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Galvanic Applied Sciences 943-TGX Operation Manual

Automatic process uv spectrophotometer for tail gas analysis
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943-TGX
Automatic Process UV Spectrophotometer for Tail Gas Analysis
OPERATION MANUAL
P/N: MA7428
Revision 4
August 2019
Galvanic Applied Sciences, Inc.
7000 Fisher Road S.E.
Calgary, Alberta, T2H 0W3
Canada
Phone: (403) 252-8470
Fax: (403) 255-6287
E-mail:
info@galvanic.com
World Wide Web: http://www.galvanic.com

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  • Page 1 943-TGX Automatic Process UV Spectrophotometer for Tail Gas Analysis OPERATION MANUAL P/N: MA7428 Revision 4 August 2019 Galvanic Applied Sciences, Inc. 7000 Fisher Road S.E. Calgary, Alberta, T2H 0W3 Canada Phone: (403) 252-8470 Fax: (403) 255-6287 E-mail: info@galvanic.com World Wide Web: http://www.galvanic.com...
  • Page 2 No part of this manual may be reproduced or transmitted in any form or by any means without the written permission of Galvanic Applied Sciences, Inc. Note: Changes or modifications not expressly approved by Galvanic Applied Sciences, Inc. could void the user's authority to operate the equipment.

  • Page 3: Table Of Contents

    Table of Contents 943-TGX T ...... 12 ECTION ODEL NALYZER PECTROPHOTOMETER VERVIEW ........................... 12 VERVIEW ......................13 NALYTICAL ETHOD ....................... 13 NALYZER ESIGN ......................14 AMPLING YSTEM ..................... 15 YSTEM PERATING ONTROL ....................15 ONTENTS OF THIS ANUAL ........................ 16...
  • Page 4 ......................30 ECTION YSTEM ONTROL ..............30 NTERACTION ROGRAM VERVIEW ............30 SING THE NBOARD ISPLAY AND EYPAD 4.2.1 The Onboard Display .................... 30 4.2.2 The Hand Held Keypad ..................31 ......................32 NALYSIS 4.3.1 Online/Offline Button .................... 32 4.3.2 Air Demand, H S, SO COS and S...

  • Page 5: Analyzer

    ....................... 66 ECTION AINTENANCE ........................... 66 VERVIEW ................66 OUTINE REVENTATIVE AINTENANCE 6.2.1 Visual Inspection of Key Operating Parameters........... 66 6.2.2 Maintenance Check Out Procedure ..............68 ................70 HANGING THE OLARANT OLUTION ..............72 PTIMIZING THE PECTROMETER NERGY EVEL 6.4.1 Automated Optimization ..................
  • Page 6 Tables 6-1: N ............67 ABLE ORMAL ALUES OF PERATING ARAMETERS 7-1: A ....................76 ABLE NALYZER AULT ABLE 8-1: D ................... 90 ABLE OCUMENT ACKAGE HECK 11-1: O ......................101 ABLE 11-2: T ......................101 ABLE Revision 4 August 02, 2019...
  • Page 7 The Notice symbol is used to highlight information that will optimize the use and reliability of the system. Applies to the 943-TGX-CE only. 943-TGX-CE Protective earth terminal. Revision 4...
  • Page 8 Any safety recommendations or comments contained herein are suggested guidelines only. Galvanic Applied Sciences Inc. bears no responsibility and assumes no liability for the use and/or implementation of these suggested procedures. This system, when operating in its normal mode, and/or when it is being serviced, maintained, installed and commissioned contains items which may be hazardous to humans if handled or operated incorrectly or negligently.
  • Page 9 The beam is extremely intense and will cause permanent eye damage. Should visual inspection of the beam be required, point the end of the fibre at an inanimate object and view the illumination reflection. Never expose human skin to the radiation from the optical fibres. 943-TGX-CE Device Group: II 2 G.
  • Page 10 Manufacturer’s Warranty Statement Galvanic Applied Sciences Inc. (“Seller”) warrants that its products will be free from defects in materials and workmanship under normal use and service in general process conditions for 12 months from the date of Product start-up or 18 months from the date of shipping from Seller’s production facility, whichever comes first (the “Warranty Period”).
  • Page 11 outside the environmental specifications for the instrument, use by unauthorized or untrained personnel or improper site maintenance or preparation. • Products that have been altered or repaired by individuals other than Seller personnel or its duly authorized representatives, unless the alteration or repair has been performed by an authorized factory trained service technician in accordance with written procedures supplied by Seller.

