DURAG HM-1400 TRX 2 Operating Manual
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DURAG HM-1400 TRX 2 Operating Manual

Total mercury analyser
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HM-1400 TRX 2
Total Mercury Analyser
Before starting any work please read the operating
manual!
Article no.:
GmbH • Kollaustraße 105 • 22453 Hamburg • Germany • www.durag.com
4 019 962

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  • Page 1 HM-1400 TRX 2 Total Mercury Analyser Before starting any work please read the operating manual! Article no.: GmbH • Kollaustraße 105 • 22453 Hamburg • Germany • www.durag.com 4 019 962...
  • Page 2 Must not be reproduced or transferred in any manner, language or medium, electronic or mechan- ● ical, without the express permission of DURAG GmbH. The same applies to parts of the manual. Relates to the current device design version at the time this documentation was updated (see page ●...

  • Page 3: Table Of Contents

    5.2.3 Electrical connection ...................... 31 Installation sequence for the measurement system............ 32 Installation......................... 33 5.4.1 Installing the sampling probe .................... 33 5.4.2 Installation of the measurement instrument .............. 34 Connections ........................ 34 5.5.1 Sampling probe and sample gas line................ 34 5.5.2 Power supply ........................ 35 HM-1400 TRX 2...
  • Page 4 Notes on cleaning ...................... 71 Technical data  73 Dimensioned drawings  75 Messages/fault elimination  80 11.1 Monitored parameters and error messages in plain text........... 80 11.2 Causes of errors and their rectification ................ 81 Parameter list (device parameters in delivered condition)  87 Index  93 HM-1400 TRX 2...

  • Page 5: Information On This Manual

    Risk that could potentially lead to less serious or minor injury. ATTENTION Risk that could potentially lead to material or envir- onmental damage. Hazardous substance symbols Harmful to health Harmful to the environment Information symbols This symbol indicates potential material and environ- mental damage HM-1400 TRX 2...
  • Page 6 Risk of injury due to incorrect spare parts. WARNING Incorrect or faulty spare parts can cause malfunctions that can lead to serious injuries. ▶ Use only original spare parts from the manufacturer. ▶ Purchase spare parts from authorised dealers or directly from the manufacturer. HM-1400 TRX 2...

  • Page 7: Safety

    Damage to the insulation or individual components can present a risk to life. Work on electrical systems must only be performed by spe- cialised electricians. Before opening the housing or removing the HM-1400 TRX 2...

  • Page 8: Hazard Due To Hot, Aggressive, Explosive Gases Or To High Pressure Of Gas To Be Measured

    The HM‑1400 TRX 2 is not suitable for use in explosive gas mix- tures! 2.2.3 Hazards due to chemicals Chemicals always pose particular risks and hazards. They should therefore only be handled by appropriately trained per- sonnel with the necessary care. HM-1400 TRX 2...
  • Page 9 The company operating the measuring device is responsible for the handling, transportation and, where necessary, disposal of the chemicals. The German Ordinance on Hazardous Sub- stances and the separate safety data sheets for all used chemic- als must be observed here. HM-1400 TRX 2...

  • Page 10: Hazards Due To Hot Surfaces

    Electricians are specially trained for the working environment in which they operate. HM-1400 TRX 2...

  • Page 11: Description And Location Of Safety Equipment And Emergency Stop Mechanisms

    The device is expressly not permitted for use in potentially ex- plosive areas. The specifications set out in Section 9 Technical data [} 73] must be observed and complied with. If the device is not used as intended, the protection provided by the device may be impaired! HM-1400 TRX 2...

  • Page 12: Product Description

    IP54, ambient temperature +5 … +40 °C, tested for suitability according to EN 15267, with speciation unit, incl. internal HgCl test gas generator Table 3.1: Examples of different variants HM-1400 TRX 2...

  • Page 13: Designation Of Device Components

    Relay Safety temperature limiter for reactor S1 Switch A31 Mass flow controller for gas generator Fuse(s) A32 Mass flow controller for dilution ① T1 Power supply unit A33 HgCl evaporator X10 Socket for external test gas generator HM-1400 TRX 2...
  • Page 14 ① Option Fig. 3.2: Overview of components, designation of sampling probe Sampling probe housing cover Weld-in pipe with mounting flange Electric terminal box Sampling tube Adapter flange for heated sampling tube Sample gas line with two inner lines HM-1400 TRX 2...

