galvanic 943-TGX User manual

943-TGX (Hybrid)
Automatic Process UV Spectrophotometer for Tail Gas Analysis
OPERATION MANUAL
P/N:
Revision 4
April 2020
Galvanic Applied Sciences, Inc.
7000 Fisher Road S.E.
Calgary, Alberta, T2H 0W3
Canada
Toll Free (North America): 1 800 458 4544
International [phone]
E-mail: su[email protected]
www.galvanic.com

NOTICES
This system is covered by a limited warranty. A copy of the warranty is included with this manual.
The operator is required to perform routine maintenance as described herein on a periodic basis to
keep the warranty in effect. For routine maintenance procedures, refer to Section 6.
All information in this manual is subject to change without notice and does not represent a
commitment on the part of Galvanic Applied Sciences, Inc.
No part of this manual may be reproduced or transmitted in any form or by any means without the
written permission of Galvanic Applied Sciences, Inc.
Note: Changes or modifications not expressly approved by Galvanic Applied Sciences, Inc.
could void the user's authority to operate the equipment.
© Copyright 2020 Galvanic Applied Sciences, Inc. All rights reserved.
Printed in Canada

Revision 4 3 April 2020
Table of Contents
REPAIRED PRODUCTS................................................................................................................... 13
LIMITATION OF REMEDY AND LIABILITY .......................................................................................... 13
SECTION 1943-TGX (HYBRID)TAIL GAS ANALYZER INTRODUCTION................................................ 14
1.1 OVERVIEW .......................................................................................................................... 14
1.2 ANALYTICAL METHOD .......................................................................................................... 14
1.3 ANALYZER DESIGN .............................................................................................................. 15
1.4 SAMPLE HANDLING SYSTEM................................................................................................ 16
1.5 SYSTEM OPERATING CONTROL ........................................................................................... 17
1.6 CONTENTS OF THIS MANUAL ................................................................................................ 17
SECTION 2INSTALLATION ............................................................................................................... 19
2.1 RECEIVING THE SYSTEM...................................................................................................... 19
2.2 ENVIRONMENTAL REQUIREMENTS........................................................................................ 19
2.2.1 Electrical Requirements ....................................................................................... 19
2.2.2 Temperature......................................................................................................... 19
2.2.2 Space Requirements............................................................................................ 19
2.2.4 Instrument Air....................................................................................................... 20
2.2.5 Steam................................................................................................................... 20
2.2.6 Area Classification................................................................................................ 20
2.3 UNPACKING ........................................................................................................................ 20
2.4 INSTALLATION PROCEDURE................................................................................................. 21
2.4.1 Mounting of the Analyzer System ........................................................................ 22
2.4.2 Mating of the Process and Analyzer System Flanges......................................... 23
2.4.3 Installation of the Sample Probe.......................................................................... 24
2.4.3 Connection of the AC Power Service................................................................... 27
2.4.4 Connection of the Analog Signal Cables ............................................................. 27
2.4.5 Connection of the Digital Signal Cables............................................................... 28
2.4.6 Connection of the Instrument Air ......................................................................... 29
2.4.7 Connections of Steam.......................................................................................... 31
2.4.8 Connection of the Loss of Purge Signal............................................................... 31
SECTION 3OPERATION .................................................................................................................. 32
3.1 OVERVIEW .......................................................................................................................... 32
3.2 FLOW CONTROL SETTINGS.................................................................................................. 33
3.2.1 Cabinet Purge Air Flow Adjust Valve................................................................... 33
3.2.2 Cabinet Cooler Air Valve...................................................................................... 34
3.2.3 Condenser Cooling Air Flow Adjust Valve ........................................................... 35
3.2.4 Zero Air Flow Adjust Valve................................................................................... 36
3.2.5 Aspirator Drive Air Flow Adjust Valve .................................................................. 37
3.2.6 System Regulator................................................................................................. 38
3.3 ANALYZER OUTPUTS............................................................................................................ 38
3.3.1 Analog Outputs..................................................................................................... 38
3.3.2 Digital Outputs (Relays) ...................................................................................... 39
3.3.2.1 Status........................................................................................................ 39
3.3.2.2 Service...................................................................................................... 40
3.3.2.3 Mode......................................................................................................... 40
3.3.2.4 Control ...................................................................................................... 41

