ABB ACF5000 User manual

—
ABB MEASUREMENT & ANALYTICS | OPERATING INSTRUCTION
ACF5000
Multi-component FTIR analyzer system
Measurement made easy

ACF5000 FTIR ANALYZER SYSTEM | OI/ACF5000-EN REV. A 3
Contents
Preface ....................................................................................................................................................................6
Safety instructions ............................................................................................................................................... 8
Intended use ................................................................................................................ 8
Safety instructions ..................................................................................................... 8
Safety instructions for handling the analyzer system ....................................... 10
Safety instructions for handling the analyzer system with integrated FID .... 11
Safety instructions for handling the FTIR spectrometer ...................................12
Safety instructions for working with poisonous gases......................................13
Description of the analyzer system....................................................................................................................14
Application and function of the analyzer system ................................................14
Components of the analyzer system .....................................................................16
Option "Hydrogen monitoring of the analyzer cabinet".....................................18
Preparation for installation ............................................................................................................................... 20
Selection of the sampling point, installation of the wall tube ......................... 20
Requirements for the installation site of the analyzer cabinet.........................22
Sample gas inlet conditions ................................................................................... 24
Operating gases and test gases............................................................................ 25
Power supply ..............................................................................................................27
Dimensions, weights and noise level .................................................................... 29
Scope of supply and delivery .................................................................................. 30
Material required for the installation (not supplied) ..........................................31
Installation............................................................................................................................................................33
General notices ......................................................................................................... 33
Installing the analyzer cabinet................................................................................ 34
Installing the gas sampling probe and filter unit ................................................37
Installing the sample gas line .................................................................................40
Installing the operating gases................................................................................ 42
Connecting the electrical leads.............................................................................. 44
Commissioning ....................................................................................................................................................47
Recommissioning ..................................................................................................... 47
Operation............................................................................................................................................................. 50
Display and operation unit...................................................................................... 50
Display .........................................................................................................................51
Message display........................................................................................................ 52
Status LEDs................................................................................................................ 53
Numeric keypad ........................................................................................................ 54
Cancel keys................................................................................................................. 55
Softkeys...................................................................................................................... 56
Text entry ................................................................................................................... 58
Operating by value input......................................................................................... 59
Operating by key entry ............................................................................................60
Password protection.................................................................................................61
Blocking operation ................................................................................................... 63
Operating the analyzer system .............................................................................. 64
Menu structure.......................................................................................................... 66
Display of measured value ...................................................................................... 67

4 ACF5000 FTIR ANALYZER SYSTEM | OI/ACF5000-EN REV. A
Adjustment: Basics ............................................................................................................................................. 68
Controlling the adjustment .................................................................................... 68
Manual adjustment................................................................................................... 69
Automatic adjustment............................................................................................. 70
Adjustment methods ................................................................................................72
FID: Conversion of concentration data................................................................. 74
Adjustment: Configuration .................................................................................................................................76
Configuring the automatic reference FTIR .......................................................... 76
Automatic Adjustment Check (AAC): Configuring the time sequence ........... 78
Automatic Adjustment Check (AAC): Settings and export of the QAL3 data 80
Configuring the Automatic Drift Check (ADC) .................................................... 83
Configuring manual adjustment............................................................................ 85
Configuring automatic adjustment of the FID.................................................... 86
Configuring automatic adjustment of the oxygen sensor ............................... 88
Check time conflicts of the automatic processes .............................................. 90
Output current response..........................................................................................91
Adjustment: Operation........................................................................................................................................92
Carrying out manual reference............................................................................... 92
Start Automatic Adjustment Check (AAC) manually.......................................... 98
Carry out manual adjustment............................................................................... 100
Manual start of automatic adjustment ...............................................................101
Configuration: Component functions..............................................................................................................102
Configuring measuring range .............................................................................. 102
Configuring automatic measuring range switching........................................ 107
Configuring filter .................................................................................................... 108
Active component selection ................................................................................. 109
Configuring limit monitoring ................................................................................110
Configuring FTIR limit monitoring ....................................................................... 111
Configuring dry base and O2reference ............................................................... 112
Changing module name.......................................................................................... 113
Configuration: System functions .....................................................................................................................114
Setting time zone, date and time .........................................................................114
Selecting user interface language ........................................................................115
Change password....................................................................................................116
Blocking operation .................................................................................................. 117
Setting system modules.........................................................................................118
Add system module................................................................................................ 120
Replace system module.......................................................................................... 121
Delete system module ............................................................................................122
Save configuration ..................................................................................................123
Configuring status signals.....................................................................................124
Configuring Ethernet connection.........................................................................125
Configuring Modbus connection ..........................................................................126
Configuring Profibus...............................................................................................127
Configuring Bus I/Os ..............................................................................................128
Configuration: Display functions .....................................................................................................................129
Display features .......................................................................................................129
Display overview ...................................................................................................... 131
Page overview...........................................................................................................132

