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

Thermo Fisher Scientific Mercury System Manual ix
Figures
Figure 1–1. Model 80iFlow Diagram..................................................................1-2
Figure 1–2. Model 81iFlow Diagram..................................................................1-4
Figure 1–3. Model 82iProbe Controller Flow Diagram ......................................1-5
Figure 1–4. Model 83iProbe Flow Diagram .......................................................1-8
Figure 1–5. Model 83iProbe Flow Diagram with Oxidizer.................................1-9
Figure 1–6. Oxidizer Flow Diagram .................................................................. 1-11
Figure 1–7. Oxidizer Components..................................................................... 1-12
Figure 1–8. Hydrator System Mount and Close-up View ................................ 1-13
Figure 1–9. Hydrator Components.................................................................... 1-13
Figure 1–10. Zero Air Panel System with Nitrogen ......................................... 1-14
Figure 1–11. Scrubber Assembly...................................................................... 1-15
Figure 1–12. Stack Mounting Flange ............................................................... 1-16
Figure 4–1. Example of Model 80iInterface Board Voltage
Test Point Locations ........................................................................................... 4-15
Figure 6–1. Hydrator Mounted Outside Rack......................................................6-2
Figure 6–2. Hydrator Mounted Inside Rack ........................................................6-3
Figure 6–3. Hydrator Electrical Pinout Diagram..................................................6-4
Figure B–1. 83iSystem Plumbing Diagram 103013-00..................................... B-2
Figure B–2. 83iwith Oxidizer System Plumbing Diagram 103013-01 .............. B-3
Figure B–3. 83iElectrical and Plumbing Installation 103535-00 ...................... B-4
Figure B–4. Wiring Interconnection with 83i GC............................................... B-5
Figure B–5. 83iwith Oxidizer Electrical and Plumbing
Installation 103535-01 ......................................................................................... B-6
Figure B–6. Tubing Interconnection with 83i GC............................................... B-7
Figure B–7. 83iGC Plumbing System Diagram 104358-00............................... B-8
Figure B–8. 83iGC with Oxidizer Plumbing System Diagram 104358-01......... B-9
Figure B–9. Interconnection Schematic........................................................... B-10
Figure B–10. 83iTerminal Block Wiring Diagram 104588-00......................... B-11
Figure B–11. 83iGC with Oxidizer Terminal Block Wiring
Diagram 104734-00............................................................................................ B-12
Figure B–12. Umbilical Wiring Detail .............................................................. B-13
Figure B–13. Model 83iwith Oxidizer Terminal Block
Wiring Diagram 105507-00................................................................................ B-14
Figure C–1. Model 80iFlowchart of Menu-Driven Firmware............................ C-2
Figure C–2. Model 81iFlowchart of Menu-Driven Firmware............................ C-3

Thermo Fisher Scientific Mercury System Manual xi
Tables
Table 1–1. Model 81iValve Mode Status...........................................................1-3
Table 2–1. Default Temperatures........................................................................2-2
Table 2–2. Initial Service Settings ......................................................................2-6
Table 2–3. Set-up Blowback Schedule................................................................2-6
Table 2–4. 80iAlarms Settings ...........................................................................2-7
Table 2–5. Probe Alarms Settings.......................................................................2-7
Table 2–6. Normal Operational Parameters - 83i...............................................2-9
Table 2–7. Normal Operational Parameters - 83i GC ...................................... 2-10
Table 3–1. Example of Parameter Settings.........................................................3-3
Table 3–2. Zero/Span Check Set Up ...................................................................3-4
Table 4–1. Troubleshooting – Most Common Service Calls ..............................4-2
Table 4–2. Troubleshooting – Power-Up Failures...............................................4-3
Table 4–3. Troubleshooting – Alarm Messages.................................................4-4
Table 4–4. Troubleshooting – System Zero and Calibration ..............................4-7
Table 4–5. Troubleshooting – Firmware and Communications....................... 4-12
Table 4–6. Probe Troubleshooting – 82iMeasurement
Interface Board LEDs.......................................................................................... 4-15
Table 4–7. Communication and 24 V Troubleshooting
– 82iInterface Board LEDs ................................................................................ 4-16
Table 4–8. Troubleshooting – Oxidizer............................................................. 4-16
Table 4–9. Troubleshooting – Miscellaneous.................................................. 4-18
Table 5–1. Preventive Maintenance Schedule ...................................................5-2
Table 6–1. Nitrogen Generator Specifications ...................................................6-7

