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Green G7000 Operation Manual

Continuous emission monitoring system
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G7000 OPERATION MANUAL
CONTINUOUS EMISSION MONITORING SYSTEM
PART NUMBER: 03135

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  • Page 1 G7000 OPERATION MANUAL CONTINUOUS EMISSION MONITORING SYSTEM PART NUMBER: 03135...

  • Page 3: Table Of Contents

    CEMS Content ....................6 NTRODUCTION ......................6 BOUT THIS ANUAL ....................7 NQUIRIES AND EEDBACK ......................7 BOUT THE YSTEM ....................9 PECIFICATIONS ................... 11 AFETY SPECTS ..................14 TRUCTURE ..........................15 1 - 5 ........................15 ROBE ..........................16 ..........................
  • Page 4 ...................... 53 PPENDIX 11.1 T ECHNICAL OCUMENTATION ...................53 12 M & T .............. 54 AINTENANCE ROUBLESHOOTING IG-G7000-001 ........................58 IG-G7000-002 ........................60 IG-G7000-003 ........................61 IG-G7000-004 ........................62 IG-G7000-005 ........................65 IG-G7000-006 ........................66 IG-G7000-011 .........................67 IG-G7000-012 ........................68 IG-G7000-013 ........................70 IG-G7000-014 ........................72 IG-G7000-017 ........................74 IG-G7000-018 ........................77 IG-G7000-019 ........................79...
  • Page 5 ....................34 IGURE AS FLOW ADJUSTING 6-1 F ....... 37 IGURE LOW CHART OF REQUIRED STEP FOR ALIDATION AND ALIBRATION 8-1: P G7000 CEMS S ......43 IGURE LANNED AINTENANCE ROGRAM FOR THE YSTEM 10-1 A ..................52 IGURE NALYZER HOSE CONNECTIONS...

  • Page 6: Introduction

    Introduction 1 Introduction About this Manual This manual contains data and instructions for the operation and maintenance of the G7000 Continuous Emission Monitoring System (CEMS). For the installation of the CEMS, please refer to the installation manual. The instructions have been made in general terms and do not take into consideration a specific installation.

  • Page 7: Inquiries And Feedback

    CEMS Inquiries and Feedback All claims and inquiries for spares shall be addressed to Green Instruments A/S or our distributors. In all correspondence or when ordering spare parts, please carefully state the equipment type and serial number, which can be found on the label of the equipment.
  • Page 8 Introduction and acidic exhaust gas after a scrubber. The robust design is aimed for harsh marine applications and long intervals between services. The CEMS is designed for easy calibration and maintenance. The system is arranged with automatic calibration by means of Internal Calibration Glasses together with instrument air.

  • Page 9: Specifications

    CEMS 2 Specifications CEMS Function Monitoring of SO2, CO2 and other required gases which is compliant with IMO regulations – NOx Technical Code 2008 and MEPC.259(68) Equipment Multigas analyzer, multiplexer in case of multiple probes, gas cooler, gas pump, condensate pump, air conditioner, HMI, PLC, Gas filter, Condensate alarm Power Supply/ Consumption Refer to electrical drawings 7.5”...
  • Page 10 Specifications ≤ ±0.3 % of full scale whichever is larger ≤ ±1 % of full scale above 100 ppm or Precision/Repeatability ≤ ±2 % of full scale below 100 ppm Each ≤ ±2 % of full scale Noise, zero drift, span drift Auto-Calibration Zero Calibration: Automatic using compressed air.

  • Page 11: Safety Aspects

    If the system is used in a manner not approved by Green Instruments A/S, the function and protection provided by the equipment may be impaired.
  • Page 12 Safety Aspects be in close proximity to the system and within easy reach of the operator. The CEMS is fitted with a safety switch, placed underneath the air condition unit, and this interrupts the power to the downstream components. Overload protection! For compliance with the safety requirements IEC 61010-1 (2010), the installation must include a means of overcurrent protection to provide protection against excessive energy being drawn from the power supply system in case of a fault in the equipment.
  • Page 13 CEMS Harmful components! The exhaust gas is hot and may contain poisonous media that are potential harmful to humans. Before removing any component in the gas sampling system, make sure that the gas channel is plugged to avoid exhaust gas escaping. Condensate from gas driers may be aggressive and cause corrosion and chemical burns.