ACF5000 FTIR ANALYZER SYSTEM | OI/ACF5000-EN REV. A 5
Parameter overview.................................................................................................133
User page configuration ....................................................................................... 134
Moving a display element from one page to another .......................................135
Moving a display element within a page .............................................................136
Configuring the bar display or point display......................................................137
Value input ................................................................................................................138
Configuring value input ..........................................................................................139
Key entry................................................................................................................... 140
Configuring key entries ..........................................................................................141
Maintenance .......................................................................................................................................................142
General notices ........................................................................................................142
Visual inspection..................................................................................................... 143
Cleaning the analyzer cabinet .............................................................................. 144
Seal integrity test ................................................................................................... 145
FID: Seal integrity and functional checks ............................................................147
Maintenance switch ............................................................................................... 149
Emergency purging ................................................................................................ 150
Monitoring the internal cabinet temperature ....................................................151
Connecting gas paths and inserting validation cells ........................................152
Changing analog output current range...............................................................153
Adjustment reset .................................................................................................... 154
Basic adjustment .....................................................................................................155
FID: Standby/Restart ............................................................................................. 156
Configuring saving of FTIR spectral data........................................................... 158
Configuring automatic back-purging of the gas extraction probe .............. 159
Replacing wearing parts.........................................................................................161
Replacing filter on the gas sampling probe........................................................162
Replacing sample gas filter in the ASP block..................................................... 164
Replacing filter in the compressed air main regulator (-J85)......................... 166
Replacing filters in the sample gas pressure regulator....................................167
Replacing filter cells in air purifier AU5............................................................... 168
Replacing filter pad in the fan .............................................................................. 169
Replacing the battery on the system controller................................................ 170
Replacing pressure equalization screws ............................................................. 171
Status messages, troubleshooting .................................................................................................................. 172
Dynamic QR code.....................................................................................................172
Process status..........................................................................................................174
System status: Status messages..........................................................................175
System status: Status signals ...............................................................................176
Status message categories ...................................................................................177
Status message system .........................................................................................179
Status messages FTIR.............................................................................................187
Analyzer system: Troubleshooting .......................................................................191
FID: Troubleshooting ..............................................................................................192
Notify service........................................................................................................... 194
Decommissioning...............................................................................................................................................195
Shutting down the analyzer system.................................................................... 195
Packing the analyzer cabinet................................................................................ 195
Disposal .................................................................................................................... 196
Index ....................................................................................................................................................................197

6 ACF5000 FTIR ANALYZER SYSTEM | OI/ACF5000-EN REV. A
Preface
Content of the operating instruction
This operating instruction contains all the information you will need to safe-
ly and properly install, commission, operate and maintain the analyzer sys-
tem.
This operating instruction contains information on all functional compo-
nents of the analyzer system. It is possible that the analyzer system deliv-
ered differs from the version described here.
System documentation
The system documentation is supplied together with the analyzer system. It
includes:
Analyzer Data Sheet,
Commissioning instruction,
Certificates (e.g., manufacturer declaration),
DVD-ROM "Software tools & technical documentation" with
Software tools,
Operating instructions,
Data sheets,
Technical information,
Certificates.
CD-ROM with the set of drawings prepared specifically for the analyzer
system delivered:
Component location diagram,
Piping diagram,
Interface diagram,
Wiring diagram,
Connection diagram.
Further information
Internet
You can find information on ABB Analytical products and services online at
http://www.abb.de/analytical.
Service contact
If the information in this operating instruction does not cover a particular
situation, ABB service will be pleased to supply additional information as
required.
Please contact your local service representative. For emergencies, please
contact
ABB Service,
Telephone: [phone], Fax: [phone] 29031,
E-mail: [e-mail]