Revision 4 4 April 2020
3.3.2.4 Loss of Purge............................................................................................ 41
SECTION 4LOCAL SYSTEM CONTROL ............................................................................................. 43
4.1 OVERVIEW.......................................................................................................................... 43
4.2 USING THE LOCAL DISPLAY AND HANDHELD KEYPAD............................................................ 43
4.2.1 Local Display User Interface................................................................................ 43
4.2.2 The Handheld Keypad ......................................................................................... 44
4.3 ANALYSIS 1PANEL.............................................................................................................. 45
4.3.1 Online/Offline Mode Toggle ................................................................................. 45
4.3.2 Concentration Fields ............................................................................................ 45
4.3.3 Air Demand .......................................................................................................... 46
4.3.4 Relay Indicator Fields........................................................................................... 47
4.3.4 Manual Zero......................................................................................................... 47
4.3.5 Back Purge Indicator and Control........................................................................ 48
4.4 ANALYSIS 2PANEL.............................................................................................................. 49
4.4.1 Online / Offline Control......................................................................................... 50
4.4.2 Concentrations, Air Demand, and Trend Graph .................................................. 50
4.4.3 System Operating Parameters............................................................................. 51
4.5 INDICATORS PANEL............................................................................................................. 51
4.5.1 Fault Conditions .................................................................................................. 53
4.5.2 Warning Conditions.............................................................................................. 53
4.6 SPECTRUM PANEL............................................................................................................... 54
4.6.1 Factory Reference................................................................................................ 56
4.7 ABSORBANCE PANEL .......................................................................................................... 57
4.8 CONFIG PANEL ................................................................................................................... 59
4.8.1 Outputs................................................................................................................. 59
4.8.2 Calculation Sub-Panel.......................................................................................... 61
4.8.2.1 Calculation Parameters ............................................................................ 61
4.8.2.2 Cell Length................................................................................................ 62
4.8.2.3 Fixed Temperature and Pressure............................................................. 63
4.8.2.4 Sample and Zero Sample Rate ................................................................ 63
4.8.3 Display.................................................................................................................. 63
4.8.3.1 Analysis 1 and 2 Trend Graph Ranges .................................................... 63
4.8.3.2 Backlight Adjustment................................................................................ 64
4.8.4 Timers/Alarms Sub-Panel.................................................................................... 64
4.8.4.1 Timers....................................................................................................... 65
4.8.4.2 Temperature Control................................................................................. 65
4.8.4.3 Alarms....................................................................................................... 67
4.8.5 Network Sub Panel............................................................................................... 68
4.8.5.1 Direct Connect...................................................................................................... 68
4.8.5.2 Network..................................................................................................... 68
SECTION 5WEB-BASED GRAPHICAL USER INTERFACE (GUI)........................................................... 70
5.1 OVERVIEW.......................................................................................................................... 70
5.2 ANALYSIS SECTION............................................................................................................. 71
5.2.1 Analysis Page....................................................................................................... 71
5.2.1.1 Value Display............................................................................................ 72
5.2.1.2 Status and Control.................................................................................... 73
5.2.1.3 Relay Indicators........................................................................................ 73
5.2.1.4 Air Demand and H2S/SO2 Trends ........................................................... 74
5.2.2 Calibration Matrix Page........................................................................................ 75

Revision 4 5 April 2020
5.2.3 Indicators Page .................................................................................................... 76
5.2.4 Spectrum Page..................................................................................................... 78
5.2.5 Absorbance Page................................................................................................. 80
5.3 CONFIGURATION SECTION.................................................................................................... 83
5.3.1 Parameters Page ................................................................................................. 83
5.3.2 Modbus Page....................................................................................................... 86
5.3.2.1 Enron Modbus Format.............................................................................. 89
5.3.2.2 Modicon 16 Format................................................................................... 90
5.3.2.3 Modicon with Floating Point Format ......................................................... 91
5.4 FACTORY SECTION .............................................................................................................. 91
5.4.1 Changing the Passwords ..................................................................................... 94
5.5 HELP SECTION .................................................................................................................... 94
5.5.1 Drawing Page....................................................................................................... 94
5.5.2 User Manual Page................................................................................................ 95
5.5.3 Revision History Page.......................................................................................... 95
SECTION 6MAINTENANCE .............................................................................................................. 96
6.1 OVERVIEW.......................................................................................................................... 96
6.2 ROUTINE PREVENTATIVE MAINTENANCE .............................................................................. 96
6.2.1 Visual Inspection of Key Operating Parameters.................................................. 96
6.2.2 Maintenance Check Out Procedure..................................................................... 97
6.3 CHANGING THE ANTI-SOLARANT SOLUTION........................................................................ 100
6.4 OPTIMIZING THE SPECTROMETER SIGNAL ..........................................................................102
6.4.1 Automated Optimization.....................................................................................103
6.4.2 Manual Optimization .......................................................................................... 103
SECTION 7SERVICE.....................................................................................................................105
7.1 OVERVIEW........................................................................................................................105
7.2 INDICATORS PANEL TROUBLESHOOTING ............................................................................105
7.3 TESTING AND REPLACEMENT OF THE OPTICAL FIBRES.........................................................107
7.4 TROUBLESHOOTING THE UV SOURCE LAMP........................................................................ 110
7.5 MEASUREMENT CELL BLOCK REMOVAL .............................................................................115
7.6 CELL WINDOWS CLEANING /REPLACEMENT....................................................................... 116
7.8 MEASUREMENT CELL INSTALLATION ..................................................................................119
7.9 STEAM PURGING THE SAMPLE PROBE ...............................................................................120
7.10 SPECTROMETER REPLACEMENT.........................................................................................122
SECTION 8THE PRODUCT QUALITY ASSURANCE PROGRAM...........................................................126
8.1 OVERVIEW........................................................................................................................126
8.2 OVERALL SYSTEM IDENTIFICATION.....................................................................................126
8.3 QA DOCUMENT PACKAGE CHECK LIST AND REQUIREMENTS...............................................127
SECTION 9DRAWINGS..................................................................................................................128
SECTION 10 SPECIFICATIONS .........................................................................................................135
SECTION 11 RECOMMENDED SPARE PARTS ....................................................................................136
SECTION 12 INPUT /OUTPUT (IO) BOARD CONFIGURATION..............................................................137
12.1 IO BOARD WEB GUI.......................................................................................................... 137
12.2 STATUS PAGE ...................................................................................................................138

