ABB ACF5000 Manual
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ABB ACF5000 Manual

Multi-component ftir analyzer system
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Frequently Asked Questions (5)
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ABB MEASUREMENT & ANALYTICS | OPERATING INSTRUCTION
ACF5000
Multi-component FTIR analyzer system
Measurement made easy
Table of Contents
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Frequently Asked Questions (5)

  • How do I troubleshoot common error messages on the ABB ACF5000 Measuring Instruments?

    Troubleshooting tasks should only be performed by qualified and specially trained personnel due to the potential for working with an open and powered analyzer system. To troubleshoot, you can use the Dynamic QR Code feature, which displays dynamically generated QR codes on the gas analyzer screen.

    This QR code contains static information for device identification (such as production number, production date, software version, and serial numbers of built-in analyzer modules and components) and dynamic data for error diagnosis (including status messages, measured values, temperature, pressure, flow values, drift values, and analyzer-specific values).

    To use it:

    1. Select the QR code in the gas analyzer's diagnosis menu to display it on the screen.
    2. Scan the displayed QR code using a QR code scanner application on a mobile device.
    3. The resulting text information can then be sent by e-mail or a suitable messenger service to the local service representative .

    For more information, see page 172 of the manual.
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  • How do I set up Modbus communication for the ABB ACF5000 Measuring Instruments?

    Modbus communication can be set up via the MENU → Configure → System → Network → Modbus menu path. The analyzer system supports the Modbus/slave protocol with RTU (Remote Terminal Unit) mode. The access interval of the Modbus master should be greater than 500 ms. Parameters that can be configured include:

    • Modbus address : Can be set in the range of 1 to 255.
    • Modbus type : Selects the interface (RS232 or RS485) through which the analyzer system connects to the Modbus network.
    • Modbus baudrate : Standard settings for data transmission are displayed.
    • Modbus parity and Modbus stopbits .

    An overview of the address position of the Modbus register can be found in the Modbus image . Note that the Modbus menu item is only displayed if the Modbus module is installed in the analyzer system.


    For more information, see page 126 of the manual.
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  • Can the ABB ACF5000 Measuring Instruments be integrated with other control systems?

    Yes, the ABB ACF5000 Measuring Instruments can be integrated with other control systems. The system controller is designed with interfaces for:

    • System-internal CAN bus .
    • Field bus systems such as Modbus and PROFIBUS .
    • Ethernet interface for remote monitoring of the entire analyzer system and data transmission via internal or external TCP/IP networks.
    • Analog outputs for measured components and relay contacts for fault/status messages are optional.

    Specifically, interfaces for measured values and status signals include standard Ethernet with TCP/IP protocol and Modbus TCP/IP protocol , with Modbus, PROFIBUS, analog and digital outputs, and analog and digital inputs available as options.

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  • What types of industrial processes can the ABB ACF5000 Measuring Instruments monitor?

    The ABB ACF5000 analyzer system is designed for continuous measurement of the concentration of individual components in the flue gas of industrial incinerators . Its primary application involves emissions monitoring , but use in process control applications is also possible.


    For more information, see page 14 of the manual.
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  • What are the environmental operating conditions for the ABB ACF5000 Measuring Instruments?

    The environmental operating conditions for the ABB ACF5000 Measuring Instruments are:

    • Ambient temperature for storage and transport: -25 to +65°C .
    • Ambient temperature during operation:
      • With built-in fan (option) : +5 to +30°C .
      • With built-in air conditioner (option) : +5 to +45°C .
    • Relative humidity during operation:
      • Annual average : max. 75% .
      • Briefly : max. 95% .
      • Seldom and slight condensation is permissible if the analyzer system is switched on and the FTIR spectrometer is purged.

    Additionally, the analyzer cabinet must be protected from jets of water, contact with chemicals, strong sunlight and heat, strong air currents, extremely dusty environments, corrosive atmosphere, and vibration .


    For more information, see page 22 of the manual.
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Summary of Contents for ABB ACF5000

  • Page 1 — ABB MEASUREMENT & ANALYTICS | OPERATING INSTRUCTION ACF5000 Multi-component FTIR analyzer system Measurement made easy...

  • Page 3: Table Of Contents

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Contents Preface ..................................6   Safety instructions ............................... 8   Intended use ........................ 8   Safety instructions ..................... 8   Safety instructions for handling the analyzer system ........10   Safety instructions for handling the analyzer system with integrated FID ..11  ...
  • Page 4 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Adjustment: Basics ............................. 68   Controlling the adjustment ..................68   Manual adjustment ....................69   Automatic adjustment ..................... 70   Adjustment methods ....................72   FID: Conversion of concentration data ..............74  ...
  • Page 5 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Parameter overview....................133   User page configuration ..................134   Moving a display element from one page to another ........135   Moving a display element within a page .............136   Configuring the bar display or point display ............137  ...

  • Page 6: Preface

     Connection diagram. Further information Internet You can find information on ABB Analytical products and services online at http://www.abb.de/analytical. Service contact If the information in this operating instruction does not cover a particular situation, ABB service will be pleased to supply additional information as required.
  • Page 7 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Identification of safety instructions in this operating instruction If the safety instruction identified in this way is not observed, an accident will occur. This will result in severe bodily injury or death. If the safety instruction identified in this way is not observed, an accident may possibly occur.

  • Page 8: Safety Instructions

    Safety instructions Intended use Intended use The ACF5000 analyzer system is designed for continuous measurement of the concentration of individual components in gases or vapors. Any other use is not approved. The intended use also includes taking note of this operating instruction.
  • Page 9 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Device safety and safe operation The device is designed and tested in accordance with safety standard EN 61010 Part 1 "Safety requirements for electrical equipment for measure- ment, control, and laboratory use," and is shipped ready for safe operation.

  • Page 10: Safety Instructions For Handling The Analyzer System

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Safety instructions for handling the analyzer system The warning symbols affixed to the analyzer system must be observed: Heed the operating instruction! Hot surface! (Temperature > 60°C) Danger of electric shock! The following must also be observed: ...

  • Page 11: Safety Instructions For Handling The Analyzer System With Integrated Fid

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Safety instructions for handling the analyzer system with integrated FID Safety measures If an FID (VOC analyzer) is installed in the analyzer system, the following safety measures are taken at the factory to ensure safe operation: ...

  • Page 12: Safety Instructions For Handling The Ftir Spectrometer

    The housing of the interferometer AU3 may not be opened during normal operation. It contains no user-operated parts. The housing of the interferometer may be opened only by authorized ABB service personnel. Opening the housing of the interferometer AU3 and the interferometer module in particular can result in contact with laser radiation.