  • Page 14: Menu Structure

    Menu Structure 4 Menu Structure The monitor unit uses an HMI module as a combined work and operating station. Figure 4-1: Home Menu Screen The 5 probe buttons on top of the HMI screen with status information are common for all the views in the HMI system.

  • Page 15: Home

    CEMS Home Home displays an overview of all current measurements. The current state of the system and the probes can also be seen as status information on the probe and status buttons. It is always possible to go back to Home from any page or sub-menu by pressing the Home button on the right of the HMI screen.

  • Page 16: Log

    Menu Structure Standby: the probe is currently heated up to operation temperature and in standby mode, i.e. ready to sample. Figure 4-3: Probe 1 – Probes and analyzing cabinet in measuring state Figure 4-4: Probe 1 – Probes and analyzing cabinet in heating state Note This logging function cannot substitute the data recording and processing device according to IMO regulations MEPC 259(68)

  • Page 17: Figure 4-5: So2 Log Screen

    Each probe has its own colour trend curve. The colour is indicated in the probe buttons on top of the Log screen. Figure 4-5 shows that the blue trend curve is for probe 1(Eng-1), green for probe 2(Eng-2), yellow for probe 3(DG-1), white for probe 4(DG-2) and red for probe 5(Inc.).

  • Page 18: Login

    Menu Structure Note: Do not remove the memory stick before the “Log -> USB” button changes to the normal appearance. Historic Alarm Log can be found on the memory stick as CSV files which can be imported into a spread sheet. Login 1.

  • Page 19: Figure 4-6 Status Page In Measuring Mode

    CEMS Validate: The system is in validation mode Figure 4-6 Status page in Measuring Mode The status page displays an alarm list in a table. Message: Alarm description Date: The date when alarm starts Time: The time when alarm starts State: Status of alarm, which can be active, unacknowledged (UNACK) or acknowledged (ACK) RTN: means return to normal, which is the time when the alarm ends...

  • Page 20: Figure 4-7 Alarm List Overview

    Menu Structure HMI Error Message Warning Alarm Description Hose 2 Temp Heating Hose 2 Temp. Low Hose 3 Temp Heating Hose 3 Temp. Low Hose 4 Temp Heating Hose 4 Temp. Low Hose 5 Temp Heating Hose 5 Temp. Low Liquid A Condensate A level too High Liquid B...

  • Page 21: Io Status

    IO status page is important to diagnose any error occurred in the system. Green indicates that the components are powered with no alarms. Grey indicates either those items are not configured for the system or are unpowered.

  • Page 22: Figure 4-8: Io Status

    Green Heat Probe button means that the probe is activated. Grey Heat Probe button, means the power is OFF, • The green line at the left side of a Heat Probe button indicates the temperature of the probe is ok with no alarms •...
  • Page 23 Green line means the Gas Cooler temperature is within limits Gas Pump A-B: Green or grey Gas Pump button indicates that power is ON or OFF for the relevant Gas Pump • Red line at the edge of the button means there is a low flow alarm •...

  • Page 24: Manual Operating System Components

    I.e. if there is a flow alarm, the relevant Gas pump and valves can be turned ON or OFF manually to allow adjustment of the flow. For manual operation please refer to IG-G7000-011. 4.5.3 Reset system...

  • Page 25: Figure 4-10: Setup Screen

    The Remote Lockout and Use DI Sample have no setting page. : Grey indicates that the system is controlled via Modbus TCP. When Remote Lockout is selected (Green) it is not possible to control the system via Modbus TCP, but the measured values will still be provided.

  • Page 26: Probe Setting

    : This button, opens the Probe settings page Figure 4-13 Probe Setup Probe heating: Enable the probes to be active. The button will turn green with the text ON. The selected probes will start heating. Probe sampling: Used for manual control of sampling. When a probe is heated up to its operating temperature, the CEMS will start to sample from this probe.

  • Page 27: Alarm Setting

    CEMS 4.6.3 Alarm setting can be configured to application requirements. Warning levels: SO2/CO2 ratio, SO2 High, CO2 Low, CO2 High Alarm levels: SO2/CO2 ratio, SO2 High, CO2 Low, CO2 High Figure 4-15 Alarm Setup 4.6.4 Auto Calibration Setting Calibrate Setup: Calibration Setting screen will appear Interval [h]: Interval between two automatic calibrations.