Revision 4 6 April 2020
12.3 MANUAL OVERRIDE PAGE..................................................................................................139
12.3.1 Analog Output Calibration and Testing.............................................................. 140
12.3.2 Testing the Digital Input .....................................................................................142
12.3.3 Testing Digital Outputs.......................................................................................142
INDEX 144
Figures
FIGURE 1: MODEL 943-TGX (HYBRID) .............................................................................................. 16
FIGURE 2: MOUNTING DIMENSIONS.................................................................................................... 22
FIGURE 3: SERVICE CONNECTIONS.................................................................................................... 23
FIGURE 4: HOLE PLUG IN OVEN CABINET REMOVED........................................................................... 24
FIGURE 5: OVEN ENCLOSURE TUBING REMOVED ............................................................................... 25
FIGURE 6: INSERTING THE SAMPLE PROBE ........................................................................................ 25
FIGURE 7: OVEN ENCLOSURE TUBING REINSTALLED .......................................................................... 26
FIGURE 8: LOCATION OF ACTS IN CONTROL CABINET........................................................................ 27
FIGURE 9: LOCATION OF ANALOG OUTPUT TERMINALS ON IO BOARD.................................................. 28
FIGURE 10: LOCATION OF DIGITAL OUTPUT TERMINALS ON IO BOARD ................................................ 29
FIGURE 11: LOCATION OF INSTRUMENT AIR REGULATOR.................................................................... 30
FIGURE 12: CONTROL CABINET PURGE CONTROL BOX ...................................................................... 30
FIGURE 13: LOCATION OF AIR FLOW CONTROL VALVES IN OVEN CABINET .......................................... 32
FIGURE 14: SAMPLE SYSTEM FLOW DIAGRAM.................................................................................... 33
FIGURE 15: LOCATION OF VORTEX COOLER....................................................................................... 34
FIGURE 16: SAMPLE PROBE.............................................................................................................. 35
FIGURE 17: MEASUREMENT CELL BLOCK (EXPLODED VIEW) .............................................................. 37
FIGURE 18: LOCAL DISPLAY USER INTERFACE ................................................................................... 43
FIGURE 19: HANDHELD KEYPAD ........................................................................................................ 44
FIGURE 20: ONLINE /OFFLINE MODE TOGGLE ................................................................................... 45
FIGURE 21: ANALYSIS 1CONCENTRATION FIELDS.............................................................................. 46
FIGURE 22: AIR DEMAND VALUE AND TREND ..................................................................................... 46
FIGURE 23: RELAY INDICATORS......................................................................................................... 47
FIGURE 24: MANUAL ZERO CONTROL................................................................................................ 47
FIGURE 25: BACK PURGE INDICATOR AND MANUAL CONTROLS........................................................... 49
FIGURE 26: ANALYSIS 2PANEL ......................................................................................................... 49
FIGURE 27: ONLINE /OFFLINE CONTROL ........................................................................................... 50
FIGURE 28: DATA FIELDS AND TREND GRAPH .................................................................................... 50
FIGURE 29: SYSTEM OPERATING PARAMETERS ................................................................................. 51
FIGURE 30: INDICATORS PANEL......................................................................................................... 52
FIGURE 31: SPECTRUM PANEL.......................................................................................................... 54
FIGURE 32: SPECTROMETER PARAMETERS........................................................................................ 54
FIGURE 33: INTEGRATION PERIOD DIALOG BOX ................................................................................. 56
FIGURE 34: FACTORY REFERENCE .................................................................................................... 56
FIGURE 35: ABSORBANCE PANEL ...................................................................................................... 57
FIGURE 36: ABSORBANCE SPECTRUM FOR H2S ................................................................................. 58
FIGURE 37: ABSORBANCE SPECTRUM FOR SO2................................................................................. 58
FIGURE 38: OUTPUTS SUB-PANEL..................................................................................................... 59
FIGURE 39: CALCULATION SUB-PANEL .............................................................................................. 61
FIGURE 40: DISPLAY SUB-PANEL ...................................................................................................... 63
FIGURE 41: TIMERS /ALARMS SUB-PANEL......................................................................................... 64

Revision 4 7 April 2020
FIGURE 42: NETWORK SUB-PANEL.................................................................................................... 68
FIGURE 43: CONTROLLER BOARD...................................................................................................... 69
FIGURE 44: BRIMSTONE WEB GUI SPLASH SCREEN .......................................................................... 70
FIGURE 45: NAVIGATION MENU AND TIPS........................................................................................... 71
FIGURE 46: ANALYSIS SECTION -ANALYSIS PAGE.............................................................................. 72
FIGURE 47: TREND GRAPH Y-AXIS RANGE CHANGE DIALOG BOX....................................................... 75
FIGURE 48: SPECTROMETER............................................................................................................. 75
FIGURE 49: CALIBRATION MATRIX ..................................................................................................... 76
FIGURE 50: INDICATORS PAGE .......................................................................................................... 77
FIGURE 51: SPECTRUM PAGE............................................................................................................ 78
FIGURE 52: SPECTRUM CURVE Y-AXIS MAXIMUM VALUE DIALOG BOX................................................ 79
FIGURE 53: SET INTEGRATION TIME DIALOG BOX............................................................................... 80
FIGURE 54: ABSORBANCE PAGE........................................................................................................ 81
FIGURE 55: ABSORBANCE CURVE Y-AXIS MAXIMUM VALUE DIALOG BOX............................................ 81
FIGURE 56: ABSORBANCE SPECTRUM FOR H2S ................................................................................. 82
FIGURE 57: ABSORBANCE SPECTRUM FOR SO2................................................................................. 82
FIGURE 58: CONFIGURATION PARAMETERS PAGE.............................................................................. 83
FIGURE 59: LOGIN DIALOG BOX ........................................................................................................ 85
FIGURE 60: MODBUS PAGE............................................................................................................... 86
FIGURE 61: MODBUS TYPE DIALOG BOX............................................................................................ 88
FIGURE 62: EDITING A MODBUS LIST ................................................................................................. 89
FIGURE 63: ENRON MODBUS FORMAT............................................................................................... 90
FIGURE 64: MODICON 16 FORMAT..................................................................................................... 90
FIGURE 65: MODICON 32 FORMAT..................................................................................................... 91
FIGURE 66: FACTORY PARAMETERS PAGE......................................................................................... 91
FIGURE 67: CHANGE PASSWORD DIALOG BOX................................................................................... 94
FIGURE 68: PASSWORD ENTRY ERROR MESSAGES............................................................................ 94
FIGURE 69: REVISION HISTORY......................................................................................................... 95
FIGURE 70: REPLACING THE ANTI-SOLARANT SOLUTION .................................................................. 101
FIGURE 71: INDICATORS PANEL....................................................................................................... 105
FIGURE 72: LOCATION OF CELL HEATER FUSE ON ACTS.................................................................108
FIGURE 73: UV LAMP ENCLOSURE ..................................................................................................112
FIGURE 74: UV LAMP ENCLOSURE INTERNAL LAYOUT......................................................................113
FIGURE 75: UV LAMP ORIENTATION ................................................................................................ 113
FIGURE 76: OVEN ENCLOSURE........................................................................................................ 116
FIGURE 77: MEASUREMENT CELL BLOCK (EXPLODED VIEW)............................................................ 117
FIGURE 78: SPECTROMETER...........................................................................................................122
FIGURE 79: UTILITY PAGE............................................................................................................... 124
FIGURE 80: SPECTROMETER CALIBRATION MATRIX PDF EXAMPLE...................................................124
FIGURE 81: MOUNTING AND SERVICE CONNECTIONS .......................................................................128
FIGURE 82: OVEN CABINET DOOR REMOVED................................................................................... 129
FIGURE 83: CONTROL CABINET DOOR REMOVED.............................................................................130
FIGURE 84: POWER,STEAM,AIR,SIGNALS CONNECTION DETAILS....................................................131
FIGURE 85: AC WIRING SCHEMATIC................................................................................................132
FIGURE 86: DC SIGNALS AND WIRING DIAGRAM ..............................................................................133
FIGURE 87: FLOW DIAGRAM............................................................................................................134
FIGURE 88: IO BOARD WEB GUI......................................................................................................137
FIGURE 89: STATUS PAGE ..............................................................................................................138
FIGURE 90: MANUAL OVERRIDE PAGE............................................................................................. 140
FIGURE 91: ANALOG OUTPUT TERMINAL BLOCK P3 .........................................................................141
FIGURE 92: RELAY CONNECTION TERMINAL BLOCK P4 .................................................................... 143