  • Page 13: Safety Instructions For Working With Poisonous Gases

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Safety instructions for working with poisonous gases Some gas components whose concentration is measured with the analyzer system are hazardous to health or poisonous. For this reason, the sample gas must under no circumstances be allowed to escape from the sample gas path in either the measurement mode or when performing maintenance.

  • Page 14: Description Of The Analyzer System

    Description of the analyzer system Application and function of the analyzer system Application The ACF5000 analyzer system is a multi-component analyzer system for continuous measurement of the concentration of individual components in the flue gas of industrial incinerators. The field of application of this measuring equipment basically involves tasks associated with emissions monitoring;...
  • Page 15 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Options Validation A validation unit can be installed in the beam path of the spectrometer to confirm the validity of the spectrometer adjustment. Total carbon measurement A flame ionization detector (FID) for measurement of the total carbon con- tent (VOC) can be incorporated into the analyzer system.

  • Page 16: Components Of The Analyzer System

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Components of the analyzer system NOTICE A delivered analyzer system may not include certain individual assemblies described in this section depending on the measurement task and execution ordered. Assemblies in the analyzer cabinet...
  • Page 17 Heated selector valve for switching between two sampling points  (option) CAUTION! For measurement gas sampling, only the assemblies specified by ABB may be used, as both the temperature controls and the securing functions are aligned to this. Sample gas conditioning ...

  • Page 18: Option "Hydrogen Monitoring Of The Analyzer Cabinet

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Option "Hydrogen monitoring of the analyzer cabinet" Function The "Hydrogen monitoring of the analyzer cabinet" option is an additional safety measure when an FID analyzer is built-in in the analyzer system. If a...
  • Page 19 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A NOTICES The gas sensor installed in the analyzer cabinet is not calibrated at the fac- tory; it is not functional without calibration. The calibration of the gas sensor is the responsibility of the operator.

  • Page 20: Preparation For Installation

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Preparation for installation Selection of the sampling point, installation of the wall tube Selection of the sampling point  The sampling point must be suited for extracting a representative sam- ple stream. ...
  • Page 21 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Installation of the wall tube with mounting flange The wall tube with mounting flange (DN 65, PN 6, facing type A to DIN EN 1092-1; not included with delivery) should be installed at the sampling point such that the probe tube can be inserted and withdrawn without difficulty.

  • Page 22: Requirements For The Installation Site Of The Analyzer Cabinet

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Requirements for the installation site of the analyzer cabinet Short gas paths The analyzer cabinet should be set up as close as possible to the meas-  uring location. A short sample gas line translates into short dead times.
  • Page 23 720 m. Higher altitudes would result in insufficient gas flow through the system. The inlet pressures for the ACF5000 may not be lowered, as this directly reduces the sensitivity of the FTIR spectrometer. As a consequence, the measuring accuracy and drift in accordance with QAL1, QAL2, and QAL3 for components with a low concen- tration cannot be assured.

  • Page 24: Sample Gas Inlet Conditions

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Sample gas inlet conditions The analyzer system may not be used for the measurement of ignitable gas/air or gas/oxygen mixtures during normal service. CAUTION! The analyzer system may not be used for the measurement of gases con- taining organometallic compounds, e.g.

  • Page 25: Operating Gases And Test Gases

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Operating gases and test gases FTIR spectrometer Zero air: Quality Clean compressed air from the air purifier Inlet pressure = 2000 ± 100 hPa (2.0 ± 0.1 bar) Flow rate max. 500 l/h...
  • Page 26 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Oxygen sensor Zero gas: Quality 3 vol.% O in N (accuracy ±2%) Inlet pressure = 1500 ± 100 hPa (1.5 ± 0.1 bar) Flow rate max. 500 l/h Span gas: Quality Clean compressed air (20.96 vol.% O...

  • Page 27: Power Supply

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Power supply Power supply Voltage 230/400 VAC, 3 phases 120/208 VAC, 3 phases 100/200 VAC, 3 phases (via transformer), ± 10%, 48 to 62 Hz Fuse (external) 3 x 20 A or 3 x 25 A Power consumption approx.
  • Page 28 16 A (PFE2 + probe 42, 120 V) –F84 Heated sample gas line 16 A –F85 ACF5000 electronics box AU1, ASP block heater, gas cell heater –F86 Air purifier, FTIR spectrometer, flow monitor, system controller, power supply unit 24 V/5 A –F87...

  • Page 29: Dimensions, Weights And Noise Level

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Dimensions, weights and noise level Dimensions see "Location diagram" in the system documentation Weights Analyzer cabinet approx. 300 kg Type 40 probe tube (unheated) depends on length 500 mm 1 kg 1000 mm...

  • Page 30: Scope Of Supply And Delivery

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Scope of supply and delivery Standard scope of supply and delivery Qty. Description Analyzer cabinet (all components installed) 1 set system documentation Included with delivery if ordered Qty. Description Type 40 (unheated) or Type 42 (heated) gas sampling probe...

  • Page 31: Material Required For The Installation (Not Supplied)

    Combustion gas for the FID 1 extremely clean (hydrocarbon-free) stainless steel tube (SS316), O.D. 6 mm (ABB item no. 0017400, length = 6 m) or ¼ in. 1 two-stage cylinder pressure reducer (designed for high-purity gases) with flow restriction Test gas for FTIR 1 PTFE tube 4/6x1 mm or ⅙...
  • Page 32 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Signal lines Analog outputs Shielded cables for the analog outputs (current outputs): 2 x 0.5 mm or 2 x AWG20 per analog output Analog inputs Shielded cables for the analog inputs (current inputs with the option "external analog inputs"):...

  • Page 33: Installation

    Installation General notices  It is recommended that the analyzer system be installed by ABB.  In addition to this operating instruction, refer to the order-specific set of drawings as well as the operating instructions and data sheets for the individual devices and components when installing the analyzer system.

  • Page 34: Installing The Analyzer Cabinet

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Installing the analyzer cabinet NOTICE It is strongly recommended to have the analyzer cabinet  transported by a qualified company  while the cabinet is lying on its back as long as possible and ...
  • Page 35 Removing the transport protection of the ASP block The ASP block is fastened using a M8x80 transport protection bolt. This is routed from above through a hole in the housing of the ACF5000 electronics box AU1 and screwed into the ASP block.
  • Page 36 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A "2nd measuring location" option Installing the electrical distributor cabinet The electrical distributor cabinet for connecting the 2nd measuring location must be installed as close to the analyzer cabinet as possible. On the analyzer cabinet, cables of about 5 m in length are applied for con- nection to the electric distribution cabinet.