  • Page 28: Average Settings

    Menu Structure Ignore Analyz Error: When active Green the CEMS will ignore all errors from the GAS Analyzer Deactivate Grey Ignore Analyz Error to return to normal condition 4.6.5 Average Settings To reduce fluctuating analyzer values, it is possible to alter the Avg T90 time and Moving Average (MOV AVG) see Figure 4-17.

  • Page 29: Change Password

    CEMS 4.6.6 Change Password Change PW: Press this and the screen for changing password will appear Figure 4-19 Change Password Press at the screen for entering the new Password and confirming the new password by press and then Close. Figure 4-20 Confirm Password 4.6.7 Change PLC IP address Change PLC IP: The PLC IP Address page will appear...

  • Page 30: Hmi Screen Setting

    Menu Structure The factory default PLC IP Address is 192 168 1 10 with PLC sub net 255 255 255 0. The PLC IP Address can be changed according to the user’s system. To change the IP address, key in the new IP address and press Write IP. There are 4 function buttons: Read IP: To read the current IP address Write IP: To confirm the new IP address after it is entered...

  • Page 31: Commissioning

    CEMS 5 Commissioning Before starting the CEMS for the first measuring sequence after completing the installation, please perform the leak test. Before the leak test, please check and confirm that all connections are installed according to the installation instruction. After completing the installation, please verify the installation and setup by making sure that: Probes The probes with the seal plugs have been installed according to the instructions...

  • Page 32: Monitoring Cabinet

    It is essential to perform a leak test during commissioning of the system. The leak test must be performed using the Instruction Guide: IG-G7000-022 for External Leak Test. If the leak is above the allowable limit, the gas hose from the Multiplexers/Tee-piece to the probes and the calibrating hose from probes to calibrating valves connections must be checked.

  • Page 33: Mounting The Probe Tubes

    CEMS Mounting the probe tubes Attention Probes and sample lines are hot. Please pay attention to the risk of burn. After performed leak test, the probe tubes shall be mounted on the probe by the following steps: Turn OFF the system and remove the probe from the flange socket, then remove the sealed plug Mount the probe tube on the probe.

  • Page 34: Figure 5-2: Gas Flow Adjusting

    Commissioning Increase the flow again to 100 l/h on the Gas Pump Decrease the flow to 60 l/h on the Flowmeter Figure 5-2: Gas flow adjusting...

  • Page 35: Calibration & Validation

    To carry out a manual calibration Refer to IG-G7000-006 for Calibration of Internal Optical Glasses. If the analyzer indicates an error i.e. due to lack of instrument air during calibration, the analyzer must be recalibrated.

  • Page 36: Annual Calibration & Validation Routine With Test Gases

    Gases. Note The G7000 analyzer is calibrated at factory. Please refer to the analyzer certificate. The validation of the calibration is to be performed according to the section 6 of Appendix 4 of the NOx Technical Code 2008, in which the calibration shall be checked.

  • Page 37: Figure 6-1 Flow Chart Of Required Step For Validation And Calibration

    CEMS cceptedValues Figure 6-1 Flow chart of required step for Validation and Calibration Version 2.7 – Revision February 2021...

  • Page 38: Operation

    The air conditioner will lower the temperature inside the enclosure to ensure proper operational temperature. The cooling is provided automatically and controlled by the Air Condition temperature controller Please contact Green Instruments if you encounter excess water coming from the air conditioner bottom drain. For more information read section 8.2 Air-conditioner...

  • Page 39: Leak Test

    It is recommended to test for internal leaks prior to testing for external leaks. A leak test can be performed using the Instruction Guides: IG-G7000-021 for Internal Leak Test IG-G7000-022 for External Leak test Version 2.7 – Revision February 2021...
  • Page 40 Routine Maintenance 8 Routine Maintenance Attention Do not use sharp or hard tools to clean the system. Use a tissue soaked with water to remove salt and fouling deposits! The multiplexer, probes and sample lines are hot during operation. Please pay attention to the risk of burn.
  • Page 41 The Instruction Guides from the Planned Maintenance program are in section 12 Planned Maintenance Program Instruction Guide Description Number (IG) Analyzer Analyzer – Annual IG-G7000-017 Gas calibration. IG-G7000-018 Air conditioner Visual check of Refer to Section 8.2 Air aircon filter and...
  • Page 42 Number (IG) Visual check of heated hoses Leaking gas line Check if CO2 level drops below expected level. Condensate switch Replacement of condensate Alarm IG-G7000-015 (03182) Condensate pump Visual check of IG-G7000-014 condensate pump Hose replacement of condensate pump IG-G7000-014 (03386)