Revision 4 8 April 2020
Tables
TABLE 1: AMBIENT TEMPERATURE RANGE BY MODEL........................................................................ 19
TABLE 2:STEAM SUPPLY REQUIREMENTS ......................................................................................... 20
TABLE 3:STATUS RELAY STATES...................................................................................................... 39
TABLE 4:SERVICE RELAY STATES..................................................................................................... 40
TABLE 5:MODE RELAY STATES......................................................................................................... 40
TABLE 6:CONTROL RELAY STATES ................................................................................................... 41
TABLE 7:KEYPAD RED KEY FUNCTIONS ............................................................................................ 44
TABLE 8:SYSTEM OPERATING PARAMETERS ..................................................................................... 51
TABLE 9:ANALYZER FAULTS ............................................................................................................. 53
TABLE 10: ANALYZER WARNINGS ...................................................................................................... 53
TABLE 11: SPECTROMETER PARAMETERS ......................................................................................... 55
TABLE 12: ANALOG OUTPUT PARAMETERS ........................................................................................ 60
TABLE 13: CALCULATION PARAMETERS ............................................................................................. 62
TABLE 14: TIMERS PARAMETERS....................................................................................................... 65
TABLE 15: TEMPERATURE CONTROL PARAMETERS ............................................................................ 66
TABLE 16: ALARMS PARAMETERS...................................................................................................... 67
TABLE 17: VALUE DISPLAY PARAMETERS........................................................................................... 72
TABLE 18: STATUS AND CONTROL..................................................................................................... 73
TABLE 19: RELAY INDICATORS .......................................................................................................... 74
TABLE 20: ANALYZER FAULTS ........................................................................................................... 77
TABLE 21: ANALYZER WARNINGS ...................................................................................................... 78
TABLE 22: SPECTRUM PARAMETERS ................................................................................................. 79
TABLE 23: PARAMETERS PAGE COLOUR CODE.................................................................................. 83
TABLE 24: CONFIGURATION PARAMETERS ......................................................................................... 84
TABLE 25: MODBUS COMMUNICATION PARAMETERS .......................................................................... 87
TABLE 26: AVAILABLE MODBUS POINTS............................................................................................. 88
TABLE 27: MODBUS LIST COLUMNS................................................................................................... 89
TABLE 28: FACTORY PARAMETERS COLOUR CODE ............................................................................ 92
TABLE 29: FACTORY PARAMETERS.................................................................................................... 92
TABLE 30: NORMAL OPERATING PARAMETER AND INDICATOR CONDITIONS......................................... 97
TABLE 31: MAINTENANCE RECORD SHEET......................................................................................... 99
TABLE 32: ANALYZER FAULT /WARNING TROUBLESHOOTING ........................................................... 106
TABLE 33: LAMP TROUBLESHOOTING............................................................................................... 111
TABLE 34: DOCUMENT PACKAGE CHECKLIST ...................................................................................127
TABLE 35: RECOMMENDED SPARE PARTS -1YEAR KIT ................................................................... 136
TABLE 36: RECOMMENDED SPARE PARTS -2YEAR KIT ................................................................... 136
TABLE 37: IO BOARD WEB GUI PAGES ........................................................................................... 138
TABLE 38: STATUS PAGE SECTIONS................................................................................................139

Revision 4 9 April 2020
Safety Symbols used in Manual
The Danger symbol indicates a hazardous situation that, if not
avoided will result in death or serious injury.
The Warning symbol indicates a hazardous situation that, if not
avoided could result in death or serious injury.
The Caution symbol with the safety alert symbol indicates a
hazardous situation that, if not avoided could result in minor or
moderate injury.
The Notice symbol is used to highlight information that will
optimize the use and reliability of the system.

