DOD Technologies DOD64-FTIR User manual

DOD 64 FTIR
Gas Monitor User Manual

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FTIR Manual
©DOD Technologies, INC
675 Industrial Drive Bldg. A.
Cary, IL 60013
Phone [phone] • Fax [phone]

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FTIR Manual
Table of Contents
Chapter 1 –Overview........................................................................................................................................................................6
1.1 Introduction ..............................................................................................................................................................................6
1.2 Sampling and Analyzing..........................................................................................................................................................6
1.3 Nitrogen Purging ......................................................................................................................................................................6
1.4 Sample Line & Exhaust Connections .....................................................................................................................................7
1.5 Electrical Connections.............................................................................................................................................................7
1.6 Spectra and Event/Trend File .................................................................................................................................................7
Chapter 2 –Features ........................................................................................................................................................................8
2.1 External Layout.........................................................................................................................................................................8
2.1.1 Warning Labels, Descriptions, & Danger Zones.................................................................................................................8
2.2 Touch Screen Display..............................................................................................................................................................9
2.3 Compact Flash Drive on PC and Solid-State Storage ..........................................................................................................9
2.4 Reliable Linear Pump Technology and Control Manifolds ..................................................................................................9
2.5 FTIR Interferometer................................................................................................................................................................10
2.6 Keyed Maintenance Door & Control Access........................................................................................................................10
2.7 Transport Selectable Valve Manifold Trays ........................................................................................................................10
2.8 Status Lamp (Optional) .........................................................................................................................................................10
2.9 Tubing Connections...............................................................................................................................................................10
2.10 Service Areas........................................................................................................................................................................11
2.11 Password and Security .......................................................................................................................................................12
2.12 USB Memory Stick or Solid State.......................................................................................................................................12
Chapter 3 –Installation..................................................................................................................................................................13
3.1 Selecting A Location..............................................................................................................................................................13
3.2 Sample Tubing .......................................................................................................................................................................14
3.2.1 End of Line Particulate Filters............................................................................................................................................14
3.3 Exhaust Tubing ......................................................................................................................................................................14
3.4 Zero Gas Inlet .........................................................................................................................................................................14
3.5 A/C Power ...............................................................................................................................................................................14
3.6 Output Wiring..........................................................................................................................................................................15
3.6.1 Standard Output Module Wiring........................................................................................................................................15
3.6.2 I/O Connection Details .......................................................................................................................................................15
Chapter 4 –Setup & Configuration................................................................................................................................................16
4.1 Touch Screen Calibration......................................................................................................................................................16
4.2 Gas Selection..........................................................................................................................................................................16
4.3 Alarm Settings........................................................................................................................................................................16
4.4 Output Relays .........................................................................................................................................................................16
4.5 Concentration Log .................................................................................................................................................................16
4.6 USB Memory Stick or Solid-State Drive ..............................................................................................................................16
4.7 Setup Complete......................................................................................................................................................................17

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Chapter 5 –Basic Operation and Menus......................................................................................................................................18
5.1 Menu Overview.......................................................................................................................................................................18
5.2 General Machine Operation ..................................................................................................................................................18
5.2 Analysis Screen......................................................................................................................................................................19
5.2.1 Faults and Events ...............................................................................................................................................................23
5.2.2 Concentration......................................................................................................................................................................24
5.2.3 Spectra.................................................................................................................................................................................24
5.3 Setup Menu.............................................................................................................................................................................25
5.3.1 Setup > Adjust Flow............................................................................................................................................................25
5.3.2 Setup > Configuration.........................................................................................................................................................26
5.3.2.1 Setup > Configuration > Machine...................................................................................................................................27
5.3.2.2 Setup > Configuration > Point Names ...........................................................................................................................27
5.3.2.3 Setup > Configuration > Alarm Levels ...........................................................................................................................28
5.3.3 Setup > FTIR ........................................................................................................................................................................28
5.3.3.1 Setup > FTIR > Point Gas ................................................................................................................................................28
5.3.3.2 Setup > FTIR > Sequencing.............................................................................................................................................29
5.3.3.3 Setup > FTIR > Diagnostics.............................................................................................................................................30
5.3.3.4 Setup > FTIR > Basic Diags.............................................................................................................................................30
5.3.3.5 Setup > FTIR > RDP..........................................................................................................................................................31
5.3.4 Setup > Testing ...................................................................................................................................................................31
5.3.4.1 Setup > Testing > Alarm Outputs ...................................................................................................................................31
5.3.4.2 Setup >Testing > Values .................................................................................................................................................31
5.3.4.3 Setup > Testing > Ethernet/IP ........................................................................................................................................32
5.3.4.4 Setup > Testing > 4-20 Ma .............................................................................................................................................33
5.3.5 Setup > File Transfer...........................................................................................................................................................34
5.3.6 Setup > History....................................................................................................................................................................34
5.3.6.1 Setup > History > Faults Events .....................................................................................................................................35
5.3.6.2 Setup > History > Concentration ....................................................................................................................................35
5.3.6.3 Setup > History > Spectra ...............................................................................................................................................35
Chapter 6 –Maintenance ...............................................................................................................................................................36
6.1 Return the DOD64-FTIR to A Safe State After Service .......................................................................................................36
6.2 Service Area Door Access .....................................................................................................................................................36
6.3 End-of-Line Particulate Filter Replacement........................................................................................................................37
6.4 Flow Adjustment ....................................................................................................................................................................37
6.5 USB and Solid-State Storage Drive Replacement ..............................................................................................................37
6.6 Fuse Replacement .................................................................................................................................................................38
6.7 Detector Service.....................................................................................................................................................................38
Chapter 7 –Service & Support.......................................................................................................................................................39
Appendix A –Parts List ..................................................................................................................................................................40
Appendix B –I/O Connection Details (Cont.) ...............................................................................................................................41