  • Page 12: Overview

    Section 1 Model 943-TGX Tail Gas Analyzer Spectrophotometer Overview Overview The use of a Tail Gas Analyzer to assist in the control of combustion air to acid gas ratios in Claus Sulfur Recovery Plants is a standard procedure in industry. The plant tail gas is analyzed using ultraviolet spectroscopy and an output signal that corresponds to the air requirement is determined.

  • Page 13: Analytical Method

    Analyzer Design The Model 943-TGX Analyzer System is packaged in two (2) frame mounted cabinets: a) An oven cabinet which contains the sample handling system and associated hardware (i.e., solenoids, oven, heaters, etc.). All electrical equipment residing in the oven cabinet is installed using appropriate explosion proof and/or intrinsically safe wiring methods.

  • Page 14: Sampling System

    Sampling System The Analyzer system utilizes a close coupled mounting arrangement of the measurement cell to the tail gas process sampling point to minimize the sample system length. The short length allows for analyzer response times to be optimized while sample transport problems are mitigated.

  • Page 15: System Operating Control

    Contents of this Manual This manual contains the following information: • Section 1: Model 943-TGX Tail Gas Analyzer Spectrophotometer Overview presents introductory information about spectrophotometry and the system. • Section 2: Installation describes unpacking the analyzer, installing it in the facility and interfacing with other devices.

  • Page 16: Section 2 Installation

    It is recommended that you retain the shipping container so that it may be used for future shipment of the unit, if necessary. Environmental Requirement 943-TGX-CE Refer to the 943-TGX-CE User Manual Sections 2.1, 2.2, 2.3, 2.4, 2.5, and 2.6. 2.2.1 Electrical Requirements The power input is 100 –...

  • Page 17: Steam

    If damage has occurred, contact the shipping company and Galvanic Applied Sciences. Place the small packages and the sample probe aside in a safe, secure storage area as they are not needed at this stage of the system installation.

  • Page 18: Installation Steps

    Inspect the internal equipment to ensure that no damage has occurred and that no components have become loose during transport. If any damage is visible contact Galvanic Applied Sciences Inc. immediately and do not proceed with the system installation. Do not attempt to facilitate repairs yourself as this will negate and/or invalidate any possible insurance claim or equipment warranty.
  • Page 19 The Steam jacketed ball valve must remain closed until the sample probe is installed and connected in the sample handling oven. Figure 2-1: Analyzer Dimensions Figure 2-2 indicates the location of the various connections that have to be made. Revision 4 August 02, 2019...

  • Page 20: Mating Of The Process And Analyzer System Flanges

    Figure 2-2: Service Connections 943-TGX-CE There are no oven steam supply fittings on the 943-TGX-CE. 2.4.2 Mating of the Process and Analyzer System Flanges 943-TGX-CE Refer to the 943-TGX-CE User Manual Section 2.7.2. The analyzer is shipped with a 316 SS blind flange plate and gasket mounted inside the oven compartment to prevent the process gas from flowing into the compartment before installation of the sample probe assembly.
  • Page 21 Install the sample probe: 943-TGX-CE Refer to the 943-TGX-CE User Manual Section 2.7.3. a) Remove the hole plug from the top of the oven cabinet and insert the probe into the packing gland at the bottom of the oven until it reaches the steam jacketed ball valve.

  • Page 22: Connection Of The Ac Power Service

    If the connections are leak-tight and company safety personnel have deemed the atmosphere to be safe, breathing apparatus may now be removed. 2.4.3 Connection of the AC Power Service 943-TGX-CE Refer to the User Manual Section 2.7.4. 2.4.4 Connection of the Analog Signal Cables 943-TGX-CE Refer to the User Manual Section 2.7.5.

  • Page 23: Connection (S) Of Steam

    2.4.7 Connection (s) of Steam 943-TGX-CE Refer to the User Manual Section 2.7.7 2.4.7. 2.4.8 Connection of the ‘Loss of Purge Signal’ 943-TGX-CE The “loss of purge” is an integral function of the purge controller. Revision 4 August 02, 2019...

  • Page 24: Section 3 Operation

    Section 3 Overview The 943-TGX analyzer system is designed to operate automatically with a minimum need for human intervention. Once installation, commissioning and initial start-up have been completed, the only human intervention required is when the system indicates a problem or when routine preventative maintenance is scheduled.

