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Summary of Contents for ABB AO2000 Series
- Page 1 AO2000 Series Continuous Gas Analyzers AO2000-MultiFID14 FID Analyzer Start-Up and Maintenance Manual 41/24 105 EN Rev. 3...
- Page 3 AO2000 Series Continuous Gas Analyzers AO2000-MultiFID14 FID Analyzer Start-Up and Maintenance Manual Publication No. 41/24 105 EN Rev. 3 Edition 01.05 This start-up and maintenance manual is protected by copyright. The translation, duplication and distribu- tion in any form, even in a revised edition or in extracts, in particular as a reprint, by photomechanical or electronic reproduction or in the form of storage in data processing systems or data networks are prohib- ited without the consent of the copyright holder and will be prosecuted under civil and criminal law.
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Page 4: Table Of Contents
Table of Contents Page Some Preliminary Comments ... General Safety Notes Safety Notes for Handling Electronic Measuring Instruments Chapter 1 Preparing the Installation Installation Location Requirements Gas Inlet Conditions Combustion Air Conditioning (Option) Materials Supplied Needed Material Guideline for Installation Chapter 2 Analyzer Installation Unpack Analyzer... - Page 5 Table of Contents Page Chapter 6 Calibration Sample Component and Measurement Ranges Test Gases Test Gas Flow Monitor (Pressure Switch) Calibration Method Substitute Gas Calibration Analyzer Module Manual Calibration Concentration Data Conversion Response Factor Chapter 7 Maintenance Sample Gas Filter Replacement at Heated Sample Gas Port Cleaning the Air Injector Troubleshooting Status Messages...
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Page 6: Some Preliminary Comments
... on the contents of This Start-Up and Maintenance Manual for the AO2000-MultiFID14 FID Analyzer is the start-up and a supplement to the Operator’s Manual for the AO2000 Series Continuous Gas maintenance manual Analyzers. It contains all information you need to install, start up, calibrate and maintain the analyzer. -
Page 7: General Safety Notes
If the information in this operator's manual does not cover a particular situation, ABB Service is prepared to supply additional information as needed. Contact your local ABB service representative or ABB Service, Telephone: +49-1 80-5-12 35 80, Telefax: +49-6 21-3 81-51 35, E-mail: callcenter.automation@de.abb.com 41/24-105 EN Rev. 3... -
Page 8: Safety Notes For Handling Electronic Measuring Instruments
Safety Notes for Handling Electronic Measuring Instruments Protective Lead The connection between the protective lead terminal and a protective lead must Terminal be made before all other connections. Danger of Broken The analyzer may constitute a danger if the protective lead is broken inside or Protective Lead outside the analyzer or if the protective lead terminal becomes loose. -
Page 9: Preparing The Installation
Chapter 1 Preparing the Installation Installation Location Requirements Short Gas Paths Install the analyzer as close as possible to the sampling location Locate the gas conditioning and calibration modules as close as possible to the analyzer. Adequate Air Provide for adequate natural air circulation around the analyzer. Avoid heat buildup. Circulation When installing several system housings in a 19-inch rack, maintain a minimum spacing of 1 height unit between housings. -
Page 10: Gas Inlet Conditions
Gas Inlet Conditions The gas inlet conditions listed in the following tables apply to the inlet of the analyzer module. Definition – p where p = gauge pressure, p = absolute pressure, p = atmospheric pressure Sample Gas Temperature Inlet Pressure p Flow Rate ≤... -
Page 11: Combustion Air Conditioning (Option)
Combustion Air Conditioning (Option) Combustion Air The combustion air conditioning module, which is available as an accessory, Conditioning contains the following components (see Figure 1): Pressure regulator with moisture separator and manometer (0 to 6 bar) for instrument air Pressure regulator with manometer (0 to 4 bar) for combustion air, Catalyst for combustion air conditioning, The instrument air is split into motive air and purge air in the analyzer. -
Page 12: Materials Supplied