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B.1 EK1101 Coupler......................................................................................................................................................................41
B.2 Standard Output Module (24 v Sinking) ..............................................................................................................................42
B.2.1 DOD64 General Outputs.....................................................................................................................................................42
B.2.2 Analyzer General.................................................................................................................................................................42
B.2.3 Point Outputs**...................................................................................................................................................................43
Appendix C –System Specifications ............................................................................................................................................44
Appendix D –System Event Message ..........................................................................................................................................45
Appendix F –Optional Communication Interfaces......................................................................................................................47
F.1 Ethernet IP ..............................................................................................................................................................................47
F.2 MODBUS TCP/IP ....................................................................................................................................................................48
F.3 Pump Panel Diagram.............................................................................................................................................................51
F.4 Flow Diagram..........................................................................................................................................................................52
F.4 Control Box Diagram..............................................................................................................................................................52

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Chapter 1 –Overview
1.1 Introduction
The DOD Technologies DOD64-FTIR can sequentially monitor 16 to 64 locations (called sample points) and is
designed for fast and accurate multi-sequential analysis of a variety of gases. The DOD64-FTIR incorporates
Fourier Transform Infrared gas detection technology to detect low levels of many Infrared active gases.
Sample points can be placed up to 400 ft. (121 m) from the central unit, allowing operators to monitor gas
concentrations in areas removed from the detector’s location. A sample from each point is drawn to the
central location of the monitor via tubing and analyzed for toxic, corrosive and flammable gases based on the
applications requirements. Contact DOD for specific gas calibration details or for interest in specific
calibration requirements which may require a development partnership.
The DOD64-FTIR system can be configured with a maximum of 4 manifolds and each manifold has 16
sample points. Gas detection and analysis occurs in the DOD64’s Interferometer located above the pump
panel within the service door. Sample activity, data collection and corresponding output action occurs in the
DOD64-FTIR onboard PC located in the control box.
The system responds to gases that exceed a programable alarm level or a system fault by:
• Triggering outputs or communication method installed on the unit.
• Displaying the point number, gas type, and gas concentrations in red.
• Electronically storing Alarms, Concentrations, Spectra data, and History.
The DOD64-FTIR triggers outputs for each individual point at two levels of gas concentrations. These
programmable limits are selectable and have default factory settings for their respective gas ranges. The
DOD64-FTIR is designed for maximum uptime, so routine maintenance and service can be performed quickly
and easily. The DOD64-FTIR uses FTIR technology which includes an interferometer with either MCT Sterling
cooled detector or a DTGS detector. The preferred detector type should be specified at the time of purchase.
1.2 Sampling and Analyzing
The DOD64 FTIR extracts a sample continuously from each point to reduce sample transport time. Reduction
in transport time is achieved with one dedicated transport pump per 16 sampling locations continuously
pulling a sample. There is also one independent analysis pump which draws the sample line intended to be
analyzed through the DOD64-FTIR’s sampling cell after the individual point valve is opened. The DOD64-FTIR
also allows for continuous sampling of a single location through the “lock on point feature”.
1.3 Nitrogen Purging
Nitrogen purging is a critical to the operation of the DOD64-FTIR. Nitrogen is used to perform periodic
background checks to eliminate detector output drift due to humidity and temperature shifts that can occur in
different environments. The Nitrogen background function also assist in the correction of changes that occur
naturally within the interferometer. These background checks can be initiated manually or can be set to occur
automatically at user-defined time intervals.
The nitrogen supply connection is located on the right-hand side of the machine, in the upper left corner. If
the system is located in an enclosed area, be sure to take all the safety requirements necessary in the use of
nitrogen, which may include monitoring for loss of oxygen in this area. Contact DOD Technologies for
additional oxygen deficiency monitoring if needed.