  • Page 43: Figure 8-1: Planned Maintenance Program For The G7000 Cems System

    Description Number (IG) Test of calibration IG-G7000-029 air supply. Figure 8-1: Planned Maintenance Program for the G7000 CEMS System Air conditioner 8.2.1 Preventative Maintenance The air conditioner requires regular cleaning of the condenser air inlet filter. Wash the filter, whenever it appears physically dirty. Restriction to the flow of air over the condenser coil will degrade the performance of the equipment, causing it to overheat, reduce cooling and can damage the compressor.
  • Page 44 Routine Maintenance and thorough back-flush rinsing. Refer to directions on the cleaning compounds selected. Acid wash is not recommended as it reduces the life of the coil Condenser and Evaporator Fans use high efficiency, long life, sealed ball bearing fans engineered for optimum performance that require no maintenance. Keep fan blades clean for optimal performance...
  • Page 45 CEMS 9 Spare Parts Spare parts are not included in the standard delivery. Spare parts can be ordered when necessary. When ordering spare parts, please mention the serial number of the system. Part No. Part Description The specific appearance of the spare parts is subject change without notice;...
  • Page 46 Spare Parts Part No. Part Description The specific appearance of the spare parts is subject change without notice; the function however will not change DI/DO Modul – relay 03218 03219 AI modul (Temp) 03220 DO modul - PNP DO modul – relay 03221 03236 Gas cooler...
  • Page 47 CEMS Part No. Part Description The specific appearance of the spare parts is subject change without notice; the function however will not change Multiplexer block – for 3…5 stacks 03077 Multiplexer block –for 2 stacks 03029 03210 Safety switch 03276 Door switch 03121 Alarm relay...
  • Page 48 Spare Parts Part No. Part Description The specific appearance of the spare parts is subject change without notice; the function however will not change Calbr.Valve – 2 03343 Interface module for Ethernet RJ 03183 Flow alarm – Controller 03204 03206 Fuse base 02198 Fuse Automatic 10A...
  • Page 49 CEMS Part No. Part Description The specific appearance of the spare parts is subject change without notice; the function however will not change 03013 Sample Gas Filter 03235 Filter Insert-Pack of 5 pcs 00657 Filter Regulator 1/8, 0-2 bar 03136 Temperature Sensor Ø3x30mm Compl.Probe Head without Probe 03388...
  • Page 50 Spare Parts Part No. Part Description The specific appearance of the spare parts is subject change without notice; the function however will not change AC – Filter Insert 03385 03386 Tube f. Condensate Pump 03387 Bellow f. Gas Pump 03234 Bypass v/v f.gas pump 03044 Heating element...
  • Page 51 No Of Probe of probes. The table below can be used based on number of probes. 1 x 03848 Maintenance Kit 1-year G7000 for each probe 1 x 03662 Maintenance Kit 1-year G7000 1 stack system 2 x 03848 Maintenance Kit 1-year G7000 for each probe 1 x 03663 Maintenance Kit 1-year G7000 2…5 stacks system...