Quantity Description Supplied AO2000-MultiFID14 Analyzer Analyzer Data Sheet (in the system housing) AO2000 Series Operator’s Manual AO2000-MultiFID14 Start-Up and Maintenance Manual CD-ROM containing technical documentation and communication software Power cord, 5 m long, with screwed-on connector for non-heating appliances and separate grounded connector for the power supply... -
Page 13: Needed Material
Needed Material The following overview should help you, before beginning installation, to procure and prepare the necessary material not supplied. Installation 19-inch housing: • 4 oval-head screws (M6 recommended, but depends on the cabinet/shelf (see page 20 for system) instructions) •... -
Page 14: Guideline For Installation
Combustion gas Instrument air Connection of the signal, control and interface lines as well as the system bus (see “Electrical Line Connection” Chapter of the AO2000 Series Operator’s Manual for instructions) Power supply line connection 24 VDC Analyzer module power supply... -
Page 15: Analyzer Installation
Chapter 2 Analyzer Installation Unpack Analyzer CAUTION! The analyzer weighs approx. 25 kg. Two persons are needed for unpacking and carrying. Unpacking Step Action Remove the analyzer and foam packing or wrapping from the shipping box. Remove the foam packing or wrapping and set the analyzer aside on a clean surface. -
Page 16: Identification Plates And Analyzer Data Sheet
• Connection diagrams for signal inputs and outputs, • Connection diagrams for gas inlets and outlets. In addition, the user (and also ABB Service) can document service tasks and modifications performed on your analyzer in the analyzer data sheet. Where is the analyzer The analyzer data sheet is kept in an envelope which is attached •... -
Page 17: Dimensional Diagrams
Dimensional Diagrams Figure 2 19-Inch Housing (Dimensions in mm) Error Maint Power Figure 3 Wall-Mount Housing (Dimensions in mm) • The connection box shown with dashed lines in the dimensional diagram is flange-mounted to the IP-54 housing. • Observe the installation location requirements (see Page 9). •... -
Page 18: Gas Connection Installation
Gas Connection Installation Since the gas ports are now easily accessible connect the gas lines to the analyzer module before the analyzer is installed. Port Design The ports for the supply gases and test gases are designed as connection nipples with 1/8 NPT internal threads. - Page 19 Gas Connection Installation, continued Figure 4 Connection Diagram (Gas Ports) 11 10 Pressure compensator opening with particle filter Instrument air inlet Test gas outlet Span gas inlet Zero gas inlet 10 Combustion gas inlet 11 Combustion air inlet 12 Exhaust air outlet 13 Sample gas inlet (the figure shows an unheated sample gas port) 14 Bypass nozzle •...
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Page 20: Analyzer Installation
Analyzer Installation CAUTION! The analyzer weighs approx. 25 kg. The following points should be observed: • Two persons are needed for installation. • The location (e.g., bay, 19-inch rack, wall) must be capable of supporting the analyzer’s weight. • The 19-inch housing must be supported with rails in the bay or rack. •... -
Page 21: Gas Line Connection
Chapter 3 Gas Line Connection Gas Line Connection CAUTION! The gas lines and fittings must be free of any residue (e.g., particles left over from manufacturing). Contaminants can enter the analyzer and damage it or lead to false measurement results. Follow the fitting manufacturer’s instructions. -
Page 22: Sample Gas Line Connection (Heated Sample Gas Port)
Sample Gas Line Connection (Heated Sample Gas Port) CAUTION! Before start-up of the analyzer module it is imperative to remove any plastic sealing stopper inserted in a sample gas inlet at the factory. Sample Gas Line Use PTFE or stainless steel sample gas line. (Recommendation: use heated Material sample gas line TBL 01.) The medium temperature reaches 200 °C. - Page 23 Sample Gas Line Connection (Heated Sample Gas Port), continued Figure 6 Sample Gas Line Connection on Heated Sample Gas Port (Wall-mount housing, view from above right) Heated Sample Gas Line (tube with 4/6-mm ID/OD) O-Ring 6.02 x 2.62 Fitting O-Ring 12.42 x 1.78 Connection of Additional Sample Gas Line or Plug: Sample Gas Line (tube with 4/6-mm ID/OD) or 6 x 20 Stopper Pin either with...