Thermo Fisher Scientific Mercury System Manual 1-1
Chapter 1
Introduction
Note This manual is for use with the Mercury FreedomSystem
integrated by Thermo Fisher Scientific. Systems integrated by others will
vary from the information provided in this document. ▲
The Model 80iis normally configured as one component of an integrated
Hg Continuous Emission Monitoring System (CEMS). The Thermo
Scientific Mercury FreedomSystem is comprised of a Hg analyzer
(Model 80i), a Hg calibrator (Model 81i), a Hg probe controller (Model
82i), and a Hg probe (Model 83i) along with additional peripheral
components, such as a zero air supply, umbilical, and instrument rack.
However, the Model 80iis also available as a stand-alone instrument.
The Model 80iAnalyzer is based on the principle that Hg atoms absorb
ultraviolet (UV) light at 254 nm, become excited, then decay back to the
ground energy state, emitting (fluorescing) UV light at the same
wavelength. Specifically,
)254(*)254( nmh+HgHgnmh+Hg



The sample from the Hg probe (Model 83i) is introduced to the rear panel
of the instrument as either Total Hg or Elemental Hg from the appropriate
probe umbilical connection (see Figure 1–1). When the Model 80iis
sampling Total Hg, the total sample is routed into the fluorescence
chamber via Solenoids S1 (NO state) and S3 (NO state). During this time,
the Elemental Hg sample bypasses the chamber via Solenoid S2 (NO state).
When the Model 80iis sampling Elemental Hg, the elemental sample is
routed via Solenoids S2 (normally closed (NC) state) and S3 (normally
open (NO) state) into the fluorescence chamber. During this time, the
Total Hg sample bypasses the chamber via Solenoid S1 (NC state). As the
monitored sample (Total or Elemental) leaves the optical chamber, it passes
through a flow sensor, then to an external pump. The external pump is
used to draw the sample through the instrument and to create the
instrument vacuum which is measured with the pressure transducer.
System Overview
Model 80
i

Introduction
Model 81i
1-2 Mercury System Manual Thermo Fisher Scientific
Figure 1–1. Model 80iFlow Diagram
Either the Total or Elemental sample is introduced into the fluorescence
chamber, where UV light from a high energy Hg line source lamp excites
the Hg atoms. The UV light is directed to the fluorescence chamber by a
rejection mirror/beam splitter combination. A reference detector monitors
the lamp intensity by viewing the transmitted light from the beam splitter.
As the excited Hg atoms decay back to the ground energy state, they emit
UV light that is proportional to the Hg concentration. The Hg
fluorescence is monitored by a solar blind photomultiplier tube (PMT)
placed at a right angle to the exciting radiation. The PMT detects the UV
light emission from the decaying Hg atoms.
Calibration gas from the Hg calibrator (Model 81i) is plumbed to the zero
air and cal gas bulkheads on the rear panel of the Model 80i. The zero or
span gas is routed through an internal critical orifice, through either the
NO or NC port of Solenoid S4, through the NC port of Solenoid S3 and
into the fluorescence chamber. During this time, both Total and Elemental
Hg samples bypass the chamber and are sent to the external pump exhaust.
The Model 80ioutputs the Total Hg or Elemental Hg concentration to
the front panel display, the analog outputs, and also makes the data
available over the serial or Ethernet connection.
The Model 81iMercury (Hg) Calibrator generates known concentrations
of gas phase elemental Hg by combining the output flow of a temperature
controlled, saturated Hg vapor source with a flow of Hg-free dilution air or
nitrogen. The Model 81iis normally configured as one component of an
integrated Hg Continuous Emission Monitoring System (CEMS). The
Thermo Scientific Mercury FreedomSystem is comprised of a Hg
analyzer (Model 80i), a Hg calibrator (Model 81i), a Hg probe controller
Model 81
i

Introduction
Model 81i
Thermo Fisher Scientific Mercury System Manual 1-3
(Model 82i), and a Hg probe (Model 83i), along with additional peripheral
components, such as a zero air supply, umbilical, and instrument rack.
However, the Model 81iis also available as a stand-alone calibrator.
Table 1–1 shows the Model 81isolenoid valve status for the different
calibrator modes. Use this table along with Figure 1–2 when reading the
principle of operation description that follows. Note that a valve status
shown as ON describes a valve that is energized, or in the Normally Closed
(NC) state. A valve status shown as OFF describes a valve that is de-
energized, or in the Normally Open (NO) state.
Table 1–1. Model 81iValve Mode Status
Solenoid ID Standby Instrument
Zero
Instrument
Cal
Orifice
Zero
Orifice
Cal
System
Zero
System
Cal
Valve 1 ON ON ON ON ON ON ON
Valve 2 OFF OFF ON OFF ON OFF ON
Valve 3 OFF OFF ON OFF ON OFF ON
Valve 4 OFF OFF OFF ON OFF ON OFF
Valve 5 OFF OFF ON ON OFF ON OFF
Orifice Valve OFF OFF OFF ON ON OFF OFF
Spike Valve OFF OFF OFF OFF OFF ON ON
Clean, dry, Hg-free pressurized air/nitrogen (30-40 psig) feeds both a high
flow (0-20 slpm) dilution air mass flow controller (MFC) and a low flow
(0-50 sccm) Hg source MFC (Figure 1–2).

