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