ABB ACF-NT User manual

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: [phone], 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: [phone], 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!