Revision 4 10 April 2020
Important Safety Guidelines for the 943-TGX (Hybrid)
Field Programmable Tail Gas Analyzer System
Please read the following warnings and cautions carefully before using the 943-TGX (Hybrid) Tail Gas
Analyzer System:
This equipment must be used as specified by the manufacturer or overall safety will
be impaired.
Access to this equipment should be limited to authorized, trained personnel ONLY.
Due to the thermal mass of the hardware, cooling of the items takes substantial
time.
Observe all warning labels on the analyzer enclosures.
Install fuses of the Type and Rating as shown on the Fuse Identifier labels.
The analog outputs and alarm relay contacts may be powered by a source separate from the
one(s) usedto power the analyzer system. Disconnecting the AC Mains Source (s) maynot remove
power from the analog output signals.
Any safety recommendations or comments contained herein are suggested guidelines only.
Galvanic Applied Sciences Inc. bears no responsibility and assumes no liability for the use and/or
implementation of these suggested procedures.
This system, when operating in its normal mode, and/or when it is being serviced, maintained,
installed and commissioned contains items which may be hazardous to humans if handled or
operated incorrectly or negligently. These items include, but are not limited to:
High Voltage Electrical Energy
Toxic and Explosive Gases
Intense Ultraviolet Radiation
High Temperature Surfaces
Installation of the system requires the opening of the process sample point to allow for the insertion
of the system sample probe assembly. To achieve this, removing the process access point blind
flange is necessary. When the flange is removed, toxic, hot (approximately 150ºC/300ºF) gases
and molten sulfur may be expelled to the atmosphere until the system sample probe and its
associated flange are in place and securely fastened.
It is recommended that the personnel installing the probe wear plant approved breathing air
apparatus, and approved personal protective equipment (i.e. gloves, coveralls and protective eye

Revision 4 11 April 2020
wear) suitable for high temperature work. This applies even if the Tail Gas Line (Process Stream)
is believed to be at negative pressure.
During normal operation, toxic gases, (H2S, SO2, COS and CS2) are present in the tubing,
measurement cell, aspirator and all other system components through which the tail gas sample
flows. They should not be opened before the complete system is purged with zero gas (an inert
gas or instrument air), and the system is blocked using the two valves in the sample oven identified
as the Sample Flow and Vent Flow on/off valves.
Purging of the system should be performed with both valves in the open position and maintained
for approximately five (5) minutes. Once purging is complete, and with the purge gas still flowing,
the two valves should be switched to the Off position. The purge gas can now be shut off and the
tubing or associated apparatus opened.
The sampling system will be under positive pressure. Loosen a fitting and allow the pressure to be
released before completely disconnecting the tubing.
The entire system is enclosed in an oven cabinet that is heated and maintained at approximately
150ºC/300ºF to prevent the condensation of sulfur. Maintenance performed before the cooling of
the oven and hardware should be done while wearing suitable protective clothing, eye wear, and
gloves to prevent burns to the hands and arms.
The system includes an Ultraviolet spectrometer which employs a source that generates intense
UV radiation that is transmitted to the measurement cell and spectrometer through fibre optic
cables.
This radiation is extremely harmful to the naked eye and skin, even in short duration exposures.
Always extinguish the UV radiation source (lamp) before removing a fibre optic cable or the lamp
power supply cover by turning the AC power to the lamp power supply ‘Off’. Should the lamp be
turned on for any reason while the cover is off, ensure that certified eye protection is worn, and that
the exposure is limited to the bare minimum.
Although the UV radiation is transmitted through a narrow diameter fibre, it should never be viewed
directly. The beam is extremely intense and will cause permanent eye damage. Should visual
inspection of the beam be required, point the end of the fibre at an inanimate object and view the
illumination reflection. Never expose human skin to the radiation from the optical fibres.
943-TGX (Hybrid) (Hybrid) (CSA)
Class I, Division 2, Groups C and D, Temperature Code T3, Type Z Purge
IP Protection: NEMA 4
Ambient Temperature: +5°C to 40°C
The control cabinet purge gas is to be instrument air only.

Revision 4 12 April 2020
Manufacturer’s Warranty Statement
Galvanic Applied Sciences Inc. (“Seller”) warrants that its products will be free from defects in materials
and workmanship under normal use and service in general process conditions for 12 months from the
date of Product start-up or 18 months from the date of shipping from Seller’s production facility,
whichever comes first (the “Warranty Period”). Products purchased by Seller from a third party for
resale to Buyer ("Resale Products") shall carry only the warranty extended by the original
manufacturer. Buyer agrees that Seller has no liability for Resale Products beyond making a
reasonable commercial effort to arrange for procurement and shipping of the Resale Products. Buyer
must give Seller notice of any warranty claim prior to the end of the Warranty Period. Seller shall not
be responsible for any defects (including latent defects) which are reported to Seller after the end of
the Warranty Period.
THIS WARRANTY AND ITS REMEDIES ARE IN LIEU OF ALL OTHER WARRANTIES OR
CONDITIONS EXPRESSED OR IMPLIED, ORAL OR WRITTEN, EITHER IN FACT OR BY
OPERATION OF LAW, STATUTORY OR OTHERWISE, INCLUDING BUT NOT LIMITED TO,
WARRANTIES OR CONDITIONS OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE, WHICH SELLER SPECIFICALLY DISCLAIMS.
Seller’s obligation under this warranty shall not arise until Buyer notifies Seller of the defect. Seller’s
sole responsibility and Buyer’s sole and exclusive remedy under this warranty is, at Seller’s option,
to replace or repair any defective component part of the product upon receipt of the Product at
Seller’s production facility, transportation charges prepaid or accept the return of the defective
Product and refund the purchase price paid by Buyer for that Product. If requested by Buyer, Seller
will use its best efforts to perform warranty services at Buyer’s facility, as soon as reasonably
practicable after notification by the Buyer of a possible defect provided that Buyer agrees to pay for
travel time, mileage from the Seller’s facility or travel costs to the airport / train station closest to
Buyer’s facility plus all other travel fees, hotel expenses and subsistence.
Except in the case of an authorized distributor or seller, authorized in writing by Seller to extend
this warranty to the distributor’s customers, the warranty herein applies only to the original
purchaser from Seller (“Buyer”) and may not be assigned, sold, or otherwise transferred to a third
party. No warranty is made with respect to used, reconstructed, refurbished, or previously owned
Products, which will be so marked on the sales order and will be sold “As Is”.
Limitations
These warranties do not cover:
•Consumable items such as lamps.
•Analyzer components which may be damaged by exposure to contamination or fouling
from the process fluid due to a process upset, improper sample extraction techniques or
improper sample preparation, fluid pressures in excess of the analyzer’s maximum rated
pressure or fluid temperatures in excess of the analyzer’s maximum rated
temperature. These include but are not limited to sample filters, pressure regulators,
transfer tubing, sample cells, optical components, pumps, measuring electrodes, switching
solenoids, pressure sensors or any other sample wetted components.
•Loss, damage, or defects resulting from transportation to Buyer’s facility, improper or
inadequate maintenance by Buyer, software or interfaces supplied by Buyer, operation