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1.4 Sample Line & Exhaust Connections
Flow connections for sample lines and exhaust lines are installed using “quick-connect” ports on the inlet
manifolds and right-side panel of the DOD64-FTIR. Sample ports are labeled by number, from 1 to 64
depending on your specific instrument configuration. Exhaust ports are located on the right-side panel of the
DOD64-FTIR and are also labeled. Each sample line should be extended a maximum of 400 ft. and each
exhaust line should be extended a maximum of 25 ft.
IMPORTANT: Be sure to exhaust system to an appropriate scrubber vent as all samples drawn from location
exhaust here at the systems exhaust ports. If gas is present at the locations monitored it will be transported
to this area so be sure to place the exhaust appropriately.
1.5 Electrical Connections
Knock out panels for external electrical connections are provided on the right-side panel of the DOD64-FTIR
(See installation Package). The DOD64-FTIR can be purchased with a side mounted power switch or internal
hard wire option with A/C filter.
1.6 Spectra and Event/Trend File
The DOD64-FTIR stores both Spectra and Event/Trend history to an external solid-state hard drive. All files
are transferable to a USB memory stick. A periodic process should be set up to remove this data from the
system to avoid memory capacity issues. Trend/Event files will be saved as .CVS files and can easily be
opened in common programs such as Excel. The Spectra files are saved in .LAB format or .SPC depending on
the interferometer type purchased with the DOD64-FTIR. The files can be viewed on an external PC using the
DOD spectra viewer. Spectra data stored in .LAB format can also be converted.SPC format, which is
compatible with other spectra open source viewers. Contact DOD Technologies for further information on
Spectra Format and viewers. All historical Spectra and Event/Trend files can be retrieved locally on the
system if needed. (Section 5.2.3)

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Chapter 2 –Features
2.1 External Layout
Figure. 2.1
2.1.1 Warning Labels, Descriptions, & Danger Zones
The below table references all warning labels and their meanings that may be encountered while
operating and servicing the DOD64-FTIR gas detection system.
WARNING:
Hot Surface. This surface will be hot to touch and may cause injury. Please avoid or
take caution when working near this zone.
WARNING:
Protective Earth Ground. Terminal Intended for connection to external conductor
for protection against electric shock in case of fault.
ATTENTION:
Please read operators manual for all instruction for this machine. If manual is not in
country’s native language, requested updated manual before use of equipment.
Sample Manifold
Keyed Control Box Access
Keyed Door for analyzer
and pump panel access
Power and Exhaust Fan
Service Area Door
19” Touch Screen Interface

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WARNING:
Electric Shock is possible, please use caution when accessing this zone.
WARNING:
Moving Parts and Hand Crushing possible. Please watch hand placement when
working near this zone.
2.2 Touch Screen Display
The DOD64-FTIR features a 19”, full color, LCD touch screen display, enhancing the presentation and visibility
of data. All DOD64-FTIR menus and data points are accessible through this state-of-the-art HMI. (Figure
2.1). The display also offers the ability to use USB type mouse and keyboard during data analysis.
2.3 Compact Flash Drive on PC and Solid-State Storage
The system is controlled using a reliable din mounted PC controller. Achieving of data and system
operational software are all based on compact flash technologies or solid-state drive which gives the system
optimum performance with high reliability. (Figure 2.4)
2.4 Reliable Linear Pump Technology and Control Manifolds
The systems transport and analyzing flow is performed through a reliable linear pump technology
(Figure 2.5). The DOD64-FTIR transport and flow pumps require no maintenance with an anticipated two to
three-year life (application specific). The option to replace pumps or rebuild pumps is available.
Figure 2.2

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2.5 FTIR Interferometer
The DOD64-FTIR features an MKS MCT Detector or Perk & Elmer DTGS detector. The MKS detector comes
with a patented 400ml IR cell with a 10-meter optical path and an internal cooling system. This design allows
a fast sampling time that leads to reduced total time for analysis. The optical path length and MCT detector
allow the DOD64-FTIR to obtain the lowest detectable limits in the multi-channel FTIR market today. FTIR
Interferometer and Manifold trays slide out on brackets and can be easily removed for modular quick
serviceability. (See Figure 2.3)
2.6 Keyed Maintenance Door & Control Access
In order to ensure only trained personnel, have access to the system, both upper and lower service areas are
equipped with a key lock. (See Figure 2.1)
IMPORTANT: The maintenance doors should remain closed and latched except when servicing the machine.
Do not open the doors while in Analysis Mode.
2.7 Transport Selectable Valve Manifold Trays
The DOD64-FTIR system can be upgraded to implement up to 4 individual manifolds, each capable of
transporting sixteen points. The main analysis occurs in the FTIR Interferometer located in the central unit.
(See Figure 2.3)
2.8 Status Lamp (Optional)
An optional status lamp is available on the DOD64-FTIR. This lamp indicates status with four different colors
(Red, Orange Blue and Green), allowing the status of the machine to be seen quickly and from a distance.
2.9 Tubing Connections
Sample and exhaust tubing use a quick connection system for simple installation. The connections are made
on the side-panel of the DOD64-FTIR. See section 3.3 for information on connecting the sample and exhaust
tubing. See also Appendix C for important information on transport times for gas from sampling point to the
DOD64-FTIR.
End of line filters are required at all times on each channel- See section 6.3.