  • Page 15: Theoretical Basis

    Speciation Reactor box Sample tube Sample probe Sample line Speciation Leak check Fig. 4.1: Substance flow plan HM‑1400 TRX 2 Gas inlet into stack ① Option Test connection (test gas application) Differential pressure sensor Zero gas Absolute pressure sensor HM-1400 TRX 2...

  • Page 16: Sampling System

    The sampling probe has a test gas connection. In order to test the measuring system, defined test gases are injected into the system via this inlet using a test gas generator. HM-1400 TRX 2...

  • Page 17: Thermocatalytic Reactor

    This is not soluble in water and has a sufficiently high vapour pressure. It remains in gas form even at temperat- ures around freezing point. As a result, the sample gas can be cooled to ambient temperature once it has left the reactor. HM-1400 TRX 2...
  • Page 18 To achieve this, a small quantity of potassium hydroxide solution is added to the sample gas. The potassium hydroxide solution reacts with and binds the acidic components of the gas. The potassium hydroxide solution prevents contamination of the gas-carrying lines and cross-sensitivity to sulphur dioxide. HM-1400 TRX 2...

  • Page 19: Gas Drier

    The photometer in the HM‑1400 TRX 2 therefore has two cells, a measurement cell and a reference cell. The sample gas first flows through the measurement cell. It is then transported via a selective mercury filter, after which it flows through the reference cell with the mercury removed. HM-1400 TRX 2...

  • Page 20: Standardisation

    As the flow decreases, the t-90 time in- creases. If the flow is too high, the cooler will be overloaded, and it will no longer be possible to guarantee the drying of the gas. The measurement process itself does not depend on the flow. HM-1400 TRX 2...

  • Page 21: Speciation (Optional)

    One special feature here is the device variant HM‑1400 TRX 2xx‑230‑x1xxH. This device does not contain a reactor, and continuously measures only the concentration of elemental mer- cury. Dilution (optional) The dilution option is not certified to EN 15267 and is only inten- ded for process measurements. HM-1400 TRX 2...
  • Page 22 To il- lustrate this, the dilution gas flow is marked in blue and the refer- ence gas flow is marked in green in the figure below. HM-1400 TRX 2...

  • Page 23: Zero Adjustment

    This value is then used as a new zero posi- tion, and all further measurements will be in relation to this zero position. HM-1400 TRX 2...

  • Page 24: Leak Test

    185 °C. The actual material flows of the mercury standard solution and the carrier gas are continu- HM-1400 TRX 2...

  • Page 25: Back-Purging

    HM‑1400 TRX 2 is performed by a PLC. There is an operat- ing display connected to the PLC, showing the current status and measured value. The parameterisation of the HM‑1400 TRX 2 is also performed via this display. HM-1400 TRX 2...

  • Page 26: Checking For Malfunctions

    5. The photometer does not have a stable zero point and is in- stead showing strong fluctuations. Maintenance requirement messages require a prompt response, as otherwise the measuring system will fail. HM-1400 TRX 2...

  • Page 27: Installation, Commissioning

    Carry out assembly work only when the plant is at a standstill. ▶ Before opening duct access points, ensure that there is no overpressure in the duct and that no hot or harmful gas is present. ▶ Wear personal protective equipment. HM-1400 TRX 2...
  • Page 28 (ESD). ▶ Take measures against electrostatic discharges (ESD protec- tion), to protect the components for all work on the opened device. ▶ Use a personnel grounding system or similar, to prevent static charging of the human body. HM-1400 TRX 2...

  • Page 29: Preparation For Installation

    It is not sufficient to insulate only the unheated sections! The temperature of all components containing sample gas must not drop below 160°C at any point. The target temperature of controlled heated components must not fall below 180°C. HM-1400 TRX 2...
  • Page 30 Possible material damage when making the opening in the duct. Falling parts may damage the duct wall or its coating. Do not allow parts that are cut out to fall into the duct. Create an opening in the measurement duct. HM-1400 TRX 2...