ACF5000 FTIR ANALYZER SYSTEM | OI/ACF5000-EN REV. A 7
Identification of safety instructions in this operating instruction
If the safety instruction identified in this way is not observed, an accident
will occur. This will result in severe bodily injury or death.
If the safety instruction identified in this way is not observed, an accident
may possibly occur. This may result in severe bodily injury or death.
If the safety instruction identified in this way is not observed, an accident is
likely to or will definitely occur. This may result in moderately severe or slight
bodily injury.
CAUTION! Denotes information about possible equipment damage when there is no
danger to personnel.
NOTICE Denotes information about particular features with regard to the handling of
the analyzer system and the use of this operating instruction.
Letters and numbering used in this operating instruction
1, 2, 3, … Is the way reference numbers are used in the figures.
Display Is the way information is presented in the display.
Input Indicates an input by the user
either by pressing a softkey
or by selecting a menu item
or via the numeric keypad
peGauge pressure
pabs Absolute pressure
pamb Atmospheric pressure

8 ACF5000 FTIR ANALYZER SYSTEM | OI/ACF5000-EN REV. A
Safety instructions
Intended use
Intended use
The ACF5000 analyzer system is designed for continuous measurement of
the concentration of individual components in gases or vapors.
Any other use is not approved.
The intended use also includes taking note of this operating instruction.
The analyzer system may not be used for the measurement of ignitable
gas/air or gas/oxygen mixtures during normal service. The analyzer system
may not be set up in potentially explosive atmospheres.
In normal service, the interior of the analyzer system contains no potentially
explosive atmosphere. Accordingly, installation of explosion protection in
the interior is not necessary for operation of the analyzer system.
Safety instructions
Requirements for safe operation
In order to operate in a safe and efficient manner the device should be
properly handled and stored, correctly installed and set-up, properly oper-
ated and correctly maintained.
Personnel qualifications
Only persons familiar with the installation, commissioning, operation and
maintenance of comparable devices and certified as being capable of such
work should work on the device.
Special information and precautions
These include
The content of this operating instruction,
The safety instructions affixed to the device,
The applicable safety precautions for installing and operating electrical
devices,
Safety precautions for working with gases, acids, condensates, etc.
National regulations
The regulations, standards and guidelines cited in this operating instruction
are applicable in the Federal Republic of Germany. The applicable national
regulations should be followed when the device is used in other countries.

ACF5000 FTIR ANALYZER SYSTEM | OI/ACF5000-EN REV. A 9
Device safety and safe operation
The device is designed and tested in accordance with safety standard
EN 61010 Part 1 "Safety requirements for electrical equipment for measure-
ment, control, and laboratory use," and is shipped ready for safe operation.
To maintain this condition and to assure safe operation, read and follow the
safety instructions in this operating instruction. Failure to do so can put
persons at risk and can lead to device damage as well as damage to other
systems and devices.
Protective conductor terminal
The protective ground conductor should be attached to the protective con-
ductor terminal before any other connection is made.
Danger of a disconnected protective ground conductor
The device can be hazardous if the protective ground conductor is inter-
rupted inside or outside the device or if the protective conductor terminal is
disconnected.
Dangers involved in opening the covers
Current-bearing components can be exposed when the covers or parts are
removed, even if this can be done without tools. Current can be present at
some connection points.
Dangers involved in working with an open device
All work on a device that is open and connected to power should only be
performed by trained personnel who are familiar with the dangers involved.
When safe operation can no longer be assured
If it is apparent that safe operation is no longer possible, the device should
be taken out of operation and secured against unauthorized use.
The possibility of safe operation is excluded:
If the device is visibly damaged,
If the device no longer operates,
After prolonged storage under adverse conditions,
After severe transport stresses.

10 ACF5000 FTIR ANALYZER SYSTEM | OI/ACF5000-EN REV. A
Safety instructions for handling the analyzer system
The warning symbols affixed to the analyzer system must be observed:
Heed the operating instruction!
Hot surface! (Temperature > 60°C)
Danger of electric shock!
The following must also be observed:
The safety instructions for handling the analyzer system with integrated
VOC analyzer (see page 11),
the safety instructions for handling the FTIR spectrometer (see page 12),
and
the safety instructions for working with poisonous gases (see page 13).
The gas paths in the analyzer system and the integral analyzer must not be
opened! The gas paths can become leaky as a result.
If the gas paths inside the analyzer system must nevertheless be opened, it
is essential that they be subjected to a leak test after being closed again.

