ABB ACX Installation and operation manual

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—
ABB MEASUREMENT & AN
ALYTICS | COMMISSIONING INSTRUCTION | CI/ACX-EN REV. D
ACX
Advanced CGA Solutions
—
A
BB Automation GmbH
Measurement & Analytics
Stierstädter Str. 5
60488 Frankfurt am Main
Germany
Tel:
[phone]
Email:
[email protected]
abb.com/analytical
Analyzer System for Emission
Monitoring, Cement Applications
and Process Measurement
Measurement made eas
y
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.
© ABB 2020 3KXG141002R4401
=== 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
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
as
•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: [phone], 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.
1
,
2
,
3
, … 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.

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 11
Notes on data safety
Obligations of the
owner
This product is designed to be connected to a network interface and to communicate
information and data via this network interface.
It is the operator’s sole responsibility to provide and continuously ensure a secure
connection between the product and your network or any other network (as the case
may be).
The operator shall establish and maintain any suited measures (such as but not limited
to the installation of firewalls, application of authentication measures, encryption of
data, installation of anti-virus programs, etc.) to protect the product, the network, its
system and the interface against any kind of security breaches, unauthorized access,
interference, intrusion, leakage and / or theft of data or information.
ABB Automation Products GmbH and its affiliates are not liable for damages and / or
losses related to such security breaches, any unauthorized access, interference,
intrusion, leakage and / or theft of data or information.
Digital communication
The ABB guidelines prevent communication through unsecured communication
protocols, provided that the operator does not explicitly allow this.
These communication protocols are blocked by default.
The device software has been supplemented with menu items through which the
operator can explicitly release communication.
The communication protocols are blocked again after software updates and must be
released once again.
Services and ports on
the Ethernet interface
Port
Description
22/tcp Used only for software updates.
No direct access to the device.
8001/tcp Binary proprietary protocol for:
•Remote HMI for operation
•AnalyzeIT program for continuous monitoring
•OPC Server, external OPC Server for ACX systems
501/tcp Used for Modbus/TCP.
The device allows connection to any Modbus client.

12 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D
Installation Preparation
"Hydrogen Monitoring of the Analyzer Cabinet" option
Function If an FID (VOC Analyzer) is installed, the analyzer system can be supplied with the
‘Hydrogen monitoring of the analyzer cabinet’ option as an additional safety measure.
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 delivery Installed in the analyzer cabinet:
•in the upper area, an ATEX-certified gas sensor with connection socket,
•on the exterior on the right-hand side wall, a solenoid valve, connected with the
combustion gas input of the analyzer cabinet, which cuts off hydrogen supply in the
event of a failure of the power supply, or at 40 % LEL (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 electric wiring of the gas sensor and the gas warning center to shut down the
power supply in the event of a fault is not installed in the analyzer system in the
factory-delivered condition.
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 (H2) 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-signalling contact in the gas warning center. The fault-
signalling 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 (digital 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 disconnected no component in the
analyzer cabinet (contactor, relay, motor etc.) that could generate an ignition spark
can be actuated from the outside.
The measurement and status signals supplied potential-free as well as bus
connections must not be activated separately in the event of a gas alarm. If however a
non potential-free external signal is fed in, the operator should make sure that if a gas
alarm is triggered, it is activated via a cut-off relay, for example.

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 13
•
The gas sensor installed in the analyzer cabinet is not factory calibrated; it is
inoperable without calibration. 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.
WARNING!
If the above-mentioned instructions are not observed or the hydrogen monitoring of
the analyzer cabinet is installed incorrectly, a hydrogen explosion may occur in the
event of a malfunction.
Operation of this safety device should be checked during commissioning and at
regular intervals (min. 1 time a year).

14 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D
Installing the Analyzer System
•
We recommend having the analyzer system installed by ABB.
•When installing the analyzer system, in addition to this manual, comply with the
information contained in the drawings set.
•If there is shipping damage which points to improper handling file a damage claim
with the shipper (railway, mail or freight carrier) within seven days.
•Make sure the enclosed accessories are not lost (see the “Items Delivered” section,
page 23).
•
Keep the packaging material for future shipping needs.
Installation – Overview
Step
Action
Page
1 Prepare the gas sampling probe installation site. 15
2 Prepare the analyzer cabinet installation site. 16
3 Install the gas sampling probe and filter unit. 25
4 Install the sample gas line. 35
5 Install the back-purging unit (if applicable). 39
6 Install the analyzer cabinet. 47
7 Install the instrument air and test gas supply (if applicable). 49
8 Connect the gas lines to the analyzer cabinet. 51
9 Connect the electrical leads to the analyzer cabinet. 52