  • Page 25: Cabinet Cooler Air Valve

    3.2.2 Cabinet Cooler Air Valve The system provides on/off control of the air to the cabinet cooler via a solenoid valve with respect to a configuration set-point. The Cabinet Cooler Air Valve is located on the top of the analyzer behind the purge box. The Cabinet Cooler Air Valve is a coarse flow rate adjustment of air to the vortex tube cabinet cooler (typically on or off with minor throttling possible).

  • Page 26: Aspirator Drive Air Flow Adjust Valve

    sample system clogging (liquid accumulation), the Zero Air Flow Adjust Valve may be opened wide to provide a solid back purge pressure. Alternately, the Zero Air Flow Adjust Valve may be turned down to a trickle for an extended period (20-30 minutes) allowing the heat of the oven to re-liquefy any solid accumulation (plugging) before increasing the back purging pressure to clean out the plumbing.

  • Page 27: Analyzer Outputs

    Analyzer Outputs The 943-TGX analyzer generates both analog and digital output signals for connection to the users’ plant control system. The analog signals include the calculated Air Demand, and the S, SO , and optionally a user selectable signal for analog measured concentrations of H output 4.

  • Page 28: Digital Outputs

    3.3.2 Digital Outputs There are four (4) digital outputs available from the analyzer. The digital outputs are present in the form of zero potential form C relay contacts. The digital outputs are isolated to 250 . The digital outputs are provided to indicate analyzer operational status. The operational status outputs are: •...
  • Page 29 c) Mode (Calibrate / Run) Indicator The Mode (Calibrate / Run) output indicates when a zero calibration or a manually requested forced zero back purge is in progress. This indicator will be in the ‘Run’ state unless one of the following is true: •...

  • Page 30: Section 4 System Control

    System Control Section 4 The User Interaction Program - Overview The system includes an onboard computer, display panel and a hand held keypad that is local to the analyzer. As an alternative, a web based graphical user interface (GUI) can be used to view and enter information on a remote basis.

  • Page 31: The Hand Held Keypad

    The green dot in the upper right corner indicates that the system is monitoring a sample. If the Back Purge function is selected (see Section 4.3.5), the system is performing a Manual Zero operation (Section 4.3.4) or if the system is offline, the dot will be red. This dot is common to all panels.

  • Page 32: The Analysis 1 Tab

    The Analysis 1 Tab The Analysis 1 tab (Figure 4-1) presents a summary of the present status of the system 4.3.1 Online/Offline Button Clicking the Online / Off Line button changes the status from On Line (green) to Off Line (red) and vice-versa.
  • Page 33 4.3.3 Relay Indicator Fields The relay indicators show the state of the analyzer outputs: a) Status Normal (Green) status indicates that the system is working properly Fault (Red) status indicates that the computer has detected an error in one of the critical analyzer functions.

  • Page 34: Manual Zero

    4.3.4 Manual Zero The Manual Zero button starts the zero calibration sequence of the analyzer which incorporates the checking and adjusting of the instrument zero (baseline). No span correction is required under normal circumstances on an installed analyzer. The calibration sequence is identical whether triggered manually or automatically.

  • Page 35: Analysis 2 Panel

    Analysis 2 Panel The Analysis 2 panel (Figure 4-3) presents the present H S and SO concentrations in a single graphic window. The default full scale values and the time scale can be set on the Config panel (Section 4.8) a range between 0% and the configured full scale analog output concentration.

  • Page 36: Indicators Panel

    Indicators Panel The Indicators panel (Figure 4-4) is used to present details of the last 25 fault and warning events. The current status of each of the items is indicated on the right side and the last 25 events are indicated on the grid. Green - System is functioning within the accepted range Yellow - System requires service Red - System is not functioning properly...

  • Page 37: Spectrum Panel

    Spectrum Panel The Spectrum Panel (Figure 4-5) displays the present spectrum and allows the operator to change the integration time. The Peak Height, First Vector Pixel and Dark Level refer to the instantaneous readings for those parameters. Figure 4-5: Spectrum Tab The Integration time refers to the period of time for which the data is collected to provide a data point and is a compromise to optimize the resolution while minimizing the noise in the spectrum.
  • Page 38 Figure 4-6: Integration Period Dialog Box The Factory Reference spectrum refers to a spectrum of zero gas that was saved at the time of analyzer calibration at the factory. If the Show Factory Reference check box is selected, the spectrum will be superimposed on the same set of axes as the active spectrum (Figure 4-7).

