DURAG HM-1400 TRX 2 User manual

Operating manual
HM-1400 TRX 2
Total Mercury Analyser
GmbH • Kollaustraße 105 • 22453 Hamburg • Germany • www.durag.com
Before starting any work please read the operating
manual!
Article no.:
4 019 962

Version: 10016370-31-07 Previous version: 10016370-30-05
Production date: 20/07/2020
Document scope: 94
Operating manual Total mercury analyser HM‑1400TRX 2
DURAG GmbH
Kollaustraße 105
22453 Hamburg
Germany
Telephone:
Fax:
Email:
Internet:
[phone] – 0
[phone]
[email protected]
www.durag.com
This manual...
●Generally relates to the entire equipment, even when individual program modules or (parts of)
devices were not purchased.
●Must not be reproduced or transferred in any manner, language or medium, electronic or mechan-
ical, without the express permission of DURAGGmbH. The same applies to parts of the manual.
●Relates to the current device design version at the time this documentation was updated (see page
2 above for production date);
●Contains illustrations which may differ from the actual appearance due to further technical develop-
ments or for reasons of clarity. Therefore, the existing illustrations do not make any claims for deliv-
ery of identical products.

Contents
HM-1400 TRX 2 3
Contents
1 Information on this manual 5
2 Safety 7
2.1 General safety information..................................................................................................7
2.2 Device-specific hazards ......................................................................................................7
2.2.1 Hazards due to electrical equipment...................................................................................7
2.2.2 Hazard due to hot, aggressive, explosive gases or to high pressure of gas to be measured
8
2.2.3 Hazards due to chemicals...................................................................................................8
2.2.4 Hazards due to hot surfaces .............................................................................................10
2.2.5 Hazards during transportation...........................................................................................10
2.3 Personnel, qualifications ...................................................................................................10
2.4 Description and location of safety equipment and emergency stop mechanisms ............11
2.5 Intended use .....................................................................................................................11
3 Product description 12
3.1 Designation of device components ...................................................................................13
4 Theoretical basis 15
4.1 Principle of operation ........................................................................................................15
4.2 Sampling system...............................................................................................................16
4.3 Thermocatalytic reactor ....................................................................................................17
4.4 Gas drier ...........................................................................................................................19
4.5 The Hg0 photometer .........................................................................................................19
4.6 Standardisation .................................................................................................................20
4.7 Gas transport ....................................................................................................................20
4.8 Speciation (optional) .........................................................................................................21
4.9 Dilution (optional) ..............................................................................................................21
4.10 Zero adjustment ................................................................................................................23
4.11 Leak test ...........................................................................................................................24
4.12 Internal reference gas generator.......................................................................................24
4.13 Back-purging.....................................................................................................................25
4.14 Control ..............................................................................................................................25
4.15 Checking for malfunctions.................................................................................................26
5 Installation, commissioning 27
5.1 Safety................................................................................................................................27
5.2 Preparation for installation ................................................................................................29
5.2.1 Instrument location............................................................................................................29
5.2.2 Installation location of the sampling probe........................................................................29
5.2.3 Electrical connection .........................................................................................................31
5.3 Installation sequence for the measurement system..........................................................32
5.4 Installation.........................................................................................................................33
5.4.1 Installing the sampling probe ............................................................................................33
5.4.2 Installation of the measurement instrument ......................................................................34
5.5 Connections ......................................................................................................................34
5.5.1 Sampling probe and sample gas line................................................................................34
5.5.2 Power supply ....................................................................................................................35

Contents
4HM-1400 TRX 2
5.5.3 Signal lines........................................................................................................................36
5.5.4 Exhaust gas .....................................................................................................................36
5.5.5 Condensate.......................................................................................................................36
5.6 Using the chemicals necessary for operation ...................................................................36
5.7 Commissioning with preset parameters............................................................................37
5.8 Preparation for operation phase .......................................................................................37
5.9 Measuring mode ...............................................................................................................38
5.10 Decommissioning, storage, disassembly..........................................................................38
5.10.1 Decommissioning..............................................................................................................38
5.10.2 Storage .............................................................................................................................38
5.10.3 Dismantling .......................................................................................................................39
5.10.4 Disposal ............................................................................................................................40
6 Operation 41
6.1 The terminal ......................................................................................................................41
6.2 Basic rules for operation ...................................................................................................42
6.3 Measured values and system structure menu ..................................................................44
6.4 System messages.............................................................................................................46
6.5 Password protection .........................................................................................................47
6.6 Main menu ........................................................................................................................48
6.6.1 "Control room signals" menu (11, …, 14) .........................................................................49
6.6.2 "Functions" Menu (21, …, 24)...........................................................................................49
6.6.2.1 "Start, adjustment" menu (211, …, 214) ...........................................................................50
6.6.2.2 "Reactor, pump, valves" Menu (221, …, 224)...................................................................51
6.6.2.3 "Optional" menu (231, …, 233) .........................................................................................53
6.6.2.4 "Validation" Menu (241, …, 246).......................................................................................54
6.6.3 "Settings" Menu (31, …, 34) .............................................................................................56
6.6.3.1 "User" menu (311…314)...................................................................................................57
6.6.3.2 "Language" menu (341, …, 347) ......................................................................................61
6.6.4 "Status" Menu (41, …, 46) ................................................................................................61
7 Verification of the measuring system 63
7.1 Connecting an external reference gas generator..............................................................63
7.2 Testing the HM-1400TRX2 with the external test gas generator TR-81 (optional) .........64
7.3 Adjusting the HM-1400TRX2 with the internal reference gas generator.........................67
8 Maintenance 70
8.1 Notes on cleaning .............................................................................................................71
9 Technical data 73
10 Dimensioned drawings 75
11 Messages/fault elimination 80
11.1 Monitored parameters and error messages in plain text...................................................80
11.2 Causes of errors and their rectification .............................................................................81
12 Parameter list (device parameters in delivered condition) 87
13 Index 93