  • Page 31: Electrical Connection

    The customer must install a main switch in the mains supply line that can be used to disconnect the measuring system from the power supply. HM-1400 TRX 2...

  • Page 32: Installation Sequence For The Measurement System

    [} 36]. Establish the electrical connection of the HM‑1400 TRX 2 5.5.2 Power supply [} 35]. 10.Dispense the separately supplied chemicals into theHM‑1400 TRX 2 5.6 Using the chemicals necessary for op- eration [} 36]. 11.Commissioning 5.7 Commissioning with preset parameters [} 37]. HM-1400 TRX 2...
  • Page 33 7 Sampling probe connection (nuts, lock washers, washers) flange 4 Mounting flange on the weld-in 8 Sampling probe housing cover pipe Make sure the weld-in pipe is not too hot and that no harmful gases are escaping. HM-1400 TRX 2...

  • Page 34: Installation Of The Measurement Instrument

    3-way valve (Y1). The second inner line connects the test gas connection on the probe and the connection point provided in accordance with the applicable material flow sheet. HM-1400 TRX 2...

  • Page 35: Power Supply

    1.5 ‑ 1.8 Nm. The individual conduct- ors of the mains supply cable must be mutually secured (e.g. us- ing cable ties) in such a way that they cannot touch adjacent ter- minals when released. Fig. 5.4: Mains filter (example) HM-1400 TRX 2...

  • Page 36: Signal Lines

    The chemicals are supplied separately from the measuring in- strument, and must be used in the HM‑1400 TRX 2 in accord- ance with the valid maintenance instructions and taking into ac- count the information in the safety data sheets. HM-1400 TRX 2...

  • Page 37: Commissioning With Preset Parameters

    Sampling tube (E13) ● Sampling probe (E12) ● Sample gas line (E11) ● 3-way valve (Y1) ● Thermocatalytic reactor (A6 ) ● Cooler (M1) ● Sample gas temperature (B15) ● Evaporator (A33) for the internal gas generator ● HM-1400 TRX 2...

  • Page 38: Measuring Mode

    The device is disconnected from the power supply ● The device is secured against rolling away ● All chemicals have been removed from the device ● The relative humidity meets the following specifica- ● tions: ≤ 95 %, non-condensing, frost-free HM-1400 TRX 2...

  • Page 39: Dismantling

    Before disconnecting all connected lines (cables and hoses): Disconnect electrical connections from and to the device at the respective terminals. Disassemble all cables. Loosen the screw connections at the beginning and end of the sample gas line. HM-1400 TRX 2...

  • Page 40: 5.10.4 Disposal

    The national regulations for the procedure for the disposal of chemicals are set out in this Ordinance. The relevant material safety data sheets also provide important information on this subject under the headings "Disposal" and "Transport information". HM-1400 TRX 2...

  • Page 41: Operation

    Function key F2 (Back) exits a menu or screen and takes you to the previous menu or screen. Function key F3 (Event list) takes you to the event list (messages) from any menu. Function key F4 ("ENTER") executes the highlighted function in the current screen. Table 6.1: Key functions HM-1400 TRX 2...

  • Page 42: Basic Rules For Operation

    Abbreviations are often used in the display. The following table explains their meaning: Hgt/Hg Total mercury concentration total Hg0/Hg elemental mercury concentration Hg+/Hg Oxidised mercury concentration HM-1400 TRX 2...
  • Page 43 Dilution by Mass Flow Controller (option) Minimum value Monday MR/ Meas R. Measurement range Pamb./ Pabs. Ambient air pressure in hPa Programmable Logic Controller Photometer PM-Poti Potentiometer on the photometer Ref. 0 … Ref. 4 Reference gas HM-1400 TRX 2...

  • Page 44: Measured Values And System Structure Menu

    (see Fig. 6.2 ) and stays there. In this screen, the keys can be used to move between the main screen and the measured value display in the top dis- play level (depending on the device equipment; see figure be- low). HM-1400 TRX 2...
  • Page 45 The statuses of faults (FLT), maintenance or calibration (CAL) and maintenance requirements (MRQ) are shown in a line be- low the measured values, depending on the parameter con- figuration (white field = active; black field = inactive). HM-1400 TRX 2...