ACF5000 FTIR ANALYZER SYSTEM | OI/ACF5000-EN REV. A 11
Safety instructions for handling the analyzer system with
integrated FID
Safety measures
If an FID (VOC analyzer) is installed in the analyzer system, the following
safety measures are taken at the factory to ensure safe operation:
Installation of a hydrogen flow restrictor in the cabinet wall (bulkhead
fitting with an integrated flow restrictor, max. 10 l/h, for connection to
the combustion gas line),
Use of stainless steel piping, compression fittings and valves,
Shutoff of the hydrogen supply in the event of malfunctions,
Check of the combustion gas paths for leaks inside the analyzer cabinet,
Installation of pressure equalization fittings on the top of the cabinet to
allow escape of hydrogen to the outside in the event of leaks.
As an additional safety measure, the analyzer system can be equipped with
the option “Hydrogen monitoring of the analyzer cabinet” (see page 18)
The combustion gas path in the analyzer cabinet and especially in the inte-
gral FID must not be opened! The combustion gas feed path can become
leaky as a result!
If the combustion gas path inside the analyzer cabinet nevertheless is
opened, it is essential that it be subjected to a leak test with a hydrogen leak
detector after it is closed again!
The bulkhead fitting with integral flow restrictor for connection of the com-
bustion gas line is a safety-relevant component. It may be replaced only by
certified service personnel.
The integrity of the combustion gas path in the analyzer system as well as
the combustion gas feed line must be checked prior to commissioning as
well as regularly during operation.
Combustion gas that escapes from leaks in the gas paths can cause fires and
explosions, even outside the analyzer system!
Sufficient ventilation must be provided at the installation site of the analyzer
system.

12 ACF5000 FTIR ANALYZER SYSTEM | OI/ACF5000-EN REV. A
Safety instructions for handling the FTIR spectrometer
Central unit with electronics module (power supply):
The FTIR spectrometer has an unprotected metal housing that is connected
directly to ground potential via the power cable and is thus classified as
"Safety Class 1 Equipment".
Before fuses are replaced, the device must be disconnected from the power
supply.
To avoid electric shock, the device may not be operated if there is an indica-
tion that any part of the outer surface is damaged.
To protect against fires, only a fuse of the specified type and current rating
may be used.
To protect against electric shock, the protective ground conductor of the
power cable must be connected to ground potential.
CAUTION! The device must not be exposed to any source of the excessive moisture.
The device may not be used in an explosive hazardous atmosphere.
NOTICE Approval from the responsible authorities is required for measurement of
combustible gases.
Laser safety
Under normal conditions, the FTIR spectrometer can be operated completely
safely (Class 1 laser product – see name plate).
Type of laser installed in the interferometer: Class 3B VCSEL laser to
IEC 60825-1 as well as 21 CFR Chapter 1, Subchapter J
Output: max. 3 mW
Wavelength: 760 nm (laser beam invisible to the human eye)
The housing of the interferometer AU3 may not be opened during normal
operation. It contains no user-operated parts.
The housing of the interferometer may be opened only by authorized ABB
service personnel.
Opening the housing of the interferometer AU3 and the interferometer
module in particular can result in contact with laser radiation.
Radiation from Class 3B lasers poses a danger to the human eye both when
viewed directly and if reflected.

ACF5000 FTIR ANALYZER SYSTEM | OI/ACF5000-EN REV. A 13
Safety instructions for working with poisonous gases
Some gas components whose concentration is measured with the analyzer
system are hazardous to health or poisonous.
For this reason, the sample gas must under no circumstances be allowed to
escape from the sample gas path in either the measurement mode or when
performing maintenance.
The analyzer system must be checked for leaks regularly.
The diluted stack gas must be discharged outside the room where the ana-
lyzer cabinet is installed.
Ensure adequate ventilation of the room in which the analyzer system is
installed.
The legal requirements for the maximum work place limit values of the
measurement and test gases must be observed.