  • Page 52: Figure 10-1 Analyzer Hose Connections

    Packing of Gas Analyzer 10 Packing of Gas Analyzer 10.1 Packing Before disconnection: Flush the Analyzer refer to IG-G7000-029 to perform flushing of the Analyzer Unmount the gas hose (1) and (2) from the fittings and tightly seal the gas ports. See...
  • Page 53 11.1 Technical Documentation List Document name G7000 – Installation Layout – CEMS Delivered with system G7000 – Installation Layout – Multigas probe Delivered with system G7000 – Installation Layout – Heated Hose Delivered with system G7000 – Component Overview – CEMS Delivered with system G7000 –...
  • Page 54 Trouble Points of interest Guide Activate the → If a component needs to be activated IG-G7000-011 components manually → Follow the Flow alarm Flowchart Flow alarm IG-G7000-001 IG-G7000-002 IG-G7000-003...
  • Page 55 CEMS Trouble Points of interest Guide → Replace the Condensate Alarm Broken Condensate IG-G7000-015 Alarm → Replace the Condensate Pump Broken Condensate IG-G7000-016 Pump → Replace 3-Way valve Broken 3-Way Valve IG-G7000-024 Version 2.7 – Revision February 2021...
  • Page 56 Turn the flow Is the flow meter Action meter glass activate the Gas pump follow the glass pipe rotated? IG-G7000-001 pipe instruction in section 4.5.2 Make sure the gas pump can be activated before starting Is the needle valve troubleshooting.
  • Page 57 CEMS Instruction Guide Table Number Name In OM request IG-G7000-001 Turn the Flow meter glass pipe IG-G7000-002 Adjust the Flow for the Gas Pump IG-G7000-003 Replace Internal Gas Filter IG-G7000-004 Replace Probe Filter IG-G7000-005 Blocked Gas Return IG-G7000-006 Calibration with Internal Calibration cells...
  • Page 58 Maintenance & Troubleshooting Instruction Guide: G7000 MULTI GAS SYSTEM IG-G7000-001 Task: Control of incorrect mounted flow meter glass Description: This instruction identifies how to adjust the flow meter glass if it is mounted incorrect and cause a Flow alarm. And how to adjust the electric flow controller...
  • Page 59 There can be up to 15 turns to the point where the LED indication (OK and Alarm) switches from red to green or green to red. See picture “D” 3. The exact adjustment is where the OK/Alarm shift from green to red.
  • Page 60 Note: This operation must only be carried out by a trained technician Instruction: Photo: Note: The gas pump must be active. Refer to IG- G7000-011-Operate the system in manual mode Steps to adjust the Flow: 1. Open the flowmeter valve completely. By turning the valve to the left +.
  • Page 61 CEMS Instruction Guide: G7000 MULTI GAS SYSTEM IG-G7000-003 Task: Replace internal gas filter Description: This instruction identifies how to replace the internal gas filter Difficulty 1-5 Spare Parts: Estimated Time #03235 Filter insert-pack 10 min Note: This operation must only be carried out by a trained technician Turn off safety switch.
  • Page 62 -or see IG-G7000-011-Operate the system in manual mode ● Open the calibrating air valve using "Sample Probe" button. For manual operation refer to section 4.5.2 -or see to IG-G7000-011-Operate the system in manual mode ● The probe heat must remain active ●...
  • Page 63 CEMS Instruction Guide: G7000 MULTI GAS SYSTEM IG-G7000-004 Instruction: Photo: Attention: The Probe and the Filter are hot. Note: Make sure to have a new O-ring set for the handle before replacing the sample gas filter! The filter collects dust particles inside, which makes it difficult to see the amount of contamination outside.
  • Page 64 Maintenance & Troubleshooting Instruction Guide G7000 MULTI GAS SYSTEM IG-G7000-004 Note: This operation must only be carried out by a trained technician Instruction: Photo: A. Follow the instructions above B. Loos the 4 thumb screws to gain access to the probe handle and filter C.
  • Page 65 CEMS Instruction Guide: G7000 MULTI GAS SYSTEM IG-G7000-005 Task: Check for blocked Sample Gas return hose Description: This instruction identifies how to check if the sample gas return hose is blocked. Difficulty 1-5 Spare Parts: Estimated Time 30 min Note: This operation must only be carried out by a trained technician...
  • Page 66 Note: This operation must only be carried out by a trained technician Instruction: Photo: Note: A log in is required for this operation Refer to IG-G7000-011-Operate the system in manual mode Make sure there is sufficient instrument air flushed through the system for this process.