  • Page 46: System Messages

    The messages will not be deleted. During active recording, all messages can also be stored onto a USB stick in the form of a log file (see Section 6.6.3.1 "User" menu (311…314) [} 57]) HM-1400 TRX 2...

  • Page 47: Password Protection

    - Entering F2,or entering an incorrect password will cause the previous screen to be re-displayed. Previous screen e.g. XX Fig. 6.6: Password protection Once you have entered all password characters, press the ● key to complete the process. The screen will jump to the sub- menu in which you wish to work. HM-1400 TRX 2...

  • Page 48: Main Menu

    OK and there are no fault messages. The current total Hg concentration or the current device status is then shown. The current time is shown on the outer right-hand Fig. 6.8: Signal status symbol side. (* see Table 6.2 ) HM-1400 TRX 2...

  • Page 49: Control Room Signals" Menu (11

    "Functions" menu, depending on the configuration of the HM‑1400 TRX 2: Start the measurement ● Record and back up measured values, faults and statuses ● Carry out a leak test ● Switch individual components on or off ● Fig. 6.10: "Function" menu HM-1400 TRX 2...

  • Page 50: Start, Adjustment" Menu (211

    (startup protection). CAL: Use the  key to choose from the operating states I, ○ A and 0. In operating state l, measuring operation is forced (signal check, relay function tests). HM-1400 TRX 2...

  • Page 51: Reactor, Pump, Valves" Menu (221

    You can also select the menu functions in screens 211, …, 214 and 231, …, 233 directly without having to first use to return to menu level 22 and to return to menu levels 23 and 21. HM-1400 TRX 2...
  • Page 52 The result of the leak test is displayed under Status. This result in turn provides a criterion for the next mainten- ance steps to be carried out. “Poor” indicates that there is an urgent need for action. Leaks need to be repaired inside the measuring system. HM-1400 TRX 2...

  • Page 53: Optional" Menu (231

    Hg is evaluated. If this option is included in the device, it is available in A for cyclic operation in automatic measuring mode. The HM-1400 TRX 2...

  • Page 54: Validation" Menu (241

    Possible reference gases are zero gas, Hg from the internal gas generator, Hg from an external gas generator or Hg from externally connected gas cylinders. To carry out reference tests manually, select function menu ● 24 “Validation”. HM-1400 TRX 2...
  • Page 55 Selecting the “Adjust” button confirms and applies the result. Selecting the “Cancel” button cancels without ap- plying the result. These buttons can be selected with the keys, and can be confirmed by pressing the  key. HM-1400 TRX 2...

  • Page 56: Settings" Menu (31

    In the first instance, the activities and setting options in user ● level 31 are important for operation of the measuring system. HM-1400 TRX 2...

  • Page 57: User" Menu (311

    The cursor can also be moved to the left by pressing the key. Pressing the key accepts the data and takes you to the HM-1400 TRX 2...
  • Page 58 The saving of all fault messages and warning information can be activated and deactivated. key can be used to open the editing mode from the "Log file/messages" menu. Use the keys to change or select the following information: HM-1400 TRX 2...
  • Page 59 The scope of the recorded data included in the log files can be found in the following table: Data Plain Fast Basic Date/time Status information and speciation (e. g. Hg , Hg , Ref.1) Data from calibration and adjustment Measured data and analogue outputs HM-1400 TRX 2...
  • Page 60 -> User (31) Fig. 6.22: "User" menu (311…314) Pressing the key twice will take you back to the "Settings" screen (31). Press the key to select the "Language" menu entry. Pressing the key takes you to sub-menu 341. HM-1400 TRX 2...

  • Page 61: Language" Menu (341

    As well as the individual components of the measuring sys- ● tem, the sub-menus not only show the current measured val- ues, for example temperature values, they also provide evalu- ations in most cases based on the following diagram: HM-1400 TRX 2...
  • Page 62 Batch number and maintenance status for reactors A6.1 and A6.2 Line 4 Remaining operating time for the active reduction vessel / set operat- ing time for a reduction vessel Last line Date of the last confirmed modification to one of the reduction vessels HM-1400 TRX 2...