  • Page 37: Installing The Gas Sampling Probe And Filter Unit

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Installing the gas sampling probe and filter unit Installing the gas sampling probe and filter unit Observe the "Piping diagram" in the system documentation.   Install the gas sampling probe and filter unit: The pre-assembled probe tube with filter unit weights approx.
  • Page 38 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Gas connections of PFE2 Filter unit Pilot valve for cleaning filter -Y2.1 Diaphragm valve for cleaning filter -Y2.2 Pilot valve for pulsed instrument air -Y1.1 Diaphragm valve for pulsed instrument air -Y1.2 Connection for instrument air (max. 6 bar) bulkhead fitting 12 mm Connection for test gas bulkhead fitting 6 mm Connection for control air (max.
  • Page 39 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Probe tube type 40 L1 = length of the probe tube (dimensions in mm) L1 = 500/1000/1500/2000/2500 mm max. 500 °C Probe tube type 42 (dimensions in mm) 1000/1500/2000 mm  If the PFE2 filter unit with standard protective box (450 x 450 x 400mm)

  • Page 40: Installing The Sample Gas Line

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Installing the sample gas line Installing the sample gas line Observe the "Piping diagram" in the system documentation.   Connect the sample gas line to the gas sampling probe. NOTICE Neither grease or lubricant may be used during installation of the sample gas line.
  • Page 41 CAUTION! Do not connect the sample gas line to the sample gas inlet on the ASP block yet! This connection is made by ABB personnel during the commissioning procedure. First connect a PTFE tube of approx. 0.5 m in length to the sample gas inlet 2 on the ASP block.

  • Page 42: Installing The Operating Gases

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Installing the operating gases Installing the instrument air supply Observe the "Requirements for the instrument air supply" (see page 25).   Provide the material required for the installation (see page 31). ...
  • Page 43 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Combustion gas for the FID  Connect two-stage cylinder pressure reducer with flow restrictor (ver- sion for high purity gases) to the combustion gas cylinder.  Connect combustion gas line to the bulkhead fitting provided.

  • Page 44: Connecting The Electrical Leads

    4 OUT (rd/2B) 5 Not assigned NOTICE: If the ACF5000 is installed at the end of a PROFIBUS network, the load resistor on the PROFIBUS plug, which is on the bottom of the system controller housing on the inside of the cabinet door, must be switched to ON.
  • Page 45 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Connecting the electrical leads  Provide the material required for the installation (see page 31).  Observe "Arrangement diagram", "Wiring diagram" and "Terminal dia- gram" in the system documentation.  The cable glands for the electrical leads are located in the right-hand cabinet wall.
  • Page 46 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Connect power supply High leakage current: 9 mA!  Observe the "Requirements for the power supply" (see page 27).  Before connecting the power supply, make sure that the operating volt- age set on the analyzer system matches the mains voltage.

  • Page 47: Commissioning

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Commissioning Recommissioning Initial commissioning The analyzer system is essentially commissioned by the authorized person- nel of the manufacturer or of the supplier. NOTICE The initial commissioning of the option “Hydrogen monitoring of the analyzer cabinet”...
  • Page 48 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Start of the measurement On a restart, the analyzers start to measure automatically:  the oxygen sensor within a few minutes of the circuit breakers being activated; the FTIR spectrometer within 5 to 10 minutes of the circuit breakers ...
  • Page 49 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A After the pressures have been adjusted to the respective set point, the respective solenoid valve in the FID automatically connects the combus- tion gas. The combustion gas regulation attempts to adjust the pres- sure to the set point.

  • Page 50: Operation

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Operation Display and operation unit Overview The display and operation unit consists of  the display (see page 51) with  of the menu line,  the information field, and  the softkey line, ...

  • Page 51: Display

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Display The display The backlit chart display has a resolution of 320 x 240 pixels. Error Maint Power The display is split into three areas:  the menu line,  the information field and ...

  • Page 52: Message Display

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Message display Message display functions The blinking message display in the softkey line has the following functions:  It prompts for the STATUS MESSAGE key to be pressed whenever a status message is present ...

  • Page 53: Status Leds

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Status LEDs Status LEDs The three LEDs next to the screen show the user the status of the analyzer Error Maint Power system. The green "Power" LED lights when the power supply is on.

  • Page 54: Numeric Keypad

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Numeric keypad Numeric keypad The numeric keypad is located to the right of the screen, under the status Error Maint Power LED's. With  numeric keys "0" through "9"  decimal point "." and ...

  • Page 55: Cancel Keys

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Cancel keys Cancel keys The "Back" and "Meas" keys located under the numeric keypad are designat- Error Maint Power ed as cancel keys. The "Back" key allows the operator to cancel a function or menu item and return to the previous menu level.

  • Page 56: Softkeys

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Softkeys Softkeys The six keys under the screen and the softkey line at the lower edge of the Error Maint Power screen are known as softkeys. A softkey is the combination of the key and its designation in the softkey line.
  • Page 57 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A The softkeys in menu mode In menu mode, a series of softkeys appears on the softkey line, whose label- ing and therefore function change based on the situation. Their descriptions and functions depend on the specific situation.

  • Page 58: Text Entry

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Text entry Entering text When text, such as measurement components or user names, is to be en- tered an image of the numeric keypad appears on the screen. The following characters are shown using a total of four pages: ...

  • Page 59: Operating By Value Input

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Operating by value input Value input Values are entered during measurement by pressing the number key that corresponds to the position of the display element in the display and that is indicated above the display element.

  • Page 60: Operating By Key Entry

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Operating by key entry Key entry Key entries are made in measurement mode by pressing the appropriate number key that corresponds to the position of the display element on the display and that is indicated over the display element.

  • Page 61: Password Protection

    CAUTION! The user can change all passwords. Therefore it is strongly recommended to document each password changing. Only ABB service is able to reset the passwords to the factory setting.
  • Page 62 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Viewing menu items All users can view all menu items, regardless of password level, without en- tering a password. Changing menu items All users can make changes to password level 0 menu items without enter- ing a password.

  • Page 63: Blocking Operation

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Blocking operation Blocking operation using the function block configuration Regardless of the preference of a user interface, it is possible to block ac- cess to the operation of the analyzer system of a certain human-machine interface (HMI) in full.

  • Page 64: Operating The Analyzer System

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Operating the analyzer system The analyzer system is operated via the following:  The display and control unit in the door of the analyzer cabinet (local HMI)  A remote HMI  A web page...
  • Page 65 QAL3 data (see page 80),  Checking for automatic processes with scheduling conflicts (see page 90). All other functions are only determined for use by ABB service; they are not described in this operating instruction. Access and operation The Mozilla ®...