  • Page 39: Absorbance Panel

    New Reference - saves the scan to be used as a reference for calculation without running a Zero Calibration. The analyzer must be backpurging zero gas before this feature can be used. Peak Height - Height of the highest point in the spectrum First Vector Pixel - corresponds to starting wavelength for the analysis and is spectrometer dependent.

  • Page 40: Config Panel

    Config Panel The Config panel is used to set a broad range of operating parameters and includes 8 sub- panels. The Configuration Panel should be accessed only by qualified personnel. 4.8.1 Outputs Sub-Panel The Outputs sub-panel (Figure 4-9) is used to define analog outputs and SVAP control. Figure 4-9: Outputs Sub-Panel Revision 4 August 02, 2019...

  • Page 41: Calculation Sub-Panel

    a) Analog Output Full Scale - These fields can be used to set the full scale range for the S, SO and COS, the Air Demand and whichever parameter is selected for Analog Out 4. If one of these fields is selected, a dialog box similar to that shown in Figure 4-6 is presented to enter the desired value.
  • Page 42 To edit a parameter, use the Field Prev or Field Next button to access the field and press Enter. A dialog box similar to Figure 4-6 will be presented. Enter the desired value, select the Okay button and press Enter. When all desired changes have been made, select Save.
  • Page 43 h) Cell Length - Indicates the cell length of the measuring cell. This value is used in the calculation of the gas concentrations. Fixed Temperature - To select Fixed Temperature, click on the e Fixed Temperature on/off field using the Field Next button on the keypad. Use the Enter key to toggle the x on and off in this field.

  • Page 44: Display

    4.8.3 Display The Display sub-panel (Figure 4-11) is used to set the X and Y range for the display on the Analysis 1 and Analysis 2 panels. Figure 4-11: Display Sub-Panel To edit a parameter, use the Field Prev or Field Next button to access the field, enter the desired value for the parameter via the keypad and press Enter.

  • Page 45: Timers/Alarms

    4.8.4 Timers/Alarms The Timers/Alarm panel is presented in Figure 4-12. Figure 4-12: Timers/Alarms Sub-pane To edit a parameter, use the Field Prev or Field Next button to access the field. A dialog box similar Figure 4-6 will be presented. Enter the desired value for the parameter via the keypad and press Enter.
  • Page 46 a) Timers Auto Cal Interval - The time period between automatic calibrations. The range is 0 – 16,666 minutes. This parameter defines the integer time interval, in minutes, between autocalibration cycles. A value of zero (0) disables the auto-calibration function. An auto- calibration is simply an automated Manual Zero sequence.

  • Page 47: Network Sub Panel

    solenoid cycles. This parameter is used only when a probe RTD is installed and the Control with RTD function is selected. c) Alarms Low Cell (ºC) - This parameter specifies the set point temperature, in degrees C (ºC), which will cause a Low Cell Temperature fault. When the measured cell temperature falls below this value, the analyzer is placed in a Fault Delay condition.
  • Page 48 Figure 4-13: Network Sub-Panel Revision 4 August 02, 2019...

  • Page 49: Section 5 Web Based Operation

    Web Based Operation Section 5 Overview The Tail Gas Analyzer can be monitored, configured and controlled by use of a Web GUI on a personal computer. The Web GUI can be used to interface to the analyzer in two ways: through a local area network or by direct connection.

  • Page 50: Analysis Section

    Analysis Section 5.2.1 Analysis Page The Analysis page includes a display (Figure 5-2) containing the present concentration values, pressure and temperature information, an indication of the present system status, the Sample/Back Purge and the manual Zero controls and the status of various relays. Figure 5-2: Analysis Page Information Display 5.2.1.1 Value Display...

  • Page 51: Status And Control

    5.2.1.2 Status and Control • Online Status - A green indicator and the word Online is presented if the instrument is online. A flashing red indicator and the word Offline is presented if the unit is offline. The state of the Online/Offline button does not affect the operation of the analyzer. The ability to remotely signal plant operations using the relay output of the Control indicator (in conjunction with the Online/Offline button) has been incorporated as a convenience to the user.

  • Page 52: Relay Indicator Fields

    • Back Purge - The Back Purge button is used to indicate that zero gas (purge gas) should be allowed to flow through the system. The Sample/Purge indicator will be flashing red and the words Back Purge Sample will be indicated when zero gas is flowing through the system.