  • Page 63: Verification Of The Measuring System

    To do this, the reference gas supply must be connected to the reference gas connection on the sampling probe. When Hg is used, additional measures will need to be taken to heat the outer connection line to a minimum of 160 °C. HM-1400 TRX 2...

  • Page 64: Testing The Hm-1400 Trx 2 With The External Test Gas Generator Tr-81 (Optional)

    The following solutions are available: Description: Hg content Expected concen- HM-1400 WT …   tration [ ppm ] [ µg/m  ] LSG-0,1ppm Hg2+HCl 1M Approx. 20 LSG-0,2ppm Hg2+HCl 1M 35 … 40 LSG-0,3ppm Hg2+HCl 1M 50 … 60 Table 7.1: Hg standard solutions HM-1400 TRX 2...
  • Page 65 −  Add 1M hydrochloric acid to the wash bottle so that it is     filled 1/3 of the way to the top. Completely dissolve     the tin(II) chloride. −  Add 20 ml of Hg standard solution to a dry conical     flask and immerse the suction hose of the peristaltic     pump in the solution. HM-1400 TRX 2...
  • Page 66    (1st column) resulting from the ambient conditions and the    mercury content of the standard solution. - The new target span value being determined (2nd column). 13.After the measurement has started, the 3-way valve (Y1) moves to the “Reference” or “Zero gas” position. HM-1400 TRX 2...

  • Page 67: Adjusting The Hm-1400 Trx 2 With The Internal Reference Gas Generator

    (MRQs) are shown at the output provided for this purpose and on the display. The internal gas generator can also be operated manually. This means that an additional test can be carried out independently of the cyclical tests if necessary. HM-1400 TRX 2...
  • Page 68 In the following display, the two preset values for offset and span can still be changed manually with the editor function (  key) before they are applied. 10.Selecting “Back” with the  key applies the new values and ends the reference gas test. HM-1400 TRX 2...
  • Page 69 The numer- ical value of the span can be retrieved from the menu. The numerical value is usually between 0.8 and 1.2. ▶ Before handling the listed chemicals, refer to the applicable safety data sheets. HM-1400 TRX 2...

  • Page 70: Maintenance

    Table 8.1: Maintenance work on the control unit Interval Maintenance work Regularly recurring maintenance work 3 months Replace particle protection filter in the sampling probe or as required 3 months Replace particle protection filter (13) upstream of the photometer HM-1400 TRX 2...

  • Page 71: Notes On Cleaning

    Notes on cleaning The device must only be cleaned when in de-energised condition. Dusty surfaces can be cleaned with a suitable vacuum cleaner. Remove any adhering dirt using a cloth that has been lightly moistened with water. HM-1400 TRX 2...
  • Page 72 Refer to the relevant safety data sheet when doing so. In the event of visible damage due to the long-term impact of cor- rosive substances, take the device out of operation and contact the manufacturer or specialised personnel who have been trained by the manufacturer. HM-1400 TRX 2...

  • Page 73: Technical Data

    Weld-in pipe with flange similar to DN65 PN6, pipe D = 76 mm Analogue outputs 3 x 4 … 20 mA, max. 1000 ohm, parameters can be freely configured Digital outputs 9 x relay contact NO (normally open), parameters can be freely con- figured Contacts: max 0.3 A at max. 60VDC, 25VAC HM-1400 TRX 2...
  • Page 74 Sample gas line Temperature-regulated line, min. 185 °C, with protective hose, IP65 Variants: Operating voltage 230 V L,N,PE, 50-60 Hz, 90 ... 100 W/m, maximum length: 40 m Operating voltage 120 V L,N,PE 50-60 Hz 90...100 W/m; maximum length 15 m; regulated and supplied by the HM-1400 TRX 2 HM-1400 TRX 2...

  • Page 75: Dimensioned Drawings

    10 | Dimensioned drawings Dimensioned drawings See also 2 Dimensions HM-1400 TRX 2 with cooling fans [} 76] 2 Dimensions HM-1400 TRX 2 with cooling device [} 77] 2 Dimensions sampling probe and probe tube [} 78] 2 Dimensions welded-in pipe [} 79] HM-1400 TRX 2...