  • Page 66: Menu Structure

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Menu structure Menu structure For reasons of clarity, only the suitable parameters and functions are pre- sented; the menu links onward at most menu items, e.g. to the selection of the various measured components or to the selection and settings of values.

  • Page 67: Display Of Measured Value

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Display of measured value HMI display Each display "page" shows the measured values of six measuring compo- nents. The >> key allows the operator to scroll to the next display "page". This key only allows forward scrolling.

  • Page 68: Adjustment: Basics

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Adjustment: Basics NOTICE The descriptions in this section refer to the adjustment of the analyzer modules FID and oxygen sensor. Controlling the adjustment Controlling the adjustment For the adjustment of the analyzer system, there are three methods of con- trol: ...

  • Page 69: Manual Adjustment

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Manual adjustment Definition Manual adjustment means: Zero and span are adjusted separately by press- ing the analyzer system display and control unit keys. Test gas infeed The test gas supply can be started by activating a multiple-way ball valve or solenoid valve.

  • Page 70: Automatic Adjustment

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Automatic adjustment Definition Automatic adjustment means: The adjustment of the zero point and end point proceed automatically after starting. Test gas infeed The test gases are automatically fed in via external solenoid valves.
  • Page 71 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Automatic adjustment start and cancel Start Cancel Controlled by interval: If "Activation" parameter is by appropriate configuration of the cancel set to "on" management parameter or of the function block Automatic Adjustment Externally controlled: with the "Start automatic...

  • Page 72: Adjustment Methods

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Adjustment methods Adjustment method In an analyzer module (detector) one or more (gas) components with one or more measuring ranges can be implemented. For the adjustment of the analyzer module, it needs to be defined whether the components and measuring ranges are to be adjusted jointly or individ- ually.
  • Page 73 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Overview The following table presents the adjustment methods at a glance. Qty. Adjustment MC MR method To be configured … To be adjusted … The adjustment affects … Test gas/Single the zero point and the...

  • Page 74: Fid: Conversion Of Concentration Data

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A FID: Conversion of concentration data Various units for concentration details When measuring organic carbon compounds (total C) the concentration is indicated in various units. The most important units are:  mg C/m (e.g. for measurements in accordance with 17. German Federal Regulation on Emissions) ...
  • Page 75 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Example 2 If a test gas other than propane is used, its response factor must be taken into consideration. What is the maximum test gas concentration in ppm or mg/m if methane ) is used? ...

  • Page 76: Adjustment: Configuration

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Adjustment: Configuration Configuring the automatic reference FTIR Function For the FTIR spectrometer, the automatic recording of the reference can be configured. Menu path Menu → Configure → Adjustment Data → Automatic Reference Display...
  • Page 77 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Procedure Parameter Explanation Automatic reference recording is completed only when it is activated. Enable The cycle time shows the time intervals over which automatic recording of Cycle time references is completed. Recommended setting: 12 hours.

  • Page 78: Automatic Adjustment Check (Aac): Configuring The Time Sequence

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Automatic Adjustment Check (AAC): Configuring the time sequence Function Optionally, the cycle that automatically monitors the adjustment (Automatic Adjustment Check – AAC) of the FTIR spectrometer under QAL3 monitoring can be configured. A validation filter wheel equipped with the AAC measure- ment media must be installed in the FTIR spectrometer and the "Automatic...
  • Page 79 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Parameter Explanation AAC cycle runs The run mode of the AAC must be set. split The AAC runs step by step; the AAC step interval is waited for between the individual steps. Each step takes approx. 18 minutes – with the purge time set to 240 seconds.

  • Page 80: Automatic Adjustment Check (Aac): Settings And Export Of The Qal3 Data

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Automatic Adjustment Check (AAC): Settings and export of the QAL3 data Function The settings for the cyclical "Automatic Adjustment Check" are to be made in the web page. Menu path ACF5000 Settings → QAL3 Password A level 2 password is required to access this submenu.
  • Page 81 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Edit components Measuring components that must be checked during the AAC can be acti- vated and configured in the Edit Components submenu. A level 3 password is required to access this submenu. Parameter...
  • Page 82 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Settings Whether the analyzer system transmits a status signal according to the limit values criteria on the CUSUM control chart or the Shewhart control chart, or according to both control charts, can be selected in the Settings →...

  • Page 83: Configuring The Automatic Drift Check (Adc)

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Configuring the Automatic Drift Check (ADC) Function On the analyzer system, the cyclical drift check with automatically connected test gases can be configured as an option. The "Automatic Drift Check" function must be enabled in the configuration file.
  • Page 84 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Parameter Explanation Enable The cyclical automatic drift check (ADC) is only completed when it is activat- Cycle time The cycle time specifies the time intervals in which the ADC is completed. Recommended setting: 7 days.

  • Page 85: Configuring Manual Adjustment

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Configuring manual adjustment NOTICE The descriptions in this section refer to the adjustment of the analyzer modules FID and oxygen sensor. Menu path MENU → Configure → Adjustment Data → Manual Adj. → ...

  • Page 86: Configuring Automatic Adjustment Of The Fid

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Configuring automatic adjustment of the FID Function For the FID, an automatic adjustment with test gas at the zero and end point can be configured. Menu path Menu → Configure → Adjustment Data →...
  • Page 87 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Parameter Explanation Working mode It is to be set whether an adjustment or a validation should take place. In the working mode parameter, after the validation has been selected, it must be set whether the result of the validation is to be entered in the logbook and...

  • Page 88: Configuring Automatic Adjustment Of The Oxygen Sensor

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Configuring automatic adjustment of the oxygen sensor Function For the oxygen sensor, an automatic adjustment with test gas at the zero and end point can be configured. Menu path Menu → Configure → Adjustment Data →...
  • Page 89 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Parameter Explanation Working mode It is to be set whether an adjustment or a validation should take place. In the working mode parameter, after the validation has been selected, it must be set whether the result of the validation is to be entered in the logbook and...

  • Page 90: Check Time Conflicts Of The Automatic Processes

    The web page can display the durations of these processes in calendar form to check if they overlap. Menu path ACF5000 Settings → Checking for scheduling conflicts Password A level 1 password is required to access this submenu.

  • Page 91: Output Current Response

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Output current response Menu path MENU → Configure → Adjustment Data → Output current behavior → ... Output current response Signals at the current outputs (analog outputs) Are held at the last measured value prior to starting adjustment or ...