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Page 24: Sample Gas Line Connection (Unheated Sample Gas Port)
Sample Gas Line Connection (Unheated Sample Gas Port) CAUTION! Before start-up of the analyzer module it is imperative to remove any plastic sealing stopper inserted in the sample gas inlet at the factory. Sample Gas Line There is only one sample gas inlet for an unheated sample gas line (see Figure 7). Connection If the sample gas is under positive pressure, a tee should be installed between the sample gas line and sample gas inlet. -
Page 25: Combustion Gas Line Connection
Combustion Gas Line Connection CAUTION! The pertinent safety regulations for handling combustible gases must be followed. The combustion gas path inside the analyzer is checked for leaks at the factory. No seal integrity testing is required during normal operation. Combustion Gas Line Step Action Connection... -
Page 26: Instrument Air Line Connection
If instrument air with the required properties (see “Gas Inlet Conditions” section, Alternative page 10) is not available, an internal suction pump is necessary instead of the air injector. You can request detailed information on installing an internal pump from ABB Analytical, Telefax +49-69-79 30-45 66. Housing Purge Why should the... -
Page 27: Electrical Line Connection
Chapter 4 Electrical Line Connection Power Supply Line Connection – Safety Notes CAUTION! Comply with the pertinent national safety regulations for installation and operation of electrical equipment as well as the following safety notices. Before connecting the power supply, make sure that the operating voltage setting of the analyzer matches the line voltage. -
Page 28: Connection Diagram (Electrical Connections)
Connection Diagram (Electrical Connections) Figure 8 Connection Diagram (Electrical 11 10 Connections) 1 115 / 230 VAC power supply of detector heater and if necessary of heated sample gas port (see also Figure 12) Never pull the plug connector while the power is on! 2 Electrical connection to heated sample gas port Never pull the plug connector while the power is on! 3 System bus... -
Page 29: Vdc Power Supply Line Connection
24 VDC Power Supply Line Connection 24 VDC If the analyzer system is set up so that an analyzer module is to be powered by an Connection Cable external 24 VDC power source, a 5-meter long cable (2 x 0.5 mm ) with a 4-prong plug will be supplied for connection to the analyzer module. -
Page 30: 115/230 Vac Power Supply Line Connection
115/230 VAC Power Supply Line Connection 115 / 230 VAC A 5-m connection cable (3 x 1.5 mm , see Figure 11) with 4-prong plug for Connection Cable connection to the analyzer module (see Figure 12) is supplied for the 115 / 230 VAC power supply of detector heater and if necessary of heated sample gas port. - Page 31 115/230 VAC Power Supply Line Connection, continued 115 / 230 VAC Step Action Connection Make sure the analyzer system power supply is set to the proper line voltage. Adjust the operating voltage setting as necessary. Make sure the operating voltage indicated on the MultiFID14 analyzer module identification plate is the same as the line voltage.
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Page 32: Analyzer Start-Up
Chapter 5 Analyzer Start-Up Analyzer Start-Up Analyzer Start-Up Step Action Turn on power supply, initial heating phase, turn on supply gases Before connecting the power supply, check once again that both the operating voltage set on the analyzer power supply and the operating voltage indicated on the MultiFID14 analyzer module identification plate match the line voltage. - Page 33 Analyzer Start-Up, continued Step Action In the Controller values menu item also the variables for the internal pressure regulators are indicated; set the supply gas pressures by means of the variables: Input Instrument air at combustion-chamber inlet Output Instrument air at combustion-chamber outlet Combustion air Combustion gas (H or H...