  • Page 80: 11 | Messages/Fault Elimination

    "Offset difference too high" ● "Limit value exceeded" ● Miscellaneous: "General internal fault" ● "Fault external unit" ● "Fault external line (SHS)" ● "Service request" ● "Standby (internal)" ● Table 11.1: Monitored parameters and fault messages in clear text HM-1400 TRX 2...

  • Page 81: Causes Of Errors And Their Rectification

    # B1/B2 "Reactor Filling A6.x needs to be exchanged" Description:  Description: The reactor material has been used up and needs to be replaced Possible cause: Rectification: Reactor material has reached the end of its service life. Replace reactor material. HM-1400 TRX 2...
  • Page 82 Reset the zero position at the photometer poten- Photometer has drifted to the limit tiometer. If this is not possible, send the photometer for repair # 42−47 "Sens. Axxx too low/too high" Description:  Limit value breached in a span parameter for calculating the measurement signal HM-1400 TRX 2...
  • Page 83 Check and correct the input allocation # 81 "Fault external line (SHS)" Description:  A fault is reported via the ExtLine connection. Possible cause: Rectification: Fault in an externally actuated Search for defective component and rectify fault sample gas line HM-1400 TRX 2...
  • Page 84 Possible cause: Rectification: Temperature limit values not correctly programmed Check/correct the limit value input Gas sample cooling (gas drying) not working correctly See fault rectification under #24/25 Cabinet temperature >40°C Check specified parameters at the installation site HM-1400 TRX 2...
  • Page 85 Autostart is not activated. The device must be started start up manually from menu 211 # I0 "Limit value exceeded" Description:  Limit value breached, threshold limit overshot Possible cause: Rectification: System-related rise in the Hg concentration (operating Rectify the causes in the system (operating company) company) HM-1400 TRX 2...
  • Page 86 Insert new reference material or Hg reference material is contaminated/old use alternative reference material Replace reactor material Reactor material is used up In the event of a fault, it is always recommended that the device manufacturer/supplier be informed. HM-1400 TRX 2...

  • Page 87: Parameter List (Device Parameters In Delivered Condition)

    3231 200°C Sampling probe Active 3241 Setpoint 3231 185 °C Minimum 3231 165°C Maximum 3231 200°C Sampling tube Sampling tube available 3241 Setpoint 3231 185 °C Minimum 3231 165°C Maximum 3231 200°C Back purging Back purging valve activated 3241 HM-1400 TRX 2...
  • Page 88 Speed for M5 3242 30.0% Automatic offset correction for negative 3242 measured values Continuous drift correction 3242 Device name 3242 HM-1400 TRX 2 Reactor box Heating A6/Y1 3-way valve Mode Y1 heating available 3242 Setpoint 3231 185 °C Minimum 3231 165°C...
  • Page 89 Duration 32243 420 s Early termination 32243 Fault flag 32243 Reference gas generator A31 minimum 3253 250 l/h A31 maximum 3253 450 l/h M31 flow at 100 3253 Concentration of Hg standard 3253 0.500 ppm B6 span 3253 B6 offset 3253 HM-1400 TRX 2...
  • Page 90 Hold measured value 32511 Adjustment 32511 Measuring range 32511 M31 at 32511 M31 speed 32511 20/40/60/80% Y31-Y35 32511 Speciation valve Y51 32511 Cycle Sequence 32515 1 2 4 3 0 X Start time 32515 00:00 Interval 32515 Never HM-1400 TRX 2...
  • Page 91 System output #2 3244 Y31 / System output #3 3244 Y11 Leak / 3244 M5 Cont. Analogue outputs Output #1 3245 HgX R1 Output #2 3245 HgXR2 Output #3 3245 HgX R1/2 Output #4 3245 Spd M5/M31 HM-1400 TRX 2...
  • Page 92 12 | Parameter list (device parameters in delivered condition) * Depending on option ** Calculated automatically *** Determined by calibration HM-1400 TRX 2...

  • Page 93: Index

     10 Hazards Terminal  41 From chemicals  8 Tips, recommendations  6 Info line  45 Zero adjustment  12, 23 Installing the welded-in tube with connection Zero point measurement  12 flange  30 Iodised activated carbon filter  9 HM-1400 TRX 2...
  • Page 94 GmbH • Kollaustraße 105 • 22453 Hamburg • Germany • www.durag.com...

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