  • Page 67 CEMS Instruction Guide: G7000 MULTI GAS SYSTEM IG-G7000-011 Task: How to set the system in manual mode Description: This instruction identifies how the system outputs can be operated manually from the IO Status Page. Attention: Some safety features will be disabled during operation in manual mode.
  • Page 68 Maintenance & Troubleshooting Instruction Guide: G7000 MULTI GAS SYSTEM IG-G7000-012 Task: Clean/Replace the Multiplexer steel pipe Description: This instruction identifies How to clean the steel pipe from the multiplexer outlet Difficulty 1-5 Spare Parts: Estimated Time #03567 Pipe from Manifold As. Right 30 min #03568 Pipe from Manifold As.
  • Page 69 CEMS Instruction Guide: G7000 MULTI GAS SYSTEM IG-G7000-012 6. Remount the outlet steel pipes back in the same position as before. See picture “C” 7. Tighten the union nuts at the multiplexer by hand until perceptible resistance then use the 12 mm wrench.
  • Page 70 Maintenance & Troubleshooting Instruction Guide: G7000 MULTI GAS SYSTEM IG-G7000-013 Task: Check the Condensate alarm and Condensate Pump Description: This instruction identifies how to check the Condensate alarm and the Condensate Pump. Difficulty 1-5 Spare Parts: Estimated Time # 03182 Condensate alarm...
  • Page 71 CEMS Instruction Guide: G7000 MULTI GAS SYSTEM IG-G7000-013 Instruction: Photo: Inspection of the Condensate Pump: Check if: • the Condensate Pump rotates • the Condensate Pump is activated by the PLC The Condensate pump should run at all time. •...
  • Page 72 Note: Stop the Condensate Pump if necessary Refer to IG-G7000-011-Operate the System in manual mode The hose needs to be changed according to the planned maintenance program in the Operational Manual if the pump shall remain functional.
  • Page 73 CEMS Instruction Guide: G7000 MULTI GAS SYSTEM IG-G7000-014 Instruction: Photo: Warning: Protective gloves and glass is required. Note: Replacement of the Pump hose can damage the electronics. Cover all components below before start. 1. Stop the Condensate Pump Refer to IG-G7000-011-Operate the System in manual mode 2.
  • Page 74 #03881 Test gas kit Note: To perform this operation, log in is required. See Guide IG-G7000-011-Operate the system in manual mode Attention: This instruction requires Software greater then: V3.4.0 This operation must only be carried out by a trained technician...
  • Page 75 CEMS Instruction Guide: G7000 MULTI GAS SYSTEM IG-G7000-017 Instruction: Photo 5. Press “OK” to confirm that the hose is connected. See picture “A” 6. An info screen appears with the note: “Wait 5 minute for stable readings for SO2 ppm and CO2 % “, then press “OK”.
  • Page 76 Maintenance & Troubleshooting Instruction Guide: G7000 MULTI GAS SYSTEM IG-G7000-017 Instruction: Photo SPAN Gas Validation: 9. Apply the certified mixed Span gas to the “Test Gas Inlet” (Refer to the span test gas bottle i.e.: SO2 = 200 ppm and CO2 = 10 %).
  • Page 77 #03881 Test gas kit 60 min Note: To perform this operation, log in is required. See Guide for manual operation: IG-G7000-011-Operate the system in manual mode Attention: This instruction requiers Software greater than Version 3.4.0 Perform Calibration and Validation using:...
  • Page 78 Maintenance & Troubleshooting Instruction Guide: G7000 MULTI GAS SYSTEM IG-G7000-018 Instruction: Photo: 9. Calculate Factor for SO2 �� − ������ ������������ ������ ��������������: ������ ������������ = ������ − ������ �������� �������� ��−������ = 1,02 ��.��−������,�� Write it in SO2 Factor See picture “C”...
  • Page 79 2. Check that the Air Con is switched ON, see picture “B” 3. Check the connection to the Thermo-Couples, placed on the PLC inside the enclosure, for checking pull gently in the white/green cables. see picture “C” Note: See the electrical diagrams in the documentation folder for correct connection...
  • Page 80 Maintenance & Troubleshooting Instruction Guide: G7000 MULTI GAS SYSTEM IG-G7000-019 Instruction: Photo: How to adjust the “Set-Point” If not correct adjusted. Default Setting = 30°C 8. Press and hold “SET” for 2 sec see picture “C”. The icon “°C” will start...
  • Page 81 CEMS Instruction Guide: G7000 MULTI GAS SYSTEM IG-G7000-020 Task: Replace or Clean the Air Condition Filter This instruction identifies how to clean and replace the Air Condition Description: Filter Difficulty 1-5 Spare Parts: Estimated Time #03385 AC-Filter Insert 15 min...