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 15
Choosing the Extraction Point, Wall Tube Installation
Choosing the
Extraction Point
The extraction point must be suitable for extracting a representative specimen flow.
In the case of emission monitoring systems the extraction point is specified by the
responsible technical inspection authority.
Wall Tube Installation
•
Install the wall tube with mounting flange (DN 65, PN 6, type A according to
DIN EN 1092-1; not supplied) at the extraction point in such a way that the sampling
probe tube can be easily installed and removed (see Figure 1).
•The sampling probe tube must be easily accessible to allow maintenance work to be
performed.
•Align the boreholes of the mounting flange in relation to the flow direction of the
process gas (see Figure 1).
Observe the separate instructions for installation of probe tube type 40W on page 27!
Figure 1
Wall Tube Installation
(Dimensions in mm)
Brickwork Brickwork with metal sheeting
α
1 2 5 34
1 2 5 3
Isolated sheet-metal channel Flow direction of process gas
1 2 5 3
Wall tube
Wall tube mounting flange DN 65, PN 6, Form A to DIN EN 1092-1
Gasket
Welded-on rectangular block
Sampling probe tube flange
Minimum distance xmin of the mounting flange (wall tube flange) from the wall
depending on mounting angle α:
α 10° 15° 20° 25° 30° 35°
xmin/mm 229 248 268 287 307 324

16 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D
Analyzer System Installation Site Requirements
CAUTION!
The analyzer system must not be installed in hazardous locations.
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 115 VAC power supply on account of pressure drop build-up in the line
and the required electrical fusing.
For fast measurement at preheater/CO monitoring of ESP, the sample gas line length
is limited to 10 meters.
The test gas cylinders should be installed as close as possible to the analyzer system.
Protection from
Adverse Conditions
Protect the analyzer cabinet against
•Water spray
•Contact with chemicals
•Strong sunlight and heat radiation
•Strong air currents
•Heavy dust load
•Corrosive atmospheres
•Vibration
Installation Indoors
or Outdoors
The sheet steel cabinet and the mounting plate are only suitable for installation
indoors. An air-conditioned room is recommended.
The GRP cabinet is suitable for installation indoors and outdoors. A weather
protection roof must be provided.
Ambient Temperature Operation: Mounting plate 0 to +35 °C
Sheet steel cabinet with ventilation fan 0 to +35 °C
with cooling unit 0 to +45 °C
GRP cabinet with ventilation fan –20 to +35 °C
with cooling unit –20 to +45 °C
Storage and transport: +2 to +60 °C
after draining and
drying parts in contact with condensate –25 to +60 °C
Relative Humidity Year-round average max. 75%, short-term max. 95 %,
occasional slight condensation is permitted
Installation Site
Altitude
The maximum installation altitude is 2000 m above sea level.
Continued on next page

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 17
Analyzer System Installation Site Requirements, continued
Dimensions and Space
Requirement
Refer to the “Layout Plan” in the drawings set.
Installation Site
Stability
The installation site floor must be plane and capable of supporting the cabinets
weight (see page 22).
The installation site wall must be capable of supporting the weight of the mounting
plate and the separate electrical distribution cabinet (see page 22).
Sample Gas Inlet Conditions (at the Extraction Point)
CAUTION!
The analyzer system must not be used for measurement of flammable gases and
ignitable gas/air or gas/oxygen mixtures!
In the case of toxic gases, the threshold limit value (TLV) must be complied with.
Application Temperature Pressure pabs Flow
Emission Monitoring max. 500 °C 850 to 1100 hPa (0.85 to 1.1 bar) max. 250 l/h
Kiln or Calciner Outlet (T > 900 °C) max. 1300 °C 850 to 1100 hPa (0.85 to 1.1 bar) 1) max. 100 l/h
Calciner max. 900 °C 850 to 1100 hPa (0.85 to 1.1 bar) max. 125 l/h
Wet Kiln Gas Outlet max. 300 °C 850 to 1100 hPa (0.85 to 1.1 bar) max. 250 l/h 2)
Preheater/CO Monitoring of ESP max. 450 °C 850 to 1100 hPa (0.85 to 1.1 bar) max. 250 l/h
3)
Coal Bunker, Coal Mill max. 500 °C 850 to 1100 hPa (0.85 to 1.1 bar) max. 250 l/h
Process Measurement max. 500 °C 850 to 1100 hPa (0.85 to 1.1 bar) max. 250 l/h
1) at the sample gas inlet of the analyzer system
2) max. 60 l/h with SO2measurement
3) max. 300 l/h with probe F
Test Gas Connection at the Gas Sampling Probe or upstream of the
Sample Gas Cooler: Test Gas Inlet Conditions
CAUTION!
When handling test gases, the lower explosion limit (LEL)as well as the threshold
limit value (TLV) must be complied with.
Specification Pressure peFlow
Test gases 1, 2, 3 Sample component or substitute gas
component in N2or air
1000 ±100 hPa
(1.0 ±0.1 bar)
130 to 250 l/h