Introduction
Model 82i
1-4 Mercury System Manual Thermo Fisher Scientific
Figure 1–2. Model 81iFlow Diagram
The output of the low flow MFC is passed through a coiled, Teflontube
encapsulated Hg source, which is maintained at a precisely known
temperature and pressure. The Hg saturated flow is directed by Valve V2
(NC) to combine with dilution flow from Valve V3 (NC) providing
calibration gas to either:
●A Hg analyzer via Valve V5 (NC)
●Or the Hg probe via Valve V5 (NO)
Calibration gas to the probe is sent directly to the critical orifice or to the
spike port (for filter flooding) by switching the appropriate probe valve
(orifice or spike).
The check valve is used to keep the orifice (located in the probe) from
being over pressurized during an orifice zero or calibration.
Excess flow (atmospheric dump) during a probe calibration is routed
through an internal Hg scrubber prior to being sent to exhaust. Also during
any zero air mode (instrument, orifice, or system), the Hg saturated flow is
directed via V2 (NO) through a Hg scrubber prior to being sent to exhaust.
The Model 82iMercury (Hg) Probe Controller is configured as one
component of the Thermo Scientific integrated Hg Continuous Emission
Monitoring System (CEMS). The Model 82iis not available as a stand-
alone instrument.
Model 82
i

Introduction
Model 82i
Thermo Fisher Scientific Mercury System Manual 1-5
Clean, dry, pressurized (~85 psig) air feeds two electo/pneumatic pressure
transducers which adjust and maintain output pressure to the Model 83i
probe eductor and blowback pneumatics (Figure 1–3).
Pressurized (~85 psig) Hg-free zero air or nitrogen feeds a third
electo/pneumatic pressure transducer which adjusts and maintains dilution
gas pressure to the Model 83iprobe dilution module.
Three electronic pressure transducers (Figure 1–3) associated with the
individual regulators are also contained within the Model 82i, as well as an
electronic vacuum transducer monitoring the dilution module vacuum in
the Model 83i.
Figure 1–3. Model 82iProbe Controller Flow Diagram
The Model 82icommunicates with the Model 80ivia a RS-485 link. The
Model 80iacts as the master component in the Mercury Freedom
System with both the Models 81iand 82islaved to the analyzer. All
commands are initiated by the Model 80i. The Model 82ireceives
commands and sends information to the analyzer.
The Model 82i also receives two 4-20 mA signals from the probe critical
orifice pressure transducer and the fast loop venturi pressure transducer.
Pneumatics
Electronics

Introduction
Model 83i
1-6 Mercury System Manual Thermo Fisher Scientific
The Model 82icontrols the temperatures of the probe, the heated
umbilical line, and converter (located within the probe). These
temperatures are set and recorded via the Model 80i.
The Model 82iprovides both 220 and 110 AC voltage to the Model 83i
Probe. The 220 VAC powers the probe’s stinger heater and filter/eductor
heater. The 110 VAC powers the Total Hg converter as well as 4 to 6
probe solenoid valves for cal/zero gas, stinger blowback, filter blowback,
and Hg spike.
The Model 82ihas a dedicated 220 VAC feed to power the heated
umbilical line.
The Model 83iMercury (Hg) Extraction Probe is configured as one
component of the Thermo Scientific integrated Hg Continuous Emission
Monitoring System (CEMS). The Thermo Scientific Mercury Freedom™
System is comprised of a Hg analyzer (Model 80i), a Hg Calibrator (Model
81i), a Hg Probe Controller (Model 82i), and a Mercury Extraction Probe
(Model 83i) along with additional peripheral components, such as a zero
air supply, umbilical, and instrument rack. The Model 83i with built-in
diluting probe has been designed specifically to monitor gaseous Hg
emissions from coal-fired power plants.
The system is housed in a stainless steel enclosure and is designed to meet
NEMA 4X specifications. To prevent sample condensation, all key
elements (filter, diluting probe and sample eductor) have been mounted
between heated aluminum blocks that can be maintained at temperatures as
high as 250 °C.
The enclosure also houses an accumulator tank for back purging of the
filter tube (blowback). External to the enclosure is a section with the
electrical connections, solenoids for filter and stinger blowback, cal gas, an
Hg spike, a differential pressure transducer, and an additional pressure
transducer for the pressure at the critical orifice.
A special four-inch adapted mounting flange has been supplied for
installation onto the port of the stack or duct.
Clean dry pressurized (~85 psig) air/nitrogen feeds two electronic pressure
regulators in the Model 82i, which adjust and maintain output pressure to
the Model 83iprobe eductor and blowback pneumatics (Figure 1–4).
Pressurized (~65 psig) Hg-free zero air feeds a third electronic regulator in
the Model 82i, which adjusts and maintains dilution air pressure to the
Model 83iprobe dilution Module. Also contained within the Model 82i
are three electronic pressure transducers associated with the individual
Electrical Power
Model 83
i