Thermo Scientific Mercury Freedom 80i User manual

Mercury System Manual
Part Number 105933-00
28Jan2008

© 2007 Thermo Fisher Scientific Inc. All rights reserved.
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Thermo Fisher Scientific
Air Quality Instruments
27 Forge Parkway
Franklin, MA 02038
1-508-520-0430
www.thermo.com/aqi

Thermo Fisher Scientific Mercury System Manual i
About This Manual
This manual provides information about installing, maintaining, and
servicing the Mercury System.It also contains important alerts to ensure
safe operation and prevent equipment damage. The manual is organized
into the following chapters and appendices to provide direct access to
specific operation and service information.
●Chapter 1 “Introduction” provides an overview of Mercury System
instruments and describes associated Mercury System components.
●Chapter 2 “System Installation, Set Up and Shut Down” describes how
to setup, start up, and shut down the instrument. It also provides the
recommended initial parameter settings.
●Chapter 3 “Calibration” provides the manual system calibration
procedure, the auto system calibration procedure, and the calibration
check procedure.
●Chapter 4 “Troubleshooting” presents guidelines for diagnosing
instrument failures, isolating faults, and includes recommended actions
for restoring proper operation.
●Chapter 5 “Preventive Maintenance” describes the periodic
maintenance procedures that should be performed on the system
instruments and components to ensure proper operation.
●Chapter 6 “Optional Equipment” describes the optional equipment
that can be used with the Mercury System.
●Appendix A “Warranty” is a copy of the warranty statement.
●Appendix B “System Reference Drawings” provides the plumbing and
electrical drawings for the Mercury System instruments and associated
components.
●Appendix C “Flowcharts of Menu-Driven Firmware” presents detailed
flowcharts for the 80iand the 81imenu-driven firmware. They are
provided here for convenience in navigating the Mercury System
menus and screens.

ii Mercury System Manual Thermo Fisher Scientific
This manual contains important information to alert you to potential
safety hazards and risks of equipment damage. Refer to the following types
of alerts you may see in this manual.
Safety and Equipment Damage Alert Descriptions
Alert Description
DANGER A hazard is present that will result in death or serious
personal injury if the warning is ignored. ▲
WARNING A hazard is present or an unsafe practice can result in
serious personal injury if the warning is ignored. ▲
CAUTION The hazard or unsafe practice could result in minor to
moderate personal injury if the warning is ignored. ▲
Equipment Damage The hazard or unsafe practice could result in property
damage if the warning is ignored. ▲
Safety and Equipment Damage Alerts in this Manual and in the individual
Mercury instruction manuals.
Alert Description
WARNING If the equipment is operated in a manner not specified by
the manufacturer, the protection provided by the
equipment may be impaired. ▲
The service procedures in this manual are restricted to
qualified service personnel only. ▲
This product is supplied with a three-wire grounding
cord. Under no circumstances should this grounding
system be defeated. ▲
Equipment Damage Do not attempt to lift the instrument by the cover or other
external fittings. ▲
To prevent damaging the probe transducer, read the
cable labels carefully and DO NOT connect the C or D
cable to the wrong connector on the 82irear panel.
Some internal components can be damaged by small
amounts of static electricity. A properly ground antistatic
wrist strap must be worn while handling any internal
component. If an antistatic wrist strap is not available, be
sure to touch the instrument chassis before touching any
internal components. When the instrument is unplugged,
the chassis is not at earth ground. ▲
Handle all printed circuit boards by the edges only. ▲
Do not remove the panel or frame from the LCD module.
Safety and Equipment
Damage Alerts

Thermo Fisher Scientific Mercury System Manual iii
Alert Description
▲
The LCD module polarizing plate is very fragile, handle it
carefully. ▲
Do not wipe the LCD module polarizing plate with a dry
cloth, it may easily scratch the plate. ▲
Do not use Ketonics solvent or aromatic solvent to clean
the LCD module, use a soft cloth moistened with a
naphtha cleaning solvent. ▲
Do not place the LCD module near organic solvents or
corrosive gases. ▲
Do not shake or jolt the LCD module. ▲
Service is available from exclusive distributors worldwide. Contact one of
the phone numbers below for product support and technical information
or visit us on the web at www.thermo.com/aqi.
1-866-282-0430 Toll Free
1-508-520-0430 International
W
here to Get
Help

