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Table of Contents
Summary of Contents for DOD Technologies DOD64-FTIR
- Page 1 DOD 64 FTIR Gas Monitor User Manual...
- Page 2 FTIR Manual © DOD Technologies, INC 675 Industrial Drive Bldg. A. Cary, IL 60013 Phone 815.788.5200 • Fax 815.788.5300 DC-ITD-FTIR-MAN01 www.dodtec.com FEB 2020 815-788-5200...
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Page 3: Table Of Contents
FTIR Manual Table of Contents Chapter 1 – Overview ..................................6 1.1 Introduction ....................................6 1.2 Sampling and Analyzing ................................6 1.3 Nitrogen Purging ..................................6 1.4 Sample Line & Exhaust Connections ............................. 7 1.5 Electrical Connections ................................7 1.6 Spectra and Event/Trend File ..............................7 Chapter 2 –... - Page 4 5.3.6.3 Setup > History > Spectra ............................... 35 Chapter 6 – Maintenance ................................36 6.1 Return the DOD64-FTIR to A Safe State After Service ....................... 36 6.2 Service Area Door Access ..............................36 6.3 End-of-Line Particulate Filter Replacement ........................37 6.4 Flow Adjustment ..................................
- Page 5 FTIR Manual B.1 EK1101 Coupler..................................41 B.2 Standard Output Module (24 v Sinking) ..........................42 B.2.1 DOD64 General Outputs ..............................42 B.2.2 Analyzer General ................................. 42 B.2.3 Point Outputs** ................................... 43 Appendix C – System Specifications ............................44 Appendix D – System Event Message ............................45 Appendix F –...
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Page 6: Chapter 1 - Overview
The DOD64-FTIR system can be configured with a maximum of 4 manifolds and each manifold has 16 sample points. Gas detection and analysis occurs in the DOD64’s Interferometer located above the pump panel within the service door. -
Page 7: Sample Line & Exhaust Connections
Exhaust ports are located on the right-side panel of the DOD64-FTIR and are also labeled. Each sample line should be extended a maximum of 400 ft. and each exhaust line should be extended a maximum of 25 ft. -
Page 8: Chapter 2 - Features
2.1.1 Warning Labels, Descriptions, & Danger Zones The below table references all warning labels and their meanings that may be encountered while operating and servicing the DOD64-FTIR gas detection system. WARNING: Hot Surface. This surface will be hot to touch and may cause injury. Please avoid or take caution when working near this zone. -
Page 9: Touch Screen Display
2.2 Touch Screen Display The DOD64-FTIR features a 19”, full color, LCD touch screen display, enhancing the presentation and visibility of data. All DOD64-FTIR menus and data points are accessible through this state-of-the-art HMI. (Figure 2.1). The display also offers the ability to use USB type mouse and keyboard during data analysis. -
Page 10: Ftir Interferometer
FTIR Manual 2.5 FTIR Interferometer The DOD64-FTIR features an MKS MCT Detector or Perk & Elmer DTGS detector. The MKS detector comes with a patented 400ml IR cell with a 10-meter optical path and an internal cooling system. This design allows a fast sampling time that leads to reduced total time for analysis. -
Page 11: Service Areas
FTIR Manual 2.10 Service Areas The service areas allow easy access to the valves, manifolds, pumps, power supply, and the interferometer. Figure 2.3 shows the internal layout with the service areas open. Service areas are equipped with a lock to restrict internal access. -
Page 12: Password And Security
The DOD64-FTIR uses a USB Memory or a Solid-State Drive to store historical information including concentration logging, event history, configuration information, and spectra files. The use of higher speed USB Memory Sticks (2x, etc.) may not be compatible with the DOD64-FTIR. USB Memory Sticks may be purchased through DOD Technologies – see Appendix A. -
Page 13: Chapter 3 - Installation
The front opening panel door is designed to be used as ramp to roll the system out of the crate (see installation package for details). The DOD64-FTIR rests on four rollers which can be locked in place and bolted to the floor if necessary. -
Page 14: Sample Tubing