14 ACF5000 FTIR ANALYZER SYSTEM | OI/ACF5000-EN REV. A
Description of the analyzer system
Application and function of the analyzer system
Application
The ACF5000 analyzer system is a multi-component analyzer system for
continuous measurement of the concentration of individual components in
the flue gas of industrial incinerators.
The field of application of this measuring equipment basically involves tasks
associated with emissions monitoring; use in process control applications,
however, is also possible.
Function
The gas to be measured is drawn from the gas channel by means of a gas
sampling probe and conveyed to the analyzer cabinet via a heated sample
gas line. The sampling probe contains a particulate filter that removes dust
particles from the gas. As a standard feature, the analyzer system controller
offers the ability to connect the zero gas and test gas to the sampling probe
upstream of the filter element automatically. Automatic cleaning of the
sampling probe filter is available as an option.
The gas path from the sampling location to the analyzer is heated through-
out (180°C) to prevent the temperature from dropping below the dew point
or condensation of flue gas. The heating is controlled and monitored by the
system's electronics.
An optional heated measuring point selector can be configured for process
measurements.
Conveying of the sample to the analyzer is based on the injector principle
and employs an air jet injector that is integrated into the heated sample
handling block (ASP block). This, in turn, is connected directly to the heated
gas cell.
Test gases can be connected either automatically or manually to both the
gas sampling probe and directly to the analyzer.
Measuring principle
The analyzer system operates on the principle of FTIR spectrometry. The
concentrations of a variety of stack gas components that exhibit absorption
bands in the mid-infrared range can be determined.
Each gas absorbs infrared radiation in a specific region of the spectrum. The
radiation absorbed at a given wavelength is a function of the gas concentra-
tion. The FTIR analyzer (spectrometer) measures how much radiation was
absorbed at specific wavelengths.
The information about the absorption processes is processed in the sys-
tem's electronics and converted into measured values. At the same time, the
spectra of all components are recorded.
A zirconium dioxide sensor for measurement of the oxygen content is an
integral part of the analyzer system.

ACF5000 FTIR ANALYZER SYSTEM | OI/ACF5000-EN REV. A 15
Options
Validation
A validation unit can be installed in the beam path of the spectrometer to
confirm the validity of the spectrometer adjustment.
Total carbon measurement
A flame ionization detector (FID) for measurement of the total carbon con-
tent (VOC) can be incorporated into the analyzer system.
Display and signal processing
The current concentration of the individual measured components and the
status signals are shown on the system display.
The system controller has been designed for the requirements of emissions
and process measurement. It offers a system-internal CAN bus and field bus
systems such as Modbus and PROFIBUS as interfaces. An Ethernet interface
for remote monitoring of the entire analyzer system and transmitting data
via internal or external TCP/IP networks is included. Remote control of the
analyzer system is possible via a UMTS router. Analog outputs for the meas-
ured components and relay contacts for fault/status messages are optional.

16 ACF5000 FTIR ANALYZER SYSTEM | OI/ACF5000-EN REV. A
Components of the analyzer system
NOTICE A delivered analyzer system may not include certain individual assemblies
described in this section depending on the measurement task and execution
ordered.
Assemblies in the analyzer cabinet
AU1 ACF5000 E-box
AU2 Analyzer box
AU3 Interferometer box
AU4 FTIR E-box
AU5 Air purifier

ACF5000 FTIR ANALYZER SYSTEM | OI/ACF5000-EN REV. A 17
Gas sampling
Stainless steel probe tube, unheated (Type 40) or heated (Type 42)
Filter unit, heated (Type PFE2), with check valve, with back-purging
(option)
Sample gas line, heated (Type TBL01)
Heated selector valve for switching between two sampling points
(option)
CAUTION! For measurement gas sampling, only the assemblies specified by ABB may be
used, as both the temperature controls and the securing functions are
aligned to this.
Sample gas conditioning
Sample gas conditioning block (ASP block), heated, with stainless steel
microfilter and air jet injector
Automatic purge and test gas switching
Flow rate, pressure and temperature sensors
Air preparation
Zero air for the spectrometer and end point gas for the oxygen sensor
and combustion air for the FID
Purge gas for the spectrometer and the entire measuring system
Analyzers
FTIR spectrometer with heated measuring cell
Oxygen sensor (ZrO2sensor)
Flame ionization detector (FID, option)
Control, operation and display
Display and control unit in the door of the analyzer cabinet
AO2000 system controller in the door of the analyzer cabinet
ACF5000 electronics box AU1
Controls for the air jet injector as well as the oxygen sensor and FID
Interfaces for
measured values and status signals (standard: Ethernet with TCP/IP
protocol and Modbus TCP/IP protocol, options: Modbus, PROFIBUS,
analog and digital outputs, analog and digital inputs)
Remote control and diagnosis (modem and/or Ethernet)
For emission measurements in compliance with applicable European Direc-
tives, the analyzer system must be operated with certified AO2000 system
software.

