalog for Analyzer Technology’

Information on the

Internet

Information on ABB Analytical products and services is available on the Internet at

“http://www.abb.com/analytical”.

Service Contact

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)1805-222580, Telefax: +49-(0)621-38193129031,

E-mail: [email protected]b.com

Symbols and

Type Format in this

Operator’s Manual

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.

, … identifies reference numbers in figures.

Display

identifies a message in the display.

Input

identifies a user entry

•either by pressing a soft key

•or by selecting a menu item

•

or via the numeric keypad.

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 7

Safety Information

Important Safety Information

Intended Conditions of

Use

The analyzer system is designed for continuous measurement of concentrations of

specific components in gases or vapor. Any other application is not compliant with the

specified use. Observation of this manual is also part of the specified use.

The analyzer system must not be used to measure flammable gases or combustible

gas/air or gas/oxygen mixtures. The analyzer system must not be installed in

hazardous locations.

The analyzer system interior remains free of explosive atmosphere during normal

operation. Therefore, the integration of explosion protection measures inside the

analyzer system is not required.

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.

Safety Labels Affixed to

the Analyzer System

Observe the safety labels affixed to the analyzer system or to the individual

components:

Consult Documentation!

Hot Surface! (Temperature > 60 °C)

Corrosive Material!

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 safety symbols 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.

8 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D

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 analyzer cabinet 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 replacements.

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.

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 9

Safety Tips for Handling the Analyzer System

CAUTION!

Do not open any gas paths in the analyzer system or in the integrated analyzers.

Doing so will damage gas path seal integrity.

If system-internal gas paths are opened, a seal integrity check must be performed

with a leak detector (thermal conductivity) when the device is reassembled.

Additional Safety Tips for Handling the Analyzer System with

Integrated VOC Analyzer

CAUTION!

The combustion gas path in the analyzer system and especially in the integrated

VOC analyzer must not be opened! The combustion gas feed path can become leaky

as a result!

If the system-internal combustion gas path is opened, a seal integrity check must be

performed with a leak detector (thermal conductivity) when the device is

reassembled.

The bulkhead connector with integrated flow limiter for connection of the

combustion gas line is a safety relevant part. It must not be removed, modified or

replaced!

It is recommended to check regularly the seal integrity of the combustion gas line

outside the analyzer system.

WARNING!

Combustion gas flowing out of leaks in the gas paths can cause fire and explosions

(even outside the analyzer system itself).

A shut-off valve must be installed in the combustion gas supply line to increase safety

in the following operating conditions:

•During shutdown of the gas analyzer,

•In the event of failure of the instrument air supply,

•Leakage in the combustion gas feed path inside the gas analyzer.

This shut-off valve should be installed outside the analyzer house in the vicinity of the

combustion gas supply (cylinder, line).

10 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D

Safety Tips for Handling Corrosive and Acidic Substances

CAUTION!

When working with corrosive reagents note the hazard information and safety

precautions contained in the applicable material safety data sheets.

Condensates are often acidic. Neutralize condensates and follow the prescribed

measures for disposal.

Safety Tips for Handling Harmful Gases

CAUTION!

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.

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