3.2 Sample Tubing Sample tubing is connected to the DOD64-FTIR on the top the unit. All sample tubes require 1/4” OD x 3/16” ID Teflon FEP (400 ft max length) which may be purchased from DOD Technologies, INC (See Appendix A). -
Page 15: Output Wiring
The standard output modules included with the system require an external 24V supply connected to the DOD64-FTIR to supply power for the outputs. Use only AWG22 to AWG18 twisted wire (wire sizes UL1015 and UL1007) Strip from 0.25” to 0.31” (6.5mm to 8.0mm) from each wire to insert into the connector. To connect the wires to the spring-loaded output connector: •... -
Page 16: Chapter 4 - Setup & Configuration
Chapter 4 – Setup & Configuration 4.1 Touch Screen Calibration After powering on the DOD64-FTIR, the machine will display a crosshair in each corner of the screen. Press the center of each crosshair to configure the touchscreen. Without the correct calibration of the screen and touch function will not work correctly. -
Page 17: Setup Complete
FTIR Manual 4.7 Setup Complete It is now safe enter analysis. DC-ITD-FTIR-MAN01 www.dodtec.com FEB 2020 815-788-5200... -
Page 18: Chapter 5 - Basic Operation And Menus
5.2 General Machine Operation When the DOD64-FTIR is powered on it will begin with the initialization screen which is followed by a countdown (figure 5.1). The machine will then go into analysis and display the analysis screen. If the operator touches the ‘SETUP MODE’... -
Page 19: Analysis Screen
FTIR Manual Figure 5.1 The touchscreen on the DOD64-FTIR is used for all configuration and control of the unit. Analysis mode is active by default approximately two minutes after power on unless an operator intervenes. At this point the DOD64-FTIR is designed to continuously monitor for gas. Various tasks can be completed while remaining in analysis, including viewing faults/events, concentration history, individual spectra files and TWA logs, or checking point configuration and flow limits. - Page 20 FTIR Manual Press Setup to end analysis Live Diagnostics Point and Gas Grid Spectra of Last Point Analyzed Figure 5.2 From here, you can see the status of each point. If more than one analyzer is installed, additional points can be viewed by pressing the left and right buttons at the top left of the screen.
- Page 21 FTIR Manual The status of each point is reported as it changes. Yellow indicates the point is being prepared for analysis. Blue indicates the point is being analyzed. Grey indicates the point is being purged of remaining gas from a previous window.
- Page 22 FTIR Manual Select the blue checkbox in order to display the calibration spectra for the chosen gas. The blue line shows the unique calibration spectra for the gas, while the red line shows the most recent full spectra analysis scan. When the spectra viewer is LIVE, the red spectra line will always show the spectra from the most recent analysis scan and change as each scan ends.
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Page 23: Faults And Events
FTIR Manual 5.2.1 Faults and Events Figure 5.3 Pressing the Faults/Events tab at the top of the Analysis screen will display the Faults/Events screen (figure 5.3), allowing you to view a detailed history of the machine’s faults and/or events. You may select any day on the calendar to view a log of that day’s events. -
Page 24: Concentration
To return to the main analysis screen, select close. The DOD64-FTIR will remain in the analysis mode while viewing this screen and the concentration log can also be accessed from the Setup > History menu. -
Page 25: Setup Menu
5.3 Setup Menu Entering the Setup Menu will end analysis and the DOD64-FTIR will no longer be actively monitoring the environment for gases. Touching the Setup button at the top of the analysis screen will bring you to the Setup menu and automatically display the Adjust Flow screen. -
Page 26: Setup > Configuration
FTIR Manual Figure 5.8 Touch the “Back” button to return to the setup menu. 5.3.2 Setup > Configuration Touching the “Configuration” while in the Setup menu will bring you to the Configuration Menu and display the Machine configuration screen (Fig 5.9). Figure 5.9 DC-ITD-FTIR-MAN01 www.dodtec.com... -
Page 27: Setup > Configuration > Machine
Flow faults are not affected by the latching faults option. Flow faults will never be latched on the DOD64-FTIR but will always be recorded in the event log when they occur and are cleared. 5.3.2.2 Setup > Configuration > Point Names Pressing the “Point Names”... -
