ABB ACF-NT User manual

ACF-NT, ACF-NT V0309
Multicomponent Analyzer Systems for Emission and Process Monitoring
Operator’s Manual 42/23572 EN Rev. 5

42/23-572 EN Rev. 5 Operator’s Manual ACF-NT, ACF-NT V0309 3
Contents
Page
Foreword 4
Important Safety Information 5
Safety Tips for Handling Electronic Measurement Devices 6
Safety Tips for Handling the FTIR Spectrometer 7
Safety Tips for Handling the VOC Analyzer 8
Safety Tips for Handling Harmful Gases 8
Special Information about the System Design for Measurement of HF 9
Chapter 1 Startup
Restart 10
Chapter 2 Operation
Display/Control Unit 11
“Measured Values” Screen 12
“Control Panel” Screen 13
“Diagnosis” Screen 15
“Ranges” Screen 16
“ASP Module” Screen 17
“Multi-FID” Screen 18
“Flow” Screen 19
Changing the Password 20
Chapter 3 Maintenance
Safety Notes 21
Cleaning Hints 21
Visual Inspection 22
Seal Integrity Check 23
Wear Part Replacement 24
Replacing the Filter Element in the Probe 25
Cleaning/Replacing the Sample Gas Filter in the SC Block 28
Replacing the Air Purifier Inlet Filter 30
Replacing the Air Conditioner Filter Mesh 30
Calibration 31
FTIR Spectrometer Zero Calibration 33
FTIR Spectrometer Span Check 35
Oxygen Analyzer Calibration 36
VOC Analyzer Calibration 37
Status Messages 38
Taking the Analyzer System Out of Service 39
Appendix
Operating Specifications 40
Index 41

4 Operator’s Manual ACF-NT, ACF-NT V0309 42/23-572 EN Rev. 5
Foreword
The Content of this
Manual
This manual contains all the information you will need to safely and efficiently
operate and maintain the 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
manual.
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
Installation Instructions 42/23-571 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.
1, 2, 3, … identifies reference numbers in figures.
Display identifies a display on the screen.
Symbols and Type
Format in this Manual
Input identifies input from the user.
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.

42/23-572 EN Rev. 5 Operator’s Manual ACF-NT, ACF-NT V0309 5
Important Safety Information
Proper Operation The 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]

6 Operator’s Manual ACF-NT, ACF-NT V0309 42/23-572 EN Rev. 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

42/23-572 EN Rev. 5 Operator’s Manual ACF-NT, ACF-NT V0309 7
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.

8 Operator’s Manual ACF-NT, ACF-NT V0309 42/23-572 EN Rev. 5
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.

42/23-572 EN Rev. 5 Operator’s Manual ACF-NT, ACF-NT V0309 9
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
Maintenance Interval The maintenance interval for the HF sample component is 3 months.
Check of
Water Vapour
Cross-Sensitivity
Checking the water vapour cross-sensitivity must be ensured (see also section
“Calibration”, page 31):
during initial start-up by the manufacturer’s or the supplier’s qualified personnel,
in the annual functional tests by an accredited measurement institute as per
EN 17025.
Use of FFKM Probe
Seals
The filter on the gas sampling probe has FFKM seals.
When they are replaced (see section “Replacing the Filter Element in the Probe”,
page 25), FFKM seals must also be used. For quick replacement, it is recom-
mended that a complete, preassembled filter element be kept at the ready. The
following wearing parts are required:
Module Part No. Comments
Filter stone 730682 The two FFKM O-ring seals from part
number 801994 must be used.
FFKM seal set 801994 Two O-ring seals on the filter stone
FFKM seal set 730722 Filter fixing device with three O-ring seals
The measurement of other components is not affected by the system version for
the measurement of HF sample components.

10 Operator’s Manual ACF-NT, ACF-NT V0309 42/23-572 EN Rev. 5
Chapter 1 Startup
Restart
Initial startup of the analyzer system should be performed by trained personnel of
the manufacturer or the supplier.
Restart Perform the following steps when restarting the analyzer system e.g. after
maintenance or a facility shutdown.
Activating the
Instrument Air Supply
Set the initial pressure (pe= 5–7 bar).
Check the moisture indicator in the air purifier: green = OK, yellow = not OK.
Activate the instrument air supply to the FTIR spectrometer at the earliest 1 hour
after activating the power supply. This will ensure the air is sufficiently dry.
Activating the
Power Supply
Make sure all circuit breakers (fuses) are deactivated.
Turn on the main switch.
Activate the circuit breakers (fuses) – starting with those for the FTIR
spectrometer.
Connecting the
Filtered Air
Check the filtered spectrometer purge air flow rate and set it to approx. 200 l/hr
if necessary.
Checking the
Temperature
Check the temperature of the heated components (gas sampling probe, filter
unit and sample gas line; desired value 180 °C).
Starting the
VOC Analyzer
Start the VOC analyzer following the instructions and information in the AO2000-
MultiFID14 Start-up and Maintenance Manual (Publication No. 41/24-105 EN).
Warm-Up Phase The warm-up phase takes approx. 3 hours.
Calibration Start the manual zero correction (see section “FTIR Spectrometer Zero
Calibration”, page 33).