  • Page 53: Graphic Display

    5.2.1.4 Graphic Display The graphic display of the Air Demand Trend and the H2S/SO2 Trend are updated once per second (Figure 5-3). The latest reading is at the extreme right of the plot. Figure 5-:3 Air Demand Trend and H2S/SO2 Trend Plots If desired, the Y axis scaling can be changed.

  • Page 54: Calibration Matrix Page

    5.2.2 Calibration Matrix Page The Calibration Matrix page (Figure 5-5) allows for viewing of the calibration matrix used by the spectrometer for the analysis of the gas. Click on the page to present the calibration matrix used by the spectrometer (Figure 5-3) in the determination of the gas concentrations.

  • Page 55: Indicators Page

    The calibration matrix is a 9 x 530 element array used in conjunction with the computed absorbance vector to determine the concentration of the various gases present in the measurement cell. Galvanic Applied Sciences, Inc. determines the calibration matrix by incorporating the molar absorptivity data of the gases with the specific spectral resolution and sensitivity characteristics of a particular spectrometer.

  • Page 56: Spectrum Curve Page

    5.2.4 Spectrum Curve Page The Spectrum Curve page (Figure 5-7) displays the present spectrum and lets the operator change the integration time. The spectrum data is updated every second. Figure 5-7: Spectrum Curve The X and Y coordinates of a data point on the curve can be determined by moving the mouse over the desired point on the spectrum.

  • Page 57: Absorbance Page

    The Integration time refers to the period of time for which the data is collected to provide a data point and is a compromise to optimize the resolution while minimizing the noise in the spectrum. A short integration time will optimize the resolution; however the noise may be relatively high.
  • Page 58 Figure 5-8: Absorbance Curve The Panorama field can be used to select a section of the spectrum for viewing. Use the mouse to define the region of the spectrum that is to be viewed. The Stop Polling box must be checked before the Panorama View can be used to zoom in on areas of the absorbance curve.

  • Page 59: Parameters Section

    Parameters Section 5.3.1 Parameters The Parameters page (Figure 5-9) lists a number of system parameters which can be viewed or edited. Figure 5-9: Parameters Page When the page is opened, the Read Only mode is active. • The pink background color groups all temperature related parameters. •...

  • Page 60: Modbus

    Modbus configuration. If the user requires assistance in setting up a Modbus configuration, the Service Department at Galvanic Applied Sciences Inc. will be pleased to assist in configuring the unit as desired.
  • Page 61 To set up a new Modbus list, press Change to Update Mode to present a dialog box for the password. After the password is entered, the New Load and Save buttons will be activated. To select a different Modbus type, press New to present the Modbus Type dialog box (Figure 5-11).

  • Page 62: The Enron Modbus Protocol

    Endian Swap and Register Swap are used to manipulate how the data is transmitted and they only apply to Modicon Modbus data. In Modicon Modbus, floating point numbers are transmitted in 2 16 bit words. Endian Swap determines if the most significant bit is transmitted first or if the least significant bit is transmitted first for each word.

  • Page 63: Factory Section

    Factory Section The Factory Parameters page (Figure 5-13) presents a number of factory set parameters. Figure 5-13: Factory Parameters Page When the page is opened, the Read Only mode is active. To change a parameter: a) Click on the Change to Update Mode field. A prompt for the password entry will appear. The default password is 9713.

  • Page 64: Changing The Passwords

    5.4.1 Changing the Passwords The Change Password dialog box (Figure 5-14) is used to change the factory password and the operator password. The operator level password allows the user to change parameters on the Configuration/Parameters page. The factory level password allows the user to change parameters on the Configuration/Parameters page and the Factory Parameters page Figure 5-14: Change Password Dialog Box To change the operator password:...

  • Page 65: Help Section

    Help Section 5.5.1 Drawings A number of assembly drawings are included in the application program. These are reproduced as Chapter 9 of this manual. 5.5.2 User Manual This manual can be accessed via the User Manual page 5.5.3 Revision History The Revision History page (Figure 5-15) presents the release ID number of the software.

  • Page 66: Section 6 Maintenance

    A list of recommended spare parts is provided in Section 11. Routine Preventative Maintenance Routine Preventative Maintenance of the 943-TGX analyzer consists of: • Visual Inspection of the Key Operating Parameters displayed on the front panel of the analyzer and verification of certain flow change of various gases and response changes on the analyzer (Section 6.2.1).

  • Page 67: Table 6-1: Normal Values Of Key Operating Parameters

    Table 6-1: Normal Values of Key Operating Parameters Inspection Description Should be: On/Off Line Indicator (Analysis On Line (green) • 1 Panel) Run/Stop Indicator • Run (green) Relay Indicators (Analysis 1 • Status “Normal” (green) Panel) • Service “Normal” (green) •...