  • Page 82 Maintenance & Troubleshooting Instruction Guide: G7000 MULTI GAS SYSTEM IG-G7000-021 Task: How to perform internal leak test Description: This instruction identifies how to perform an internal leak test. Difficulty 1-5 Spare Parts: Estimated Time # 02366 Elbow Fitting 6/4mm – ¼” PVDF...
  • Page 83 G7000 MULTI GAS SYSTEM IG-G7000-021 Instruction: Photo: To perform this operation, a log in is required. See: IG-G7000-011-Operate the system in manual mode 1. Turn off (grey) all gas pumps using the “IO Status” and manual select button. See picture “A”...
  • Page 84 Maintenance & Troubleshooting Instruction Guide: G7000 MULTI GAS SYSTEM IG-G7000-021 Instruction: Photo: For 1-stack system without multiplexer installed: 4. For 1-stack systems (Only B-side installed) disconnect the sample gas inlet hose at the tee-piece connector in the top right corner of the enclosure 5.
  • Page 85 CEMS Instruction Guide: G7000 MULTI GAS SYSTEM IG-G7000-021 Instruction: Photo: 8. For systems with multiplexer installed: Start the gas pump A via “IO Status Manual Select” See picture “A” For One-Stack systems: Start gas pump B (Only B-side installed) via “IO Status Manual Select”...
  • Page 86 Maintenance & Troubleshooting Instruction Guide: G7000 MULTI GAS SYSTEM IG-G7000-021 Instruction: Photo: 16. For 1 stack system. Remove the thumb from the Sample gas inlet connection. Reinstall the hose to the fittings 17. System with multiplexer installed. Open the gas valve through the “IO status Manual select”...
  • Page 87 CEMS Instruction Guide: G7000 MULTI GAS SYSTEM IG-G7000-022 Task: How to perform External Leak Test Description: This instruction identifies how to perform an External leak test. Difficulty 1-5 Spare Parts: Estimated Time # 02366 Elbow Fitting 6/4mm – ¼” PVDF...
  • Page 88 Maintenance & Troubleshooting Instruction Guide: G7000 MULTI GAS SYSTEM IG-G7000-022 Instruction: Photo: Commissioning Initial leak test before operation As a part of commissioning, a leak test must be performed to ensure no leakage in the system, heated hose or probe.
  • Page 89 Instruction: Photo: To perform this operation, a log in is required. See: IG-G7000-011-Operate the system in manual mode External leak test can only be performed when the probe is sealed with a sealed plug. 1. Turn OFF (grey) all Gas Pumps using the “IO Status”...
  • Page 90 4. The external leak test can be performed for “Gas Valve” [A1,2,3,4,5] or [B1,2,3,4,5] 5. To open (green) or close (grey) the “Gas Valves” use the “IO Status” page. See picture “F”...
  • Page 91 14. After end test, the flow needs to be re-adjusted: Refer to: IG-G7000-002-Adjust the Flow for The Gas Pump *(If the amount of bubbles exceeds 40 bubbles/minute then search for a leak on the...
  • Page 92 Maintenance & Troubleshooting Instruction Guide: G7000 MULTI GAS SYSTEM IG-G7000-023 Task: Replacement of Bellow and Bypass Valve in Gas Pump Description: This instruction identifies cleaning or replacement of the bellow and bypass valve in gas pump Difficulty 1-5 Spare Parts: Estimated Time #03387 Bellow f.
  • Page 93 CEMS Instruction Guide: G7000 MULTI GAS SYSTEM IG-G7000-023 Instruction: Photo: 4. Dismount the front of the Gas Pump using the Torx 10 Screwdriver, see picture “D” 5. Dismount the top of the Gas Pump using the Torx 20 Screwdriver see picture “E”...
  • Page 94 Maintenance & Troubleshooting Instruction Guide: G7000 MULTI GAS SYSTEM IG-G7000-023 Instruction: Photo: Wrap the Elbow fittings with new Teflon tape 10. Remount the gasket carefully and make sure the orientation is correct 11. Remount the new bypass valve, make sure the orientation is correct 12.
  • Page 95 Note: This operation must only be carried out by a trained technician Instruction: Photo: Note: For this Instruction, the system must be operated in manual mode. Refer to IG-G7000-011-Operate the system in manual mode. 1. Activate the Gas ValveA1, Zero Valve1 and the Gas PumpA, see picture “A”...
  • Page 96 Maintenance & Troubleshooting Instruction Guide: G7000 MULTI GAS SYSTEM IG-G7000-029 Instruction: Photo: 3. Wait approx. 2 min, and read out the measurement for the Probe1 the value should reach 0% - CO2 and 0 ppm-SO2 4. Deactivate the Gas pump,Close...
  • Page 97 Green Instruments A/S Green Instruments USA, Inc. Green Instruments (S) Pte. Ltd. sales@greeninstruments.com usa@greeninstruments.com sales.sg@greeninstruments.com Erhvervsparken 29 6750 N. Andrews Avenue Suite 200 4008 Ang Mo Kio Avenue 10 9700 Brønderslev, Denmark...

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