Thermo Fisher Scientific Mercury System Manual v
Contents
Introduction........................................................................................................ 1-1
System Overview................................................................................. 1-1
Model 80i........................................................................................... 1-1
Model 81i........................................................................................... 1-2
Model 82i........................................................................................... 1-4
Pneumatics....................................................................................... 1-5
Electronics ....................................................................................... 1-5
Electrical Power ............................................................................... 1-6
Model 83i........................................................................................... 1-6
Model 83i GC .................................................................................. 1-10
Mercuric Chloride Generator............................................................ 1-11
Component Description ................................................................ 1-11
Oxidizer Weldment .................................................................... 1-11
Heater......................................................................................... 1-11
Heater Block............................................................................... 1-12
Thermocouple ............................................................................ 1-12
Insulation.................................................................................... 1-12
Oxidizer Enclosure...................................................................... 1-12
Hydrator........................................................................................... 1-13
Nitrogen Generator........................................................................... 1-14
Zero Air Supply ................................................................................ 1-14
Scrubber Assembly ............................................................................ 1-15
Stack Mounting Flange..................................................................... 1-15
Umbilical Cable ................................................................................ 1-16
Mercury System Instruction Manuals................................................ 1-16
System Installation, Set Up and Shut Down................................................ 2-1
Lifting................................................................................................. 2-1
Hg CEMS Requirements .................................................................... 2-1
Plumbing and Electrical Hookup........................................................ 2-2
Set Temperature Defaults ................................................................... 2-2
Mercury CEMS Power-Up Sequence.................................................. 2-2
Start-Up.............................................................................................. 2-3
System Checkout ................................................................................ 2-4
Recommended Initial Parameter Settings............................................ 2-6
Initial Service Settings ...................................................................... 2-6
Set-up Blowback Schedule ............................................................... 2-6
80iAlarms Settings .......................................................................... 2-7
Probe Alarms Settings ...................................................................... 2-7
Chapter 1
Chapter 2

vi Mercury System Manual Thermo Fisher Scientific
Normal Operational Parameters (with 83i) ...................................... 2-8
Normal Operational Parameters (with 83i GC) ............................. 2-10
Nitrogen Generator Venting ............................................................. 2-10
Shut Down the System (prior to removal)......................................... 2-10
Updating Firmware........................................................................... 2-11
Calibration ..........................................................................................................3-1
Manual System Calibration................................................................. 3-1
Auto System Calibration ..................................................................... 3-3
Calibration Check Procedures............................................................. 3-4
Zero / Span Check Set-up ................................................................ 3-4
Troubleshooting.................................................................................................4-1
Safety Precautions ............................................................................... 4-1
System Troubleshooting Guides.......................................................... 4-1
Before Calling for Service Support ................................................... 4-1
Most Common Service Calls............................................................ 4-2
Power-Up Failures ........................................................................... 4-3
Alarm Messages................................................................................ 4-4
System Zero and Calibration Troubleshooting................................. 4-7
Establishing Communication Between Instruments in the Mercury
System............................................................................................ 4-11
Cabling Instruments in the Mercury System .................................. 4-11
Direct Connection ...................................................................... 4-11
Hub/Router Connection............................................................. 4-12
Hub/Router Connection with UPLINK ..................................... 4-12
Firmware and Communications Troubleshooting .......................... 4-12
Troubleshooting Interface Board Voltages...................................... 4-13
Probe Troubleshooting with 82iLEDs........................................... 4-15
Troubleshooting 82iInterface Board LEDs.................................... 4-16
Oxidizer Troubleshooting .............................................................. 4-16
Troubleshooting - Miscellaneous.................................................... 4-18
Service Locations............................................................................... 4-19
Preventive Maintenance .................................................................................5-1
Safety Precautions ............................................................................... 5-1
System Preventive Maintenance .......................................................... 5-2
Heated Umbilical................................................................................ 5-2
Heated Umbilical Maintenance........................................................ 5-3
Service Locations................................................................................. 5-4
Optional Equipment...........................................................................................6-1
Mercuric Chloride Generator.............................................................. 6-1
Hydrator ............................................................................................. 6-1
Hydrator Installation........................................................................ 6-1
Chapter 3
Chapter 4
Chapter 5
Chapter 6

Thermo Fisher Scientific Mercury System Manual vii
System Preparation ....................................................................... 6-1
Equipment Installation on Rack Exterior ...................................... 6-2
Equipment Installation on Rack Interior....................................... 6-3
Retrofit Instructions For Fielded Mercury Systems ....................... 6-3
Electrical Connections .................................................................. 6-4
Pneumatic Connections ................................................................ 6-5
80iInput/Output Configuration .................................................. 6-5
Functional Check.......................................................................... 6-6
Zero Air Supply .................................................................................. 6-7
Nitrogen Generator............................................................................. 6-7
Specifications ................................................................................... 6-7
Sources of Compressed Air............................................................. 6-10
Generator Performance .................................................................. 6-10
Recommended Configuration ........................................................ 6-10
Retrofitting Older Systems............................................................. 6-10
Warranty.............................................................................................................A-1
System Reference Drawings..........................................................................B-1
Flowcharts of Menu-Driven Firmware.........................................................262HC-1
105HIndex..................................................................................................................... I-263H1
99HAppendix A
101HAppendix B
103HAppendix C