  • Page 68: Maintenance Check Out Procedure

    6.2.2 Maintenance Check Out Procedure It is recommended that this maintenance check be performed once per week and the Maintenance Record Sheet be completed. The record sheet can be copied and it is recommended that the completed record sheets are saved in a secure location.
  • Page 69 Table 6-2: Maintenance Record Sheet Processing Unit Number Analyzer Tag Number Analyzer Serial Number Date Time Instrument Technician As Found Fault Condition Cell Temperature Cabinet Temperature Cell Pressure Integration Period Air Demand Forced Zero On Time to Stabilize Air Demand Spectrum Spectrum Peak Height Standard Spectrum Shape...

  • Page 70: Changing The Anti-Solarant Solution

    Changing the Anti-Solarant Solution Radiation generated by the analyzer’s broadband UV Source Lamp in the deep UV region (less than 200 nm) is capable of degrading the optical fibres. An optical fibre directly exposed to the broadband source will develop an absorption band that reduces fibre transmittance at wavelengths below 250 nm.
  • Page 71 c) Loosen the fluid holder locking screw (s) on the left-side of the fluid holder using a 7/64" ball driver. d) Lift the fluid holder from the base by grasping the fluid holder filler plug. Note the approximate level of Anti-Solarant Solution remaining in the chamber (it should be about 75%).

  • Page 72: Optimizing The Spectrometer Energy Level

    Optimizing the Spectrometer Energy Level Optimization of the Spectrometer Energy Level is periodically required to maintain a sufficient signal to noise ratio on the spectrometer output signal as the spectral output signal from the spectrometer will deteriorate over time. The normal causes of this deterioration are: •...

  • Page 73: Manual Optimization

    6.4.2 Manual Optimization a) Place the analyzer in Zero mode by accessing the Analysis 1 panel, place an X in the Back Purge field and pressing Enter. b) Access the Spectrum panel. c) If the peak level is between 25,000 and 32,000 then no adjustment is required at this time.

  • Page 74: Section 7 Service

    A major component failure should be handled by contacting Galvanic Applied Sciences, Inc. Galvanic Applied Sciences, Inc. offers service on a call-out basis and/or factory assistance on the 943-TGX analyzer. For Service and/or Assistance Contact: Galvanic Applied Sciences Inc.
  • Page 75 Figure 7-1: Indicators Panel The Analyzer Fault table is presented in Table 7-1 and a listing of some other issues that may be observed is presented in Table 7-2. Revision 4 August 02, 2019...

  • Page 76: Table 7-1: Analyzer Fault Table

    Table 7-1: Analyzer Fault Table Cell Temperature • Oven heater fuse is blown (ACTS:25) • Cell assembly is not securely clamped to the heaters • Oven heater(s) is inoperative • Set-point for low temperature alarm is incorrect High High Sulfur The sulfur vapor concentration in the sample has risen •...

  • Page 77: Changing The Uv Source Lamp

    Changing the UV Source Lamp The UV Source Lamp requires replacement when either the lamp will not start, or when the energy output of the lamp has diminished to a point where a peak spectrometer output level of 20,000 on the spectrum displayed on the Spectrum page cannot be achieved, and the integration time has exceeded the high integration period warning limit (1000 ms).
  • Page 78 Socket Head Cap Screw Figure 7-2: Location of On/Off Switch c) Access the purged control cabinet following proper company and/or regulatory agency procedures. d) Lift the fuse terminal tab opening the terminal block and disconnect the UV Lamp Power Supply fuse. (ACTS:28) or place the UV Lamp power switch to the Off position (see Figure 7-2 for the location of the switch).
  • Page 79 h) Remove the two (2) lamp retaining screws (5-40 x 3/8") from the lamp retaining ring using a 3/32" ball driver. Remove the lamp. Place the new lamp in the lamp retainer on the lamp mount assembly. Ensure the lamp is facing the correct direction.

  • Page 80: Changing The Fibre Optic Cable (S)

    Changing the Fibre Optic Cable (s) The Fibre Optic Cables will generally only require change-out if they suffer from mechanical damage or if they have been exposed directly (in the absence of Anti-Solarant Solution) to the UV Source radiation for definite time periods. The Fibre Optic Cable ends terminate into SMA type connectors and are intended to be installed with the Seal body at the control cabinet.
  • Page 81 g) Disconnect the Fibre Optic Cable to be replaced from either the UV Lamp Power Supply cabinet or the Spectrometer by unscrewing the nut and pulling the Fibre Optic Cable out. The fibre can then be pulled out through the cabinet seal fitting. h) Open the oven cabinet door.