18 ACF5000 FTIR ANALYZER SYSTEM | OI/ACF5000-EN REV. A
Option "Hydrogen monitoring of the analyzer cabinet"
Function
The "Hydrogen monitoring of the analyzer cabinet" option is an additional
safety measure when an FID analyzer is built-in in the analyzer system. If a
leak occurs in the hydrogen path inside the analyzer cabinet and hydrogen
accumulates inside the cabinet, both the hydrogen supply and the power
supply are shut off before the explosion limit is reached – at 40% LEL. This
prevents formation of an ignitable mixture.
Scope of supply and delivery
Installed in the analyzer cabinet:
In the upper area, an ATEX-certified gas sensor with connection socket,
Outside on the right side wall, a solenoid valve that interrupts the hy-
drogen supply at 40% LEL and at power supply failure (H2safety valve).
Also supplied:
A gas warning center for evaluating the gas sensor signal,
A contactor for disconnecting the power supply to the analyzer cabinet,
A contactor for disconnecting the UPS if the system is prepared for a
UPS.
Installation
The electrical wiring of the gas sensor and the gas warning center for
switching off the power supply in the event of an alarm has not yet been
completed in the factory delivered condition of the analyzer system.
The gas warning center must be installed outside the analyzer cabinet in a
non-hazardous area in a distribution cabinet or similar. It must be electrically
connected to the gas sensor (see the order-specific set of drawings in this
regard).
The solenoid valve for disconnecting the hydrogen supply as well as the coils
of the contactors and relays for disconnecting the power supply and UPS (if
present) must be connected to a fault-signaling contact in the gas warning
center. The fault-signaling contact must be set so that the voltage is shut
off at 40% LEL and the contact itself latches.
The measuring signals (analog outputs and inputs), the status signals (digi-
tal outputs and inputs) as well as the bus systems of the analyzer system are
so designed that after the power supply (and possibly the UPS) are discon-
nected no component in the analyzer cabinet (contactor, relay, motor etc.)
that could generate an ignition spark can be actuated from the outside.
Potential-free measurement and status signals as well as bus connections
do not have to be disconnected separately in the event of a gas alarm. If,
however, an external signal that is not potential-free is fed in, the operator
must ensure that it is shut-off when the gas alarm is triggered, e.g. via an
isolating relay.

ACF5000 FTIR ANALYZER SYSTEM | OI/ACF5000-EN REV. A 19
NOTICES The gas sensor installed in the analyzer cabinet is not calibrated at the fac-
tory; it is not functional without calibration. The calibration of the gas sensor
is the responsibility of the operator.
Installation, commissioning, parameterization, operation, signal evaluation
and maintenance of the supplied gas warning center are the responsibility of
the operator.
If the above-mentioned instructions are not observed or the hydrogen mon-
itoring of the analyzer cabinet is installed incorrectly, a hydrogen explosion
may occur in the event of a malfunction.

20 ACF5000 FTIR ANALYZER SYSTEM | OI/ACF5000-EN REV. A
Preparation for installation
Selection of the sampling point, installation of the wall tube
Selection of the sampling point
The sampling point must be suited for extracting a representative sam-
ple stream.
The probe tube must be readily accessible for maintenance work.
The PFE2 filter unit must be protected from direct exposure to heat and
soiling. The protective enclosure provides protection class IP54.
NOTICE In compliance with DIN EN 15259, the sampling point for emission measuring
equipment is specified by the responsible entities accredited in accordance
with DIN EN ISO/IEC 17025.