18 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D
AO2000-Magnos27: Test Gas Inlet Conditions
Characteristic
Pressure p
e
Flow
Zero Gas
N2500
±
50 hPa
(= 0.5 ±0.05 bar)
130 to 250 l/h
Span Gas Air
AO2000-Fidas24: Supply Gas and Test Gas Inlet Conditions
Characteristic Pressure peFlow
Instrument Air
1)
Based on ISO 8573-1 Class 2
(particle size max. 1 µm, particle density max.
1 mg/m3, oil content max. 0.1 mg/m3, pressure
dew point at least 10 °C below the lowest
expected ambient temperature)
4000
±
500 hPa
(4.0 ±0.5 bar)
approx. 1500 l/h
Combustion Air
2)
Synthetic air or catalytically cleaned air with
an org. C content of < 1% of the span
1200
±
100 hPa (1.2
±0.1 bar)
max. 40 l/h
Combustion Gas 3) H2(quality 5.0) 1200 ±100 hPa (1.2
±0.1 bar)
approx. 3 l/h
Zero Gas N2(quality 5.0) or synthetic air or catalytically
cleaned air
1000
±
100 hPa (1.0
±0.1 bar)
130 to 250 l/h
Span Gas 4) Sample component or substitute gas
component in N2or air
1000 ±100 hPa (1.0
±0.1 bar)
130 to 250 l/h
1)
Provide a shutoff valve with a pe= 4.5 to 7 bar pressure gauge.
Instrument air is used as
•drive air for the air injector (if installed),
•combustion air,
•emergency purge air.
2) Separate combustion air supply is required if the analyzer system is not equipped
with a combustion air conditioning module (catalyst).
3) Recommendation: Provide two 40 l cylinders and a switchover station.
Note: For safety reasons, a flow limiter is integrated in the bulkhead connector
provided for connection of the combustion gas line to limit the combustion gas
flow to 10 l/h.
4) As the VOC analyzer only measures the number of carbons the concentration of the
span gas has to be calculated from ppm or mg/m
3
CnHmto ppm or mg/m
3
C.
•
Perform regular inspections of the external combustion gas line.
•Install a pressure relief valve in the combustion gas line outside of the analyzer
cabinet
•Set the pressure relief valve to < 2 bar to securely limit the maximum supply
pressure.
Definition pe= pabs – pamb
with pe= positive pressure, pabs = absolute pressure, pamb = atmospheric pressure

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 19
Back-Purging Unit: Installation Site and Air Supply Requirements
Design of the
Back-Purging Unit
The back-purging unit consists of a protective cabinet with shut-off valve, 6 bar
pressure reduction valve, solenoid valves for back-purging, pressure regulator and 5 l
compressed air receiver for effective pressure pulses also with lower airflow rate.
Distance to
Sampling Probe
The distance between the back-purging unit and the sampling probe must not exceed
5 m (length of the steel-braided compressed-air hoses = 6 m).
Protection from
Adverse Conditions
Protect the back-purging unit against
•Water spray
•Contact with chemicals
•Strong sunlight and heat radiation
•Strong air currents
•Heavy dust load
•Corrosive atmospheres
•
Vibration
Pressurized air supply
requirements
•
dry (dew point < 3 °C), oil- and dust-free
•max. 6 bar for back-purging
•approx. 4 bar as control air (needed for 2-stage back-purging with Type PFE2 filter
unit and AO2000-Fidas24 VOC analyzer)
•Required air capacity approx. 100 m3/h
•Instrument air following ISO 8573-1 Class 2 (particle size max. 1 µm, particle density
max. 1 mg/m3, oil content max. 0.1 mg/m3, pressure dew point max. –20 °C)
CAUTION!
If the compressed air is not dry and clean, this will result in damage to the sample
conditioning components (valves, filters, sample gas cooler, sample gas feed unit) as
well as to the gas analyzer.

20 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D
Power Supply Requirements
Operating Voltage
230/400 V AC or 120 /208 V AC,
±
10 %, 48 to 62 Hz; 3
∼
, L1, L2, L3, N, PE.
Non-floating PEN conductor is forbidden.
Power Consumption
Basic version 1000 W
Cooling unit + 940 W
Analyzer module AO2000-Fidas24 + 285 W
NO2/NO converter + 350 W
Probe tube type 40W, partially heated (24 V AC) + 120 W
Probe tube type 42, heated + 800 W
Filter unit type PFE2 or PFE3, heated + 250 W
Probe 2, partially heated + 255 W
Probe F, partially heated + 400 W
Back-purging unit + 150 W
Sample gas line type TBL01-S, TBL01-C, heated regulated 180 °C + 90 W/m
self-regulating 100 °C + 35 W/m
self-regulating 30 °C + 15 W/m
Uninterruptible
Power Supply
Prepared for Uninterruptible Power Supply (UPS), 400 W.
230 V AC or 120 V AC, ±10 %, 48…62 Hz; L, N, PE.
Non-floating PEN conductor is forbidden.
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 or
•
mounted on a top hat rail in the separate electrical distribution cabinet.
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