Page 28: Setup > Configuration > Alarm Levels
FTIR Manual 5.3.2.3 Setup > Configuration > Alarm Levels Pressing the “Alarm Levels” tab while in the Setup > Configuration menu will bring you to the Alarm Levels screen (Fig 5.11). Figure 5.11 From here, you can set the concentration threshold of Alarm Level 1, Alarm Level 2, and Lower Explosive Limit for each individual point. -
Page 29: Setup > Ftir > Sequencing
FTIR Manual X Indicates the point is configured to detect the specific gas. Click to disable. Figure 5.12 5.3.3.2 Setup > FTIR > Sequencing While in the Setup > FTIR menu, press the “Sequencing” button to bring up the Sequencing screen Figure 5.13 This screen allows selection of the order in which points are sampled from and analyzed. -
Page 30: Setup > Ftir > Diagnostics
5.3.3.3 Setup > FTIR > Diagnostics This screen displays diagnostic values related to the function of the interferometer and is currently only available on the AIRGARD DOD64-FTIR version. Please contact DOD for more information on the DOD64-FTIR Diagnostics screen. Figure 5.14 5.3.3.4 Setup >... -
Page 31: Setup > Ftir > Rdp
5.3.3.5 Setup > FTIR > RDP This screen allows the operator to connect to the Interferometer. Note: Connecting to the Interferometer will require restarting the DOD64-FTIR. This option should only be used when necessary and by DOD a trained operator. -
Page 32: Setup > Testing > Ethernet/Ip
FTIR Manual Figure 5.17 In order to test the valve and flow system the Transport or FTIR pump should be activated. Press a specific valve to observe its flow rate, pressure, and temperature (MKS Only). The information on this screen is useful when testing pumps and individual point flow. -
Page 33: Setup > Testing > 4-20 Ma
FTIR Manual Figure 5.18 5.3.4.4 Setup > Testing > 4-20 Ma If the DOD64-FTIR is purchased with the optional analog 4-20 mA outputs each output can be tested or adjusted from the Setup > Testing > 4-20 Ma screen. Figure 5.19 DC-ITD-FTIR-MAN01 www.dodtec.com... -
Page 34: Setup > File Transfer
• Copy (Only Conc > 0) – Only transfers files where concentrations read above zero From the screen you can also view the remaining space left on the internal drive of the DOD64-FTIR. 5.3.6 Setup > History Pressing the “History” button from the Setup Menu will bring you to the History menu and display the “Faults/Events”... -
Page 35: Setup > History > Faults Events
FTIR Manual 5.3.6.1 Setup > History > Faults Events This screen automatically displays when entering the Setup > History menu from the Setup menu. This screen can also be accessed from the Analysis screen by pressing the “Faults/Events” button at the top of the screen. -
Page 36: Chapter 6 - Maintenance
Please contact DOD Technologies for the safe return of your equipment. All discontinued units will be accepted back by DOD Technologies so proper recycling may take place. For information on how to return the unit contact us using the below information: 6.1 Return the DOD64-FTIR to A Safe State After Service... -
Page 37: End-Of-Line Particulate Filter Replacement
6.3 End-of-Line Particulate Filter Replacement End of line (point of detection) particulate filters which protect the DOD64-FTIR from damage are required on all points including points not being monitored. Table 7.1 details the type of filter required for each gas. -
Page 38: Fuse Replacement
FTIR Manual 6.6 Fuse Replacement The system is protected with a 6-amp fast acting (5x20mm) fuse WARNING: Turn off machine and disconnect power cord from the power source before servicing the fuse. 6.7 Detector Service Refer to the detector user manual for specific maintenance requirements related to either the Spectrum 2 or AIRGARD. -
Page 39: Chapter 7 - Service & Support
FTIR Manual Chapter 7 – Service & Support For information on service and support for your DOD64 contact DOD Technologies, INC. using the information below. solutions@dodtec.com Email: Phone: 815-788-5200 Fax: 815-788-5300 www.dodtec.com Web: Hours: 8:30 – 5 PM CST Office Location: 675 Industrial Dr. -
Page 40: Appendix A - Parts List
4 $1,490.00 2-800-A14-96 ASSEMBLY TRANSDUCER PCB (new style) up to 8 $380.00 2-200-251 Industrial PC For DOD64-FTIR $3,600.00 2-800-206 Manifold FTIR Valve $740.00 2-800-A33 FTIR Pump Assy - Side Port - 115 VAC (SN: 8399 and Below) $430.00... -
Page 41: Appendix B - I/O Connection Details (Cont.)