  • Page 92: Adjustment: Operation

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Adjustment: Operation Carrying out manual reference Creating manual reference Function A manual reference can be created for the FTIR spectrometer. First, Menu → Service/Test → System → Manual gas path must be set to apply zero air either locally or via sampling (see page 152).
  • Page 93 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Procedure Press ENTER to select the FTIR spectrometer. The analyzer system automatically switches to zero air and the Manual reference menu is displayed. Switch between the various display pages using the < and > softkeys.
  • Page 94 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Once the recording of the manual reference has stopped, a message confirms if the process was completed successfully or not. If the manual reference was recorded successfully, save the reference as SECURE AS LKG (Last Known Good). It is then activated in the FTIR.
  • Page 95 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Displaying the status of the last reference Menu path Menu → Adjust → Manual Adjustment Procedure Select FTIR analyzer and press ENTER to select the Manual reference menu. Display the last reference status by selecting REF. DATA.
  • Page 96 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Displaying diagnosis values of the reference measurement Function The last reference measurement's diagnosis values for the FTIR spectrome- ter can be displayed on the HMI. Menu path Menu → Service/Test → Analyzer Spec. Adjustment →...
  • Page 97 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Saving the reference as an initial reference Function After recording the manual reference, it can be saved as an initial reference. The initial reference serves as the valuation basis for the following reference recordings.

  • Page 98: Start Automatic Adjustment Check (Aac) Manually

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Start Automatic Adjustment Check (AAC) manually Function The automatic cyclic monitoring of the adjustment of the FTIR spectrometer (Automatic Adjustment Check – AAC) can be started manually. The handling depends upon configuration of the AAC cycle to “split” or “complete” or “complete &...
  • Page 99 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A AAC cycle “complete” or “complete & reference” Display Operation START AAC Start complete AAC. STOP Abort the running AAC. The analyzer system is purged with sample gas and returns to measuring mode. No set values and actual values for the FTIR span values are output.

  • Page 100: Carry Out Manual Adjustment

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Carry out manual adjustment NOTICE The descriptions in this section refer to the adjustment of the analyzer modules FID and oxygen sensor. Adjustment should only be carried out after the warm-up phase. Before a manual end point adjustment, a manual zero point adjustment must be carried out.

  • Page 101: Manual Start Of Automatic Adjustment

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Manual start of automatic adjustment NOTICE The descriptions in this section refer to the adjustment of the analyzer module FID and oxygen sensor. Adjustment should only be carried out after the warm-up phase.

  • Page 102: Configuration: Component Functions

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Configuration: Component functions Configuring measuring range Switch measuring range Menu path MENU → Configure → Component-specific → Measuring Range (→ Select component) → ... Selection Displayed are all measuring ranges configured (at the plant) for a measured component.
  • Page 103 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Changing measuring range limits NOTICE The measuring range limits of the FTIR sample components cannot be changed. Menu path MENU → Configure → Component-specific → Measuring Range (→ Select component) → ... Selection Displayed are all measuring ranges configured (at the plant) for a measured component.
  • Page 104 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Change number of decimal places Menu path MENU → Configure → Component-specific → Measuring Range (→ Select component) → ... Selection Displayed are all measuring ranges configured (at the plant) for a measured component.
  • Page 105 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Add measuring range NOTICE Adding measuring ranges is only possible with the analyzer module FID. Menu path MENU → Configure → Component-specific → Measuring Range (→ Select component) → ... Selection Displayed are all measuring ranges configured (at the plant) for a measured component.
  • Page 106 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Delete measuring range NOTICE Deleting measuring ranges is only possible with the analyzer module FID. Menu path MENU → Configure → Component-specific → Measuring Range (→ Select component) → ... Selection Displayed are all measuring ranges configured (at the plant) for a measured component.

  • Page 107: Configuring Automatic Measuring Range Switching

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Configuring automatic measuring range switching Menu path MENU → Configure → Component-specific → Autorange → Select Component → ... NOTICE The automatic measuring range switching works only perfectly if the meas- uring ranges MB1, MB2, … were configured in ascending order, i.e. MB1 <...

  • Page 108: Configuring Filter

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Configuring filter Menu path MENU → Configure → Component-specific → Filter → Select Component → ... Procedure Parameter Explanation Action Non-linear filter: T90-1 Low-pass time constant for constant measured value. Range for FTIR sample components: 0 to 300 s...

  • Page 109: Active Component Selection

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Active component selection Menu path MENU → Configure → Component-specific → Active Component Active component With this FID analyzer module, several measured components can be config- ured however, only one measured component is measured and displayed.

  • Page 110: Configuring Limit Monitoring

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Configuring limit monitoring Menu path MENU → Configure → Component-specific → Limit Values → Select Limit Monitor → ... Selection All available limit value monitors are shown. Procedure Parameter Explanation Action Direction < = Alarm when falling below the limit or Select >...

  • Page 111: Configuring Ftir Limit Monitoring

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Configuring FTIR limit monitoring Function The monitoring of the FTIR measured values with regard to exceeding limit values can be configured. If a measured value exceeds the configured limit value, the analyzer system switches to zero air.

  • Page 112: Configuring Dry Base And O

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Configuring dry base and O reference Correcting the measurement value The measurement gas concentrations can be converted to dry waste gas or normal conditions. The measurement gas concentrations can also be based on a pre-determined oxygen concentration. The correction functions are available only when this option has been ordered and configured ex-works in the analyzer system.

  • Page 113: Changing Module Name

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Changing module name Menu path MENU → Configure → Component-specific → Module Name Module name The module name is shown in the display next to the module type. Here you can enter a name relating to the measuring point, for example.

  • Page 114: Configuration: System Functions

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Configuration: System functions Setting time zone, date and time Menu path MENU → Configure → System → Date/Time Procedure Parameter Explanation The time zone can be selected either from the list of GMT Time zone values or from the list of continents/countries/cities.

  • Page 115: Selecting User Interface Language

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Selecting user interface language Menu path MENU → Configure → System → Language Language selection The user interface languages German and English are factory-set in the ana- lyzer system as per order. It is possible to switch between these languages...

  • Page 116: Change Password

    CAUTION! The user can change all passwords. Therefore it is strongly recommended to document each password changing. Only ABB service is able to reset the passwords to the factory setting.

  • Page 117: Blocking Operation

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Blocking operation Menu path MENU → Configure → System → Changing Password Blocking operation The operation of the analyzer system, i.e. the calling up of the main menu and therefore the switching to menu mode, can be protected with a pass- word.

  • Page 118: Setting System Modules

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Setting system modules Menu path MENU → Configure → System → Set System Modules Function If system modules are added to an analyzer system or replaced (changed) or removed, this also needs to be configured in the software.
  • Page 119 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Unknown system module If in the Set system module menu item, a system module has the status Unknown, there are several possible causes: Cause: After activating the power supply of the analyzer system, the system module could not be found (status message no.