- Page 34 Analyzer Start-Up, continued Step Action Flame ignition (automatic) Adjust supply-gas pressures to set points Combustion air pressure set to start value Ignition coil switched on Combustion air pressure raised steadily Ignition coil switched off Flame on? Number of ignition attempts = 10? Combustion gas pressure Combustion gas pressure and...
- Page 35 Select the Date/time menu item: MENU → Configure → System → Date/Time Check and, if necessary, correct the date and time (for more information see AO2000 Series Operator’s Manual). Adjusting the Filter The MultiFID14 analyzer module has a non-linear filter.
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Page 36: Warm-Up Phase
Warm-Up Phase Definitions The warm-up phase covers the period after the power supply has been turned on until measurement drift is acceptable. This depends on the measurement span. The warm-up phase includes the initial heating phase. The initial heating phase covers the period after the power supply has been turned on until the detector temperature reaches the threshold value (150 °C). -
Page 37: Calibration
Chapter 6 Calibration Please also read the Chapter “Analyzer System Calibration” of the AO2000 Series Operator’s Manual. Sample Component and Measurement Ranges Sample Component The MultiFID14 analyzer module always has at least 1 sample component with and Measurement 1 measurement range. -
Page 38: Test Gases
Test Gases Test Gases for Type, Quality Inlet Pressure p Flow Rate Calibration Zero gas: 1000 ± 100 hPa , 5.0 grade or synthetic or catalytically 130 to 250 l/h (1.0 ± 0.1 bar) purified air with an organic C content <... -
Page 39: Test Gas Flow Monitor (Pressure Switch)
Test Gas Flow Monitor (Pressure Switch) Test Gas Pressure and By setting the test gas pressure such that the test gas flow at the sample gas inlet Test Gas Flow Rate corresponds to the gas inlet conditions (130 to 250 l/h) the test gas surplus will flow toward the sampling site and prevent sample gas traces from influencing the calibration results. -
Page 40: Calibration Method
Calibration Method Please also consult Chapter “Analyzer System Calibration” of the AO2000 Series Operator’s Manual for a detailed description of calibration methods. Calibration Method The calibration method choice depends on • number of sample and/or substitute gas components and Choice •... -
Page 41: Substitute Gas Calibration
Substitute Gas Calibration Substitute Gas If the test gases for calibration are not available the analyzer module can be Calibration factory-set for calibration with substitute gases. Example Substitute gas calibration of the MultiFID14 analyzer module is described using the example of Acetone in Ambient Air. Acetone in Test gas containers cannot be filled with high concentrations of acetone. -
Page 42: Analyzer Module Manual Calibration
Analyzer Module Manual Calibration • The MultiFID14 analyzer module should only be calibrated after the warm-up phase, i.e., approx. 2 hours after connecting the power supply. • The zero should be calibrated manually prior to a manual span calibration. Test Gas Supply If the test gases enter at the zero or span gas input, the test gas supply is controlled by the integral valves. -
Page 43: Concentration Data Conversion
Concentration Data Conversion Different Concentra- The concentration is expressed in various units in the measurement of organic tion Data Units carbon compounds (total C): • mg org. C / m (e.g., in measurements per 17. BImSchV [17 Regulation of Federal Emission Protection Act]) •... - Page 44 Concentration Data Conversion, continued Example 2 If a gas other than propane is used, its response factor must be considered (see "Response Factor" section on page 45). If methane (CH ) is used, how large can the maximum test gas concentration be in ppm or mg/m without exceeding the measurement range? ×...