Revision 4 13 April 2020
outside the environmental specifications for the instrument, use by unauthorized or
untrained personnel or improper site maintenance or preparation.
•Products that have been altered or repaired by individuals other than Seller personnel or
its duly authorized representatives, unless the alteration or repair has been performed by
an authorized factory trained service technician in accordance with written procedures
supplied by Seller.
•Products that have been subject to misuse, neglect, accident, or improper installation.
•The sole and exclusive warranty applicable to software and firmware products provided by
Seller for use with a processor internal or external to the Product will be as follows: Seller
warrants that such software and firmware will conform to Seller’s program manuals or other
publicly available documentation made available by Seller current at the time of shipment
to Buyer when properly installed on that processor, provided however that Seller does not
warrant the operation ofthe processor orsoftware or firmwarewill be uninterrupted or error-
free.
The warranty herein applies only to Products within the agreed country of original end destination.
Products transferred outside the country of original end destination, either by the Seller at the
direction of the Buyer or by Buyer’s actions subsequent to delivery, may be subject to additional
charges prior to warranty repair or replacement of such Products based on the actual location of
such Products and Seller’s warranty and/or service surcharges for such location(s).
Repaired Products
Repaired products are warranted for 90 days with the above exceptions.
Limitation of Remedy and Liability
IN NO EVENT SHALL SELLER BE LIABLE TO BUYER FOR ANY INDIRECT, CONSEQUENTIAL,
INCIDENTAL, SPECIAL OR PUNITIVE DAMAGES, OR FOR ANY LOSS OF USE OR
PRODUCTION, OR ANY LOSS OF DATA, PROFITS OR REVENUES, OR ANY CLAIMS RAISED
BY CUSTOMERS OF BUYER OR ANY ENVIRONMENTAL DAMAGE OR ANY FINES IMPOSED
ON BUYER BY ANY GOVERNMENTAL OR REGULATORY AUTHORITIES, WHETHER SUCH
DAMAGES ARE DIRECT OR INDIRECT, AND REGARDLESS OF THE FORM OF ACTION
(WHETHER FOR BREACH OF CONTRACT OR WARRANTY OR IN TORT OR STRICT
LIABILITY) AND WHETHER ADVISED OF THE POSSIBILITY OF SUCH DAMAGES OR NOT.

Revision 4 14 April 2020
Section 1 943-TGX (Hybrid) Tail Gas Analyzer
Introduction
1.1 Overview
The use of a Tail Gas Analyzer to assist in the control of combustion air to acid gas ratios in
Claus Sulfur Recovery Plants is a standard procedure in industry. The plant tail gas is analyzed
using ultraviolet spectroscopy and an output signal that corresponds to the air requirement is
determined. This observed signal is proportional to the percentage change required in the
combustion air to provide stoichiometric concentrations of the principal reactants; H2S and SO2.
When the process is optimized and the correct stoichiometric concentrations of H2S and SO2
are achieved, the feedback signal (normally referred to as Air Demand) is zero (which means
that no change is required).
The simplified Air Demand equation is:
    󰇛󰇟󰇠 󰇟󰇠󰇜
where:
F = plant specific gain factor
[H2S] = concentration of H2S
[SO2]= concentration of SO2
Rop = operating ratio (typically 2)
When the ratio of stoichiometric concentration of H2S to SO2 equals the operating ratio (Rop),
the Air Demand output becomes zero regardless of the plant specific gain factor (Plant
Factor) (F). When the plant factor (F) is established for a particular process, the units of Air
Demand become ‘percent change required in process air’. (i.e., a computed Air Demand of
+1.5% means that the process is 1.5% excess in air.) To achieve optimum performance of the
Claus Sulfur Recovery Plant, the Air Demand should be kept near zero.
The sample gas obtained from the sulfur plant waste or tail gas stream may also contain other
sulfur species such as COS, CS2, and sulfur vapour (Svap). These species, if present in
significant concentrations, must be analyzed for and a correction be made to avoid interference
with the H2S and SO2 analysis.
1.2 Analytical Method
The analyzer uses a spectrometer with a diffraction grating that is optimized in the spectral
region where the species ofinterest,namely hydrogensulfide (H2S), sulfur dioxide (SO2), carbon
disulfide (CS2), carbonyl sulfide (COS), and sulfur vapour (Svap) absorb (the compounds of
interest absorb between 200 and 400 nm) coupled to a detection system that maximizes
sensitivity and resolution while minimizing dark current and stray light noise. A 2048 element
CCD detector is employed to detect light across the wavelength range of interest.
The UV radiation is supplied by a highly stable deuterium broadband source and is transmitted
to/from the measurement cell via UV fibre optic cables. This approach provides for analytical