  • Page 120: Add System Module

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Add system module NOTICE As long as no system module is configured in the analyzer system at all or an added system module is not yet configured, the NEW softkey appears in the display in measuring mode.

  • Page 121: Replace System Module

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Replace system module Uninstallation and reinstallation of the same system module If an existing system module is uninstalled and (e.g. after a repair) rein- stalled, the setting of this system module is usually not necessary.

  • Page 122: Delete System Module

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Delete system module Sequence when removing system modules When removing system modules from the analyzer system, the following sequence must always be applied: Delete system module in the software (instructions see below). Remove system module from the analyzer system.

  • Page 123: Save Configuration

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Save configuration Menu path MENU → Configure → System → Save configuration Automatic saving of the configuration The database with the configuration data and logbook entries is saved au- tomatically in two configuration files.

  • Page 124: Configuring Status Signals

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Configuring status signals Menu path MENU → Configure → System → Status Signals Function The configuration of the status signals is already defined when ordering the analyzer system and set at the plant.

  • Page 125: Configuring Ethernet Connection

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Configuring Ethernet connection Menu path MENU → Configure → System → Network → TCP/IP Network Function The analyzer system can be integrated via the Ethernet 10/100/1000BASE-T interface in an Ethernet network (with TCP/IP protocol).

  • Page 126: Configuring Modbus Connection

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Configuring Modbus connection Menu path MENU → Configure → System → Network → Modbus Function The analyzer system can, on the one hand, be integrated via the RS232 or the RS485 interface and, on the other hand, via the Ethernet interface (Modbus via TCP/IP) in a network with Modbus protocol.

  • Page 127: Configuring Profibus

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Configuring Profibus Menu path MENU → Configure → System → Network → Profibus Parameter Parameter Selection Explanation 1 to 126 Profibus address Profibus DP Connection to the RS485 interface Profibus type Profibus PA...

  • Page 128: Configuring Bus I/Os

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Configuring Bus I/Os Menu path MENU → Configure → System → Network → BUS IO Number of Bus I/Os Changing the number of Bus I/Os will affect the Modbus address range, Profibus map and Ethernet linking.

  • Page 129: Configuration: Display Functions

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Configuration: Display functions Display features The display can be configured In measurement mode the analyzer system screen is freely configurable. A standard layout is configured on each delivered unit (see below). Display elements Display elements are: ...
  • Page 130 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A User pages In addition to the system pages, the user can set up so-called user pages (see page 134). Function blocks as sources The values of all the function blocks in the system can be configured as a source for the display.

  • Page 131: Display Overview

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Display overview Display overview Parameter Parameter Explanation Page Name of page on which the value is displayed Pos. Position of the display on the page Description Name of the value Softkeys in the screen overview...

  • Page 132: Page Overview

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Page overview Page overview Parameter Parameter Explanation Page number and status ("On" or "Off") Name of the page Name Page assignment Assignment Type System: Pages configured by system with standard layout User: Page configured by the user...

  • Page 133: Parameter Overview

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Parameter overview Parameter overview Parameter Parameter Explanation The name of the display element set by the system cannot be changed. Name The description entered for the Test point appears over the element display Test point during measurement.

  • Page 134: User Page Configuration

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A User page configuration User page configuration Select Display menu item. Call up the page overview. Start configuring a new page with NEW. Either: Enter the page name. The page overview is displayed. Or: Go directly to the page overview. In this case the system assigns the name "Page #"...

  • Page 135: Moving A Display Element From One Page To Another

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Moving a display element from one page to another Moving a display element from one page to another Select Display menu item. Select the display element in the display overview. Select the Page parameter.

  • Page 136: Moving A Display Element Within A Page

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Moving a display element within a page Moving a display element within a page Select Display menu item. Select the display element in the display overview. Select the Position parameter. The nine possible positions are graphically represented.

  • Page 137: Configuring The Bar Display Or Point Display

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Configuring the bar display or point display Configuring the bar display or point display Select Display menu item. Start configuration of the new display element with NEW. Select the Source parameter. The function block menu is displayed.

  • Page 138: Value Input

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Value input Configuring the value input Description The source of the display element Value Input is the function block Con- stant that is automatically generated during configuration. The output of this function block accepts the entered value.

  • Page 139: Configuring Value Input

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Configuring value input Configuring value input Select Display menu item. Start configuration of the new display element with NEW. Select the Page parameter. The page overview is displayed. Select the page on which the display element is to be displayed. Only those pages can be selected with an assignment <...

  • Page 140: Key Entry

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Key entry Configuring key entries Description The source of the display element Key entry is one or more Constant function blocks that is automatically generated during configuration. Upon "actuation", the output of this function block assumes the value that was established during configuration.

  • Page 141: Configuring Key Entries

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Configuring key entries Configuring key entries Select Display menu item. Start configuration of the new display element with NEW. Select the Page parameter. The page overview is displayed. Select the page on which the display element is to be displayed. Only those pages can be selected with an assignment <...

  • Page 142: Maintenance

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Maintenance General notices NOTICE Only persons familiar with the maintenance of comparable analyzer systems and who possess the qualification required for such work are allowed to work on the analyzer system. The following must be observed during all maintenance work: ...

  • Page 143: Visual Inspection

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Visual inspection Internal view of the analyzer cabinet Visual inspection External instrument air regulator 5.5 to 7 bar External gas cylinder pressure reducers: Zero gas, O analyzer (3 vol. % O in N 1.5 ±...

  • Page 144: Cleaning The Analyzer Cabinet

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Cleaning the analyzer cabinet CAUTION! The door of the analyzer cabinet must be closed at all times during operation! Notes on cleaning the analyzer cabinet  Never use water or solvents to clean parts of the analyzer cabinet interi- ...

  • Page 145: Seal Integrity Test

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Seal integrity test CAUTION! Do not use any leak search spray or similar leak search tools in the under- pressure area of the analyzer system. These media may result in damage to the analyzer system in the event of a leak.
  • Page 146 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Simplified seal integrity test via FID This method can be employed only if an FID is built into the analyzer system. It is based on allowing hydrocarbon to act on any leaking points in the sam- ple gas path and observing the measured value on the FID at the same time.

  • Page 147: Fid: Seal Integrity And Functional Checks

    If these conditions are not provided or the prescribed materials are not available, seal integrity and functional checks must be carried out by ABB service. Seal integrity check of the combustion gas path...
  • Page 148 In this case, the analyzer system may not be put into operation! The combustion gas inlet valve must be replaced by ABB service. After conclusion of the seal integrity test, set the combustion gas pres- sure to 1.2 bar.