1 | Information on this manual
HM-1400 TRX 2 5
1 Information on this manual
This manual is aimed at qualified
specialised personnel.
The manual is part of the product and must be stored in the im-
mediate vicinity of the place of operation such that it is access-
ible to the personnel at all times. The instructions on preventing
dangers and damage indicated in this manual must be followed.
The following symbols are used
Warning symbols Warning symbols (general)
Warning of electrical voltage
Warning of corrosive substances
Warning of toxic substances
Warning of hot surfaces
ESD-sensitive components
Signal words DANGER Risk leading to death or serious injury.
WARNING Risk that could potentially lead to death or serious
injury.
CAUTION Risk that could potentially lead to less serious or
minor injury.
ATTENTION Risk that could potentially lead to material or envir-
onmental damage.
Hazardous substance symbols Harmful to health
Harmful to the environment
Information symbols This symbol indicates potential material and environ-
mental damage

1 | Information on this manual
6HM-1400 TRX 2
This symbol indicates a notification or tip
This symbol indicates the required special tool and
the particular technical equipment.
Text [ nnn]
Text presented in this way indicates a link to addi-
tional information. The (final) number before the in-
dicates the page number where this information can
be found. In the PDF version of the manual, you can
click on the link to go to the required information.
Safety information is displayed particularly clearly in this manual
( example ):
WARNING Risk of injury due to incorrect spare parts.
Incorrect or faulty spare parts can cause malfunctions that can
lead to serious injuries.
▶Use only original spare parts from the manufacturer.
▶Purchase spare parts from authorised dealers or directly from
the manufacturer.

2 | Safety
HM-1400 TRX 2 7
2 Safety
2.1 General safety information
Only operate the product in perfect condition and in accordance
with the operating manual. Perceptible changes from normal op-
eration indicate functional impairments and should be taken seri-
ously.
Malfunction detection Look out for:
●Formation of smoke or unusual odours
●Unusual noises caused by and occurring during operation of
the device (e.g. including the fan)
●Unusual vibrations
●Unusually high surface-temperatures of system components
●Unexpected changes in power consumption
●Triggering of safety monitoring devices
●Unusual and significant fluctuations or shifts in the measure-
ment results
●Device warning and fault messages
Safety information As a general rule, the following safety information applies for the
described product:
●When preparing and performing work:
Follow the statutory regulations valid for the plant and the cor-
responding technical rules. Observe national safety and acci-
dent prevention regulations.
●Maintenance work and repairs not described in this manual
must not be performed without prior arrangement with the
manufacturer.
2.2 Device-specific hazards
The following section describes residual risks determined by the
risk assessment.
Follow the safety instructions listed here and the warning inform-
ation in the subsequent chapters of this manual in order to re-
duce health hazards and prevent dangerous situations.
The personnel assigned to carry out installation, commissioning
and maintenance must be thoroughly familiar with all potential
hazards and repair measures as set out in this manual.
2.2.1 Hazards due to electrical equipment
The device is operated with electric current. There is an immedi-
ate risk to life when touching parts carrying live voltage. Damage
to the insulation or individual components can present a risk to
life. Work on electrical systems must only be performed by spe-
cialised electricians. Before opening the housing or removing the