  • Page 82: Measurement Cell Removal

    w) Remove the backpurge by selecting the Sample check box. x) Click the On Line / Off Line switch to indicate that the system is On Line. The system will automatically restart itself. The analyzer may show a fault and be in Manual (back purge) mode when put On Line.
  • Page 83 The oven compartment and all of its components are HOT (50ºC/120ºF). Wear appropriate personal protective equipment (gloves, eye wear, clothing etc) if working with hot surfaces or wait until surface have cooled to safe temperatures before performing maintenance tasks. The control cabinet door may NOT be opened while the analyzer is energized UNLESS the area is known to be non-hazardous.

  • Page 84: Cell Windows Replacement

    Cell Windows Replacement Under normal operating conditions, cell window replacement is necessary only when the particular window becomes cracked, chipped, etched or stained to a non-cleanable degree. Changing the cell windows is most easily accomplished by removing the entire measurement cell assembly from the oven compartment.

  • Page 85: Measurement Cell Installation

    g) Inspect the measurement cell body. Clean with isopropyl alcohol, using a nonabrasive lint free tissue such as KimWipes® or a cotton swab. Thoroughly rinse the cleaned surface with pharmaceutical grade distilled water and dry completely before reassembly. h) Hold the measurement cell vertically and install the new bottom O-Ring in the top window recess, ensuring that it is centered and sitting in the O-Ring seat.
  • Page 86 The system is now pressurized and a leak check should be made using a soap and water solution (e.g. Snoop ). When the system is verified to be leak-tight it can be restarted. ® g) Turn the Sample Inlet valve (V5) and the Sample Vent valve (V3) to the On position. h) Reconnect the fibre optic cables to the cell.

  • Page 87: Steam Purging The Sample Probe Assembly

    Steam Purging the Sample Probe Assembly Steam Purging the Sample Probe Assembly is recommended only when a plug in the probe is suspected and should only be performed as a last resort to avoid the possibility of steam or condensate introduction to the measurement cell. The residue of some boiler water chemicals in the measurement cell will cause a loss of spectrometer energy.

  • Page 88: 7.10 Spectrometer Replacement

    On Line. This is due to a low oven temperature. Once the oven temperature reaches its set point and the preset time delay expires, the system will automatically restart. 7.10 Spectrometer Replacement Consult Galvanic Applied Sciences for spectrometer replacement. Revision 4 August 02, 2019...

  • Page 89: Section 8 The Product Quality Assurance Program

    Section 8 Overview The Galvanic Applied Sciences product quality assurance program is designed to ensure that the system meets all manufacturing specifications and is built to meet the customer’s specific requirements. This chapter consists of a number of forms which provide the overall QA procedure and should be retained.

  • Page 90: Qa Document Package Check List And Requirements

    QA Document Package Check List and Requirements Table 8-1 is completed during the manufacturing process and QA inspection to ensure that the all relevant operations are performed. Table 8-1: Document Package Check List Serial Number: _______________ Description Initial Date Sample System Pressure Checked - System Heaters Sample System Pressure Checked –...

  • Page 91: Section 9 Drawings

    Drawings Section 9 Six assembly drawings are provided in this section. These drawings can also be viewed on the Drawing page of the Help section of the computer software. Figure 9-1: Mounting and Service Connection Detail Figure 9-2: Oven Cabinet Detail Figure 9-3 Control Cabinet Detail Figure 9-4: Power/Air/Steam Requirements and Input/Output Detail Figure 9-5: AC Wiring Diagram...
  • Page 92 943-TGX-CE There are no oven steam supply fittings on the 943-TGX-CE. Figure 9-1: Mounting and Service Connection Revision 4 August 02, 2019...
  • Page 93 943-TGX-CE There are no oven steam supply fittings on the 943-TGX-CE Figure 9-2: Oven Cabinet Detail Revision 4 August 02, 2019...
  • Page 94 Figure 9-3 Control Cabinet Detail Revision 4 August 02, 2019...
  • Page 95 943-TGX-CE There is no requirement for oven heater steam on the 943-TGX-CE. Figure 9-4: Power/Air/Steam Requirements and Input/Output Detail Revision 4 August 02, 2019...
  • Page 96 Figure 9-5: AC Wiring Diagram Revision 4 August 02, 2019...
  • Page 97 Figure 9-6: DC Signal and Wiring Diagram Revision 4 August 02, 2019...
  • Page 98 This Page Intentionally Blank Revision 4 August 02, 2019...