  • Page 149: Maintenance Switch

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Maintenance switch Function The analyzer system can be set permanently to "Maintenance" status using the "Maintenance switch" function ("Maintenance mode" status signal). Menu path Menu → Service/Test → System → Maintenance switch Display The appearance of the softkeys indicates the current status of the mainte- nance switch.

  • Page 150: Emergency Purging

    External trigger of the emergency purging If a digital I/O module is installed with the ACF5000 cabinet status, the emergency purging can also be triggered externally via the digital input 4.

  • Page 151: Monitoring The Internal Cabinet Temperature

    The digital output 4 of a digital I/O module with the function block applica- tion ACF5000 cabinet status is set. This normally results in the deactivation of the air purifier; the valve for bypassing the air purifier is opened. An ex- cessively high internal cabinet temperature also results in the triggering of the emergency purging (see page 150).

  • Page 152: Connecting Gas Paths And Inserting Validation Cells

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Connecting gas paths and inserting validation cells Function The gas path in the analyzer system can be connected manually, e.g. to emit test gases. The menu can be exited without waiting for the purge times and any neces- sary changeover of the measuring model.

  • Page 153: Changing Analog Output Current Range

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Changing analog output current range Method The current range of the individual analog outputs can be changed using the parameter setting of the corresponding function blocks analog output. The Technical Information "Function blocks – Descriptions and configuration"...

  • Page 154: Adjustment Reset

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Adjustment reset NOTICE The adjustment reset is only possible with the analyzer modules FID and oxygen sensor. What does the adjustment reset do? An adjustment reset returns the analyzer module's adjustment to basic ad- justment values.

  • Page 155: Basic Adjustment

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Basic adjustment NOTICE The adjustment reset is only possible with the analyzer modules FID and oxygen sensor. What does the basic adjustment do? A basic adjustment of an analyzer module sets the module back in an initial state.

  • Page 156: Fid: Standby/Restart

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A FID: Standby/Restart Menu path MENU → Service/Test → Analyzer Spec. Adjustment → Standby/Restart FID Display of the operating condition of the FID The key operating data of the FID are displayed: Flame temperature...
  • Page 157 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Putting the FID in standby mode If in the Standby/Restart FID menu the STANDBY or STANDBY PURGING softkeys are displayed, the FID can be set to standby mode: STANDBY Standby mode is activated.

  • Page 158: Configuring Saving Of Ftir Spectral Data

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Configuring saving of FTIR spectral data Function It can be configured whether the FTIR spectral data are saved in the analyzer system. The spectral data saved can be loaded with the download tool or via web access from the analyzer system.

  • Page 159: Configuring Automatic Back-Purging Of The Gas Extraction Probe

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Configuring automatic back-purging of the gas extraction probe Recommended program run for back-purging Start cleaning -Y2.1/-Y2.2: Cleaning filter End cleaning -Y3.1/-Y3.2: Cleaning filter Cleaning cycle surface and probe tube -Y1.1/-Y1.2: Pulsed compressed air...
  • Page 160 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Set the cycle time and date and time of the next back purge. Select the I1:Active parameter and press >> . Activate on the selected Constant function block the back purging: FB value = 0: back purging is deactivated.

  • Page 161: Replacing Wearing Parts

    Every 12 months top of the cabinet (see page 171) Spare parts information Information on spare parts can be found on the Internet in "ABB Business Online" at https://online.abb.com/. NOTICE Only genuine ABB spare parts and consumables may be used!

  • Page 162: Replacing Filter On The Gas Sampling Probe

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Replacing filter on the gas sampling probe Wearing parts Wearing parts Item no. Replacements Stainless steel filter with 8329410 At least every 12 months, depending two FFKM O-ring seals on the dust content of the sample gas...
  • Page 163 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Preparing to remove the filter, interrupting measuring mode Switch analyzer system to “Zero gas local”. Wait until all FTIR measured values have dropped to zero. Disconnect the sample gas line from the gas sampling probe and seal the probe connection with a blind fitting.

  • Page 164: Replacing Sample Gas Filter In The Asp Block

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Replacing sample gas filter in the ASP block Wearing parts Wearing parts Item no. Replacement, comment Sample gas filter in the 769427 At least every 12 months, depending ASP block, mounted on the dust content of the sample gas...
  • Page 165 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Use the degreased tool to grip the sample gas filter unit 3 at the spring, remove from the ASP block and set down on the working surface. Fitting the filter 10 Use the degreased tool to grip the new filter at the spring and carefully insert it into the ASP block.

  • Page 166: Replacing Filter In The Compressed Air Main Regulator (-J85)

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Replacing filter in the compressed air main regulator (-J85) Wearing parts Wearing parts Item no. Replacements Filter in the compressed air main controller 990048 Every 12 months Replacing the filter element The compressed air main regulator is pressurized (5.5 to 7 bar)! Preparing to replace the filter, interrupting measuring mode Switch analyzer system to Zero gas probe.

  • Page 167: Replacing Filters In The Sample Gas Pressure Regulator

    Replacing the filter Slacken 5 screws and remove the cover of the ACF5000 E-box AU1. The paper filters in the sample gas pressure regulator are located on the right-hand side in the ACF5000 E-box.

  • Page 168: Replacing Filter Cells In Air Purifier Au5

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Replacing filter cells in air purifier AU5 Wearing parts Wearing parts Item no. Replacements 2 PU+CA filter in air purifier 8329425 Approx. every 3 years (depending (AU 5), mounted on the instrument air quality)

  • Page 169: Replacing Filter Pad In The Fan

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Replacing filter pad in the fan Wearing parts Wearing parts Item no. Replacements Filter pad in the inlet and 990046 At least every 12 months, depending outlet filter on the dust content in the ambient air...

  • Page 170: Replacing The Battery On The System Controller

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Replacing the battery on the system controller Wearing parts Wearing parts Type Replacements Battery on the Varta CR3032 (type no. Approx. every 4 years (as part system controller 6032) or Renata CR2032 of the maintenance work on...

  • Page 171: Replacing Pressure Equalization Screws

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Replacing pressure equalization screws Wearing parts Wearing parts Item no. Replacements Pressure equalization screw 8329416 Every 12 months Replacing pressure equalization screws Slacken counter nut 1 in the top of the cabinet and remove the screw upwards.