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accuracy and allows for more precise multi-species analysis than that of a conventional
photometer which uses narrow band optical filters. The conventional photometer measures only
a few discrete wavelengths, and spectrometers having lower resolution and fewer elements in
the detector are also less precise.
If, as is frequently the case, more than one of the sulfur-containing compounds indicated above
are present, their spectra will overlap. The system uses a deconvolution protocol to separate
the signals for each component via a multi component algorithm known as the calibration
matrix .
1.3 Analyzer Design
The Model 943-TGX (Hybrid) Analyzer System is packaged in two (2) frame mounted cabinets:
1. An oven cabinet which contains the sample handling system and associated
hardware (i.e., solenoids, oven, heaters, etc.). All electrical equipment residing in the
oven cabinet is installed using appropriate explosion proof and/or intrinsically safe
wiring methods.
2. A control cabinet which contains the electrical hardware necessary for the operation
of the analyzer. Under normal operating circumstances, the interior of the control
cabinet maintains a general-purpose area classification using a Type-Z positive
pressure purge system. Both visual and electrical (contact closure) indications are
provided for monitoring the status of the control cabinet purge. Temperature control for
the control cabinet is provided by an instrument air driven Vortec vortex cooler.
All connections passing from the control cabinet to the oven cabinet are via gas-tight bulkhead
connections to prevent any process gases from passing from the oven cabinet into the control
cabinet.
An external keypad is provided for navigation of the analyzer’s user interface and for
modification of analyzer operating parameters. This keypad is connected to a port on the control
cabinet door.
The Model 943-TGX (Hybrid) uses a hybrid steam / electric heating system for the
measurement cell block and the associated sample handling system.
A drawing of the Model 943-TGX (Hybrid) is shown in Figure 1.

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Figure 1: Model 943-TGX (Hybrid)
1.4 Sample Handling System
The Analyzer system utilizes a close coupled mounting arrangement of the measurement cell
block to thetail gas process sampling point to minimize the sample handling system length. The
short length allows for analyzer response times to be optimized while sample transport problems
are mitigated. A small volume of tail gas sample is drawn through the measurement cell by use
of an air-driven aspirator where the concentrations of the various species are determined
photometrically.
The measurement sample is drawn from a central point of the process duct using a specifically
sized sample probe. After measurement, the process sample (mixed with the aspirator drive
air) is vented to the wall of the process duct. The concentric chamber design of the sample
probe provides both the sampling and venting of the tail gas sample through a single sampling
point on the process duct.
The sample probe incorporates a mechanism for reducing the dew point of sulfur vapour in the
sampled gas stream. Instrument air can be introduced to provide an exposed cool surface. to
the incoming sample gas. Excess condensed sulfur is hydrostatically returned to the process
duct. The sulfur vapour concentration is measured and displayed on the analyzer display. The
sulfur vapour concentration is useful for system troubleshooting.
Incoming sample gas is filtered to 60 micron and drawn through the measurement cell by the
aspirator. The measurement cell exposes a known length of sample to UV radiation for
spectroscopic analysis. The aspirator is integral to the measurement cell and uses instrument
air (or other inert gas) as the aspirator drive gas. The analyzer turns on the aspirator drive media
only when no analyzer faults are detected. In the event of a fault condition, the analyzer
automatically purges the entire sample handling system with instrument air.
Analyzer zeroing is accomplished by introducing higher pressure instrument air (or other inert
gas) upstream of the measurement cell. The zero gas flushes the entire sample handling system
(probe to vent) and allows readings to be taken through the measurement cell when no
absorbing species are present. To the sample system, zeroing and back purging are the same
thing. The default state (power ‘off’) of the analyzer is to have the sample system in the back
purge mode. Valving is provided for isolating the sample system components from the process

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stream. A provision is included in the oven plumbing for the steam purging of the sample probe
after a plant shut-down or turn-around, or in the event of plugging of the sample probe, should
it be required.
A temperature-controlled oven enclosure maintains all components exposed to the tail gas
sample athigher than dew point values. The oven and sample probe are mounted to an interface
plate, which in turn is directly mounted to the steam heated process duct sample nozzle
(typically a 2-inch, 150 pound pipe flange configuration). Electrical heat is applied to the
measurement cell to achieve precise temperature control of the entire oven enclosure, which
contains the measurement cell block and the associated sample handling system tubing and
valves. This electrical heat is supplemented using a steam heater in the bottom of the oven
enclosure that provides additional heat from a medium pressure steam source.
1.5 System Operating Control
The analyzer system operation is controlled by a dedicated data acquisition system which
provides supervisory control of all analyzer inputs and outputs, performs all calculations, and
provides the user interface.
The system includes an onboard computer system which provides a graphic display of key
system control parameters and their status, a digital display of the instantaneous value of the
Air Demand, H2S, SO2, and COS, and historical graphic displays of the Air Demand, H2S and
SO2. The entire control computer system, consisting of a Control Board and a Display Board,
is mounted on the door of the control cabinet. Control cabinet access is not required for viewing
or operation.
The measurement of carbonyl sulfide (CS2) is an optional measurement. Analyzers
which have not been ordered with this option cannot measure CS2.
Four loop-powered 4 –20 mA analog outputs are provided for the output of analyzer
measurement parameters. These four analog outputs are user-configurable for the output
parameter and range. Additionally, four solid-state relay outputs are provided for the output of
system status data. An RS485 serial port is also provided which can be used for available for
Modbus communication. Two Ethernet ports are provided for use either for Modbus TCP/IP
communication OR for connection of a computer for GUI access. Aside from the Ethernet ports,
one of which is located on the front door of the control cabinet and the other which is located on
the control board, all inputs and outputs are found on the analyzer’s Input / Output Board inside
the control cabinet.
A handheld keypad is provided for user interface with the analyzer. Operation of the system
with the keypad is described in Section 4. As an alternative, a web based graphical user
interface (GUI) can be used to view and enter information on a remote basis. Operation using
the web GUI is described in Section 5.
1.6 Contents of this Manual
This manual contains the following information:
Section 1: 943-TGX (Hybrid) Tail Gas Analyzer Introduction presents introductory
information about the analyzer system.