  • Page 99: Section 10 Specifications

    17 SCFM at 80 psi (maximum case with Vortec Cooler) Steam Nozzle – 50 psi Oven Heater > 150 psi 943-TGX-CE There is no requirement for oven heater steam on the 943-TGX-CE. Area Classification 943-TGX-CE Device Group II 2 G Ex protection...

  • Page 100: Section 11 Recommended Spare Parts

    It is recommended that the purchaser have the spare parts indicated below at the plant site to expedite maintenance and service procedures. Spare Parts can be obtained from: Galvanic Applied Sciences 7000 Fisher Road S.E. Calgary, AB, Canada, T2H 0W3...

  • Page 101: Table 11-1: One Year Kit

    Table 11-1: One Year Kit Item Description Part Number Quantity Unit of Measurement Cell Window BA7118 each O Rings for Cell Windows CO7134 each UV Source Lamp BA1795 each Anti-Solarant Solution CO7312 Bottle Fuse, 1.5 Amp PC7090 Pkg of 5 Fuse, 2 Amp PC7089 Pkg of 5...

  • Page 102: Section 12 The Peripheral Board

    The Peripheral Board Section 12 12.1 Accessing the Board To obtain access to the peripheral board set up menus, enter the IP address and port number of the analyzer followed by “userio.html” into your web browser’s address line as shown below.

  • Page 103: 12.2 The Status Tab

    12.2 The Status Tab 12.2.1 Information on the Status Tab The Status tab (Figure 12-1) presents information about the analog and digital inputs and outputs of the analyzer. These parameters are provided for reference and cannot be edited on this tab. Analog Outputs, Relay and Solenoid status can be edited and on the Manual Override tab (Section 12.3).

  • Page 104: 12.3 Manual Override Tab

    12.3 Manual Override Tab The Manual Override tab (Figure 12-2) allows the user to view and manually control the outputs of the analyzer. To take manual control of the outputs, place a checkmark in the Direct Peripheral Board Control check box. This tab allows the operator to make changes to the peripheral board of the instrument.

  • Page 105: Analog Output Fields

    12.3.1 Analog Output Fields Each Analog Output box allows the user to configure, calibrate and test an analog output. 12.3.1.1 Calibrating and Testing the Analog Outputs To test or calibrate any I/O point, first click on the Direct Peripheral Board Control checkbox.

  • Page 106: Testing The Digital Inputs

    The Description field for the analog output is provided to enter the name of the parameter being monitored analog output connector. The Unit field for the analog output is provided to enter the parameter units for the measured parameter. The Calculated Value field shows the present value of the output in the calibrated units. 12.3.2 Testing the Digital Inputs To test a digital Input:...

  • Page 107: Index

    Index Absorbance Page (Web GUI), 58 Dark Level, 40 AC Power Service Digital Inputs Connecting, 22 Testing, 106 Air Demand, 12 Digital Outputs, 29 Alarms, 46, 48 Testing, 106 Analog Output 4 Setup, 42 Digital Signal Cables Analog Output Fields, 105 Connection, 23 Analog Output Full Scale, 42 Display, 45...
  • Page 108 Probe Set Point, 47 Purge Fail Indicator, 30 Key Operating Parameters, 67 Keypad, 32 Quality Assurance Program, 90 LCD Backlight, 45 Loss of Purge Signal Receiving the System, 16 Connection, 24 Register Swap, 63 Low Cell Alarm, 48 Relay Indicator Fields, 34 Low Probe Alarm, 48 Relay Indicator Fields (Web GUI), 53 Routine Maintenance, 67...
  • Page 109 Unpacking, 17 User Interaction Program, 31 UV Source Lamp Changing, 78 Value Display (Web GUI), 51 WARRANTY, 10 Web Based Operation, 50 Zero Air Flow Adjust Valve, 27 Zero Hold Interval, 47 Zero Purge Interval, 47 Revision 4 August 02, 2019...
  • Page 110 Reason for Revision The changes incorporated in Revision 3.1 of the Operation Manual are in the addition of the level of detail for clarity only and do not affect product, processes or methods of protection used for approval. Revision 4 August 02, 2019...

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