  • Page 172: Status Messages, Troubleshooting

    Code represents an innovative way of customer’s communication which allows, for instance, improved case-specific support by ABB resulting in an increased availability of analyzer assets. Dynamic QR Code is compatible with the ABB application "my Installed Base" as well as with standard QR code scanner applications. Handling The QR code is selected in the gas analyzer's diagnosis menu and displayed on the gas analyzer's screen.
  • Page 173 The QR code can also be selected in Remote HMI and scanned from the computer screen. Recommended QR code scanner applications ABB recommends the use of the following QR code scanner applications (available free of charge for iOS and Android): "my Installed Base" by ABB...

  • Page 174: Process Status

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Process status Definitions The Process status (see below) provides information on measured values and the process being monitored by the analyzer system. The System status (see page 175) provides information on the status of the analyzer system itself.

  • Page 175: System Status: Status Messages

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A System status: Status messages Where are status messages generated? Status messages are generated  By the analyzer system, i.e.  The system controller (signal processing, adjustment, system bus)  The analyzer modules ...

  • Page 176: System Status: Status Signals

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A System status: Status signals Overall or individual status The status signal is factory-configured (see page 124) to output as an overall or individual status. Overall status If the analyzer system is configured to output overall status, status mes- sages are issued as overall status indications.

  • Page 177: Status Message Categories

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Status message categories Status message categories In terms of operator reaction, there are three categories of status messag-  Status messages not requiring acknowledgement  Status messages requiring acknowledgement  Status messages requiring acknowledgement and troubleshooting Status messages not requiring acknowledgement The analyzer system operates normally after the status has been cleared.
  • Page 178 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Summary The following table shows  the time sequence of the three status message categories  The identifier used to identify the status messages in the summary (q, Q and I). Status messages not requiring acknowledgement...

  • Page 179: Status Message System

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Status message system List layout The status message list contains the following information: The status message number appears in the menu line display Text Full text of the status message is shown in the detailed display x = Status message sets the overall status x = Status message sets the "Error"...
  • Page 180 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Text S A W F Reaction/Comment The Profibus module is in- see message text stalled on a wrong slot! The Profibus interface is therefore not functional. Please install the Profibus module on the slot X20/X21.
  • Page 181 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Text S A W F Reaction/Comment The system is currently being maintained with Optima SMT. The analyzer module has an Notify service. internal communication error! The analyzer module has an Notify service. internal program error! The analyzer module could not Check plug connection and wiring.
  • Page 182 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Text S A W F Reaction/Comment The pressure regulator works see status message of the relevant pressure detector erroneously. The pressure correction for this see status message of the relevant pressure detector component was deactivated because the pressure measured value is invalid.
  • Page 183 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Text S A W F Reaction/Comment A calculation error occurred Notify service. while calculating the measured value. The pressure exceeds or falls FID: Check supply gas pressures: below the top or bottom limit Output = instrument air, value 1.
  • Page 184 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Text S A W F Reaction/Comment The measured value exceeds Check measuring gas concentration. Check push con- the value range of the ana- nections in the analyzer system Notify service. log/digital converter. 400 A calculation error occurred Notify service.
  • Page 185 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Text S A W F Reaction/Comment Automatic adjustment in pro- x for information; not in the logbook gress. System bus communication disrupted during automatic adjustment. External adjustment started. for information External adjustment ended.
  • Page 186 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Text S A W F Reaction/Comment Auto validation canceled ex- for information ternally. Automatic validation in pro- x for information; not in the logbook gress. Automatic validation successful for: Automatic validation outside the limit for:...

  • Page 187: Status Messages Ftir

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Status messages FTIR List layout The status message list contains the following information: The status message number appears in the menu line display x = Status message sets the "Error" individual status x = Status message sets the "Maintenance request" individual status x = Status message sets the "Maintenance mode"...
  • Page 188 With an activated automatic reaction to temperature violation, the message is for information purposes. Web page → ACF5000 settings → Tem- perature range check 2501 Auto ref. Start For information Automatic zero point reference started.
  • Page 189 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A A W F S Short and long text Reaction/Comment 2508 AAC end For information Automatic Adjustment Check end. 2509 AAC cancelation For information Automatic Adjustment Check externally can- celed. 2510 AAC in progress For information Automatic Adjustment Check in progress.
  • Page 190 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A A W F S Short and long text Reaction/Comment 2530 x Ambient temp. >> For information The ambient temperature exceeds limit value 2531 FTIR purging << Check settings of the pressure and flow The flow rate of FTIR purging falls below the controller.

  • Page 191: Analyzer System: Troubleshooting

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Analyzer system: Troubleshooting Display of measured value flashes Measured signal exceeds measuring range limits Note: Measured value > +130% MRS or measured value < −100% MRS. In addi- tion, the status messages 344 or 345 are generated.

  • Page 192: Fid: Troubleshooting

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A FID: Troubleshooting Temperature problem Connection leads of the temperature sensor or the heater discon- nected  Check the connection leads and connectors.  Check the fit of the leads in the wire end ferrules.
  • Page 193 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Flame does not ignite Air in the combustion gas line When connecting or replacing the combustion gas bottle make sure that no air penetrates into the combustion gas supply line. Air which has penetrated the gas supply line results in the flame in the analyzer going out.

  • Page 194: Notify Service

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Notify service Who should you contact for further help? Please contact your local service representative. For emergencies, please contact ABB Service, Telephone: +49-(0)180-5-222 580, Fax: +49-(0)621-381 931 29031, E-mail: automation.service@de.abb.com Before you notify service…...

  • Page 195: Decommissioning

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Decommissioning Shutting down the analyzer system Shutting down the analyzer system temporarily Switch the gas flow control on zero gas probe (zero air connection via the probe) in order to interrupt the measured gas supply.

  • Page 196: Disposal

    If there is no possibility to dispose of the old equipment properly,  ABB service can take care of its pick-up and disposal for a fee. To find your local ABB service contact visit abb.com/contacts or call +49 180 5 222 580.

  • Page 197: Index

    ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A Index Configuring key entries • 60, 131, 140, 141 Configuring limit monitoring • 110, 174 Configuring manual adjustment • 69, 85 A  Configuring measuring range • 102 Configuring Modbus connection • 126 Active component selection • 109 Configuring Profibus •...
  • Page 198 ACF5000 FTIR ANALYZER SYSTEM OI/ACF5000-EN REV. A K  Replacing pressure equalization screws • 161, 171 Replacing sample gas filter in the ASP block • 161, Key entry • 51, 60, 133, 140 Replacing the battery on the system controller •...
  • Page 200 We reserve the right to make technical changes or modify the contents of this document without prior notice. With regard to purchase orders, the agreed particulars shall prevail. ABB does not accept any responsibility whatsoever for potential errors or possible lack of information in this document.

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