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Section 2: Installation describes unpacking the analyzer, installing it in the facility and
interfacing with other devices.
Section 3: Operation of the System explains how the operator interacts with the analyzer.
Section 4: Local System Control describes how the user enters data and views system
parameters using the keypad and the local display
Section 5: Web-based Graphical User Interface describes how to operate the analyzer
and edit the analyzer configuration using the web-based graphical user interface.
Section 6: Maintenance describes the various regular maintenance procedures that
should be followed to keep the analyzer functioning normally.
Section 7: Service gives some important service procedures that may be necessary to
keep the analyzer in operational condition.
Section 8: Product Quality Assurance includes various documentation of the Quality
Assurance that was done at the factory prior to shipping.
Section 9: Drawings gives a variety of generic drawings related to the analyzer system.
Section 10: Spare Parts lists a number of items which may be required to maintain
operation of the analyzer.
Section 11: Specifications presents the specifications for the analyzer.
Section 12: Input / Output Board Configuration provides information for the testing and
calibration of the various inputs and outputs available on the analyzer’s IO board.

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Section 2 Installation
The initial installation of the analyzer system is usually completed by the purchaser.
The start-up and commissioning is usually performed by Galvanic Applied Sciences
Inc. personnel.
2.1 Receiving the System
When the system arrives, inspect the packaging for external signs of damage. If there is any
obvious physical damage, contact the shipping agent and Galvanic Applied Sciences to report
the damage and request that the carrier's agent be present when the unit is unpacked. It is
recommended that you retain the shipping container so that it may be used for future shipment
of the unit, if necessary.
2.2 Environmental Requirements
2.2.1 Electrical Requirements
The power input is 100 –240 Vac, 1 phase, 50/60 Hz, 800 W. The operating voltage is
specified on the serial number name plate
2.2.2 Temperature
The ambient temperature range the analyzer can operate in is shown in Table 1.
Table 1: Ambient Temperature Range by Model
Model
Ambient Temperature Range
943-TGX (Hybrid)
+5 to 40°C (41 to 104°F)
Galvanic offers complete analyzer shelters from sunshades to complete buildings; please
contact Galvanic Applied Sciences, Inc. (or your local representative) for additional
information.
2.2.2 Space Requirements
The 943-TGX (Hybrid) system is composed of two cabinets mounted side by side on a
mounting frame. The dimensions of each cabinet are 30” (76 cm) H x 24” (61 cm) W x 12”
(30 cm) D. The overall outer dimension of the system with the mounting frame is 41.75” (106
cm) H x 57” (145 cm W) x 16” (41 cm) D. The weight of the system is approximately 275 lb
(125 kg); the exact weight will depend on the specifics of the analyzer. The installation
location should allow both cabinet doors to swing open to at least 90 degrees. The analyzer
should also be mounted so that the analyzer display is at or near eye level for ease of
operation.

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2.2.4 Instrument Air
The system requires instrument air at 55 to 116psig (3.8 to 8 barg) at a delivery rate of 22
SCFM (37m3/ h). Instrument air is used for cabinet cooling, cabinet purge, zero gas, and
aspirator drive air, so it is essential that the provided air meet the above pressure and flow
rate requirements. The instrument air must be clean and dry, and meet the requirements for
instrument air stipulated in ANSI/ISA Standard 57.3-1975 R (1981).
2.2.5 Steam
For the Model 943-TGX (Hybrid), two steam supplies are required, as indicated in Table 2.
Table 2: Steam Supply Requirements
Location
Minimum
Pressure
Maximum
Pressure
Minimum
Temperature
Maximum
Temperature
Sample
Probe Nozzle
2.8 barg
(40 psig)
5.5 barg
(80 psig)
140°C (285°F)
160°C
(320°F)
Measurement
Cell Oven
9.65 barg
(140 psig)
11.7 barg
(170 psig)
150°C (302°F)
200°C
(392°F)
2.2.6 Area Classification
The hazardous area classification and ingress protection for the Model 943-TGX (Hybrid)
is shown below:
2.3 Unpacking
The 943-TGX (Hybrid) analyzer system is packed for shipment in a wooden crate.
Galvanic Applied Sciences Inc. advises unpacking the system according to the following
procedure.
1. Remove the lid by undoing the marked lag bolts.
2. Once the lid is off, remove the excess packing material, boxes and sample probe from
the shipping crate. The sample probe will be wrapped in packing material. Probes with
a guide length of 5.5 feet (165cm) or longer are packed in a separate crate.
3. Visually inspect the small packages and the sample probe to ensure that no major
damage has occurred. If damage has occurred, contact the shipping company and
Galvanic Applied Sciences. Place the small packages and the sample probe aside in
943-TGX (Hybrid)
Class I, Division 2, Groups C and D, Temperature Code T3, Type Z Purge
IP Protection: NEMA 4