EK1101 module. Two different power sources are used for the module. Power to operate the module itself is supplied by the DOD64 power and prewired by DOD Technologies - Do NOT remove. Power for all outputs must be supplied by the customer on pins 6 & 7. -
Page 42: Standard Output Module (24 V Sinking)
FTIR Manual B.2 Standard Output Module (24 v Sinking) B.2.1 DOD64 General Outputs Output # Description Critical General Alarm 1 Alarm 2 Analysis Active Watchdog Power On (EMPTY) B.2.2 Analyzer General Output # Description Critical General Alarm 1 Alarm 2 Analysis Active Watchdog Power On... -
Page 43: Point Outputs
FTIR Manual B.2.3 Point Outputs** Output # Description Pt X Alarm 1 Pt X Alarm 2 Pt (X+1) Alarm 1 Pt (X+1) Alarm 2 Pt (X+2) Alarm 1 Pt (X+2) Alarm 2 Pt (X+3) Alarm 1 Pt (X+3) Alarm 2 **For Each Module X = the lowest point # DC-ITD-FTIR-MAN01 www.dodtec.com... -
Page 44: Appendix C - System Specifications
FTIR Manual Appendix C – System Specifications The DOD64-FTIR Sequential gas monitor is approved for use under the following conditions: • Indoor use only • Altitude up to 2,000 m • Temperatures 5°C - 40°C • Maximum relative humidity 80% for temperatures up to 31°C decreasing linearly to 50% relative humidity at 40 °C... -
Page 45: Appendix D - System Event Message
Critical Fault Wiring error, network error to output modules 64007 PLC Comm Error Critical Fault System Fault Contact DOD Technologies Power Fault with Perkin Elmer Check Wiring and Test Spectrum 64076 Spectrum Comm Failure Critical Fault System, connection error Software interface... - Page 46 FTIR Manual General Wiring error or power loss to 64075 Spectrum Comm Error Fault Perkin Elmer System General 64078 Spectrum Diagnostic Warning See Perkin Elmer faults Fault 64062 Exit Analysis for Setup Menu Information For information purposes only 64006 Faults & Alarms Reset Information For information purposes only 64061...
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Page 47: Appendix F - Optional Communication Interfaces
FTIR Manual Appendix F – Optional Communication Interfaces F.1 Ethernet IP FTIR Faults/ Alarms (Discrete Outputs) Token Description Type Machine Critical Fault Machine has critical fault Boolean Machine Maintenance Fault Machine has a maintenance fault Boolean Machine Gas Alarm 1 Level 1 Gas Alarm at Least 1 Machine Point Boolean Machine Gas Alarm 2... -
Page 48: Modbus Tcp/Ip
FTIR Manual Real [32] Array with Conc. For Up To Concentration Results During Scan 32 gasses Scan Date / Time **See Note Below 128 Byte Array – Alarm 1&2 for 64 Alarm Level 1 & 2 Indicators Pts. Faults / Alarms FTIR 8 Byte Array Defined Below DOD Gas Identification Number Array of 32 UINT (16 bit) Numbers... - Page 49 FTIR Manual Default Slave ID: 1 Total Size: 208 Words (Word) Address # Words Type Data Description Format 40001 Bits FTIR Analyzer Faults *See Below 40002 Bits Analyzer A Faults *See Below 40003 Bits Analyzer B Faults *See Below 40004 Bits Analyzer C Faults *See Below...
- Page 50 FTIR Manual Gas Type Code Gas & Range Range AsH3 500ppb B2H6 1000ppb GeH4 2000ppb H2Se 500 ppb 1500 ppb SiH4 50 ppm 5000 ppb 25 ppm 15 ppm 10 ppm 3200 ppb 20 ppm COCl2 4000 ppb AsH3 50 ppb 20 ppm AsH3 1000 ppb...
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Page 51: Pump Panel Diagram
FTIR Manual F.3 Pump Panel Diagram DC-ITD-FTIR-MAN01 www.dodtec.com FEB 2020 815-788-5200... -
Page 52: Flow Diagram
FTIR Manual F.4 Flow Diagram F.4 Control Box Diagram DC-ITD-FTIR-MAN01 www.dodtec.com FEB 2020 815-788-5200...
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