2 | Safety
8HM-1400 TRX 2
touch guard, disconnect the device. Check that there is no
voltage, and take measures to protect against unauthorised re-
activation.
Where there are extreme fluctuations of temperature and mois-
ture, condensation can cause moisture to build up within the
device. This can cause an electrical short circuit.
After transportation of the device, do not put it into operation until
the device, including its internal parts, has acclimatised to the
ambient temperature.
Only connect the HM‑1400TRX 2 to the supply voltage set out
on the type label.
Only switch on the operating voltage once installation is com-
plete. Only switch on the device once installation is complete.
This measuring system has been designed to ensure safe separ-
ation between primary and secondary electric circuits. Connec-
ted low voltages must therefore also be generated by safe separ-
ation.
Steps must be taken to protect the electronic components
against electrostatic discharge (ESD protection) for all work on
the open device. To prevent static charge of the human body,
use a device such as a personnel earthing system.
2.2.2 Hazard due to hot, aggressive, explosive gases or to
high pressure of gas to be measured
The HM‑1400TRX 2 is connected to the flue gas duct via the
sampling probe and the exhaust gas duct.
In the case of systems with a low hazard potential (ambient pres-
sure, low temperatures, no health hazard), mounting/removal
can be carried out during system operation or when replacing
connecting cables. The applicable provisions and safety regula-
tions for the system must be complied with and any necessary
and appropriate protective measures taken.
The HM‑1400TRX 2 is not suitable for use in explosive gas mix-
tures!
2.2.3 Hazards due to chemicals
Chemicals always pose particular risks and hazards. They
should therefore only be handled by appropriately trained per-
sonnel with the necessary care.

2 | Safety
HM-1400 TRX 2 9
WARNING Risk of chemical burns, risk of skin irritation
Corrosive chemicals such as potassium hydroxide are used in
the
HM‑1400TRX 2 to analyse the mercury concentration.
Maintenance work involves replacing these substances. Follow
the instructions on the containers and in the safety data sheets.
▶Wear appropriate protective equipment/clothing.
WARNING Risk of poisoning
With (elemental) mercury, there is a risk of inhaling the sub-
stance when breathing in.
When performing maintenance work, note the information in the
mercury safety data sheet.
▶Do not heat the iodine-activated carbon loaded with mercury
above 70°C. This prevents evaporation and the release of
mercury.
▶Wear appropriate protective equipment/clothing.
The technique for measuring the mercury concentration is to
pass the gas through an iodised activated carbon filter (between
the measurement and reference cell of the photometer). The
mercury contained in the gas being measured bonds to the car-
bon and is thus trapped in the filter.
A mercury chloride solution (HgCl2) is used for the Hgn+ gas gen-
erator integrated in the device.
Empty containers must always be replaced by full, fresh contain-
ers. Topping up empty containers is not permitted. In addition to
damage caused by spilled acidic solution in the device cabinet,
changes in the available mercury content in topped-up contain-
ers also occur.
Please note the information in the relevant safety data sheet.
If the HM‑1400TRX 2 also contains an optional speciation mod-
ule, a potassium hydroxide solution (KOH) will need to be
provided in an additional reservoir and replaced at regular inter-
vals. Please note the information in the relevant safety data
sheet.
Used chemicals that must be disposed of after a maximum of
6months as part of device maintenance:
●Contents of the selective filter (iodine-active carbon loaded
with mercury)
●Mercury chloride solution
●Any condensate collected
The company operating the measuring device is responsible for
the handling, transportation and, where necessary, disposal of
the chemicals. The German Ordinance on Hazardous Sub-
stances and the separate safety data sheets for all used chemic-
als must be observed here.

2 | Safety
10 HM-1400 TRX 2
The latest versions of the material safety data sheets included
with the chemicals are authoritative. All personnel who work with
these substances must be familiar with the contents of these
safety data sheets.
Take the necessary and appropriate protective measures as spe-
cified in the data sheets. Please also note any specified first-aid
measures.
2.2.4 Hazards due to hot surfaces
Some of the components used in the HM‑1400TRX 2, as well as
the sampling probe, sampling line, flange and flange piece ex-
ternal components, may be hot or may become hot during opera-
tion. There is a risk of burns. Observe the relevant warning sym-
bols on the device components!
2.2.5 Hazards during transportation
The HM‑1400TRX 2 is a heavy device. There are therefore risks
due to:
Suspended loads Loads may swing out and fall to the ground during lifting proced-
ures. This can lead to serious or even fatal injuries. Do not walk
underneath suspended loads, or into their swivel range. Put
down the load when you leave the work area.
Heavy weight When lifting or moving heavy loads, this can lead to back pain
and injury. Do not lift heavy loads without assistance. Use suit-
able lifting equipment or lifting tools.
2.3 Personnel, qualifications
The manual is intended for qualified specialised personnel:
Work on the HM‑1400TRX 2 must only be carried out by the fol-
lowing personnel:
●Specialised personnel are able to perform the work assigned
to them and identify hazards independently on the basis of
their technical training, knowledge and experience, as well as
their knowledge of the relevant provisions.
●With their professional training, knowledge and experience,
as well as their knowledge of the relevant standards and reg-
ulations, electricians are capable of properly carrying out work
on electrical systems and identifying potential hazards inde-
pendently. Electricians are specially trained for the working
environment in which they operate.