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Page 45: Response Factor
Response Factor Definition Meas. value indication Response factor Concentrat Meas. value indication Concentrat Response factor By definition, the response factor for propane (C ) is equal to 1.00. Response Factors Response factors for the MultiFID14 analyzer module are listed in the table below. Response factors for an individual analyzer module may differ slightly from the values below. -
Page 46: Maintenance
Chapter 7 Maintenance Sample Gas Filter Replacement at Heated Sample Gas Port When is replacement Replace the sample gas filter in the heated sample gas port if it is contaminated and needed? the sample gas flow is reduced. • Sample gas filter with O-rings (part number 0768649) Material Required •... - Page 47 Sample Gas Filter Replacement at Heated Sample Gas Port, continued Figure 14 Sample Gas Filter in Heated Sample Gas Inlet 1 Mounting screws 3 O-Ring 5 Sample Gas Filter 2 Sample Gas Filter Holder 4 O-Ring 41/24-105 EN Rev. 3 AO2000-MultiFID14 Start-Up and Maintenance Manual...
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Page 48: Cleaning The Air Injector
Cleaning the Air Injector When is cleaning The air injector should be cleaned when the sample gas outlet pressure is too needed? high, i.e. if the negative pressure can no longer be set to p < 600 hPa. • 14-mm open-end wrench Material Required •... - Page 49 Cleaning the Air Injector, continued Figure 15 Air Injector 1 Exhaust Outlet 3 Air Injector 5 O-Ring 2 Fastener 4 O-Ring 6 O-Ring 41/24-105 EN Rev. 3 AO2000-MultiFID14 Start-Up and Maintenance Manual...
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Page 50: Troubleshooting
Troubleshooting Flow Problem Sample gas nozzle or Check for obstructions in sample gas nozzle and sample gas filter in sample gas sample gas filter port. Change the sample gas filter (see page 46 for instructions). plugged Temperature Problem Faulty temperature Check the connecting lines and plug connectors. -
Page 51: Zero Drift
Troubleshooting, continued Pressure Regulator Problems Unstable pressure Adjust supply gas pressures such that the variables have the following values values (see page 33): for instrument air (Outlet) approx. 60 % for combustion air (Air) approx. 50 % for combustion gas (H2) approx. - Page 52 Troubleshooting, continued Flame Does Not Ignite Air in the Combustion Make sure no air enters the combustion gas feed lines when the combustion gas Gas Line tank is connected or changed. Air drawn into the combustion feed line can cause the flame to go out in the analyzer.
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Page 53: Status Messages
Status Messages The MultiFID14 analyzer module status messages are listed below. Please also consult Chapter “Status Messages” of the AO2000 Series Operator’s Manual, which also contains the complete list of all status messages. List Structure The list of status messages contains the following information: Number of the status message;... -
Page 54: Analyzer Shutdown And Packing
Chapter 8 Analyzer Shutdown and Packing Analyzer Shutdown Analyzer Shutdown Step Action Temporary Shutdown: Turn off the sample gas and the combustion air and combustion gas supplies. Purge the gas lines and analyzer module with dry fresh air or nitrogen for at least 5 minutes. -
Page 55: Preparing The Analyzer For Shipping And Packing
Preparing the Analyzer for Shipping and Packing CAUTION! The analyzer weighs approx. 25 kg. Two persons are needed for removal and carrying. Preparation for Step Action Shipping Remove the system bus terminating resistor from the electronics module and secure it to the housing, e.g. with adhesive tape. -
Page 56: Description
Appendix Description Measurement The flame ionization detector (FID) uses as measuring effect the ionization of Principle of the Flame organic carbon atoms in a hydrogen flame. Hydrocarbon-free combustion air must Ionization Detector be supplied to maintain the flame. The hydrogen flame burns in an electric field generated by a DC voltage between two electrodes. -
Page 57: Gas Diagram
Gas Diagram Figure 16 Gas Diagrams = 600 hPa MultiFID14 Analyzer Module with Heated Sample Gas Port (3x) and Air Injector = 700 hPa Instrument air inlet 13 Sample gas inlet D Negative pressure regulator Test gas outlet 14 Bypass nozzle E Combustion air regulator Span gas inlet Combustion gas regulator... -
Page 58: Operating Specifications
Operating Specifications The following data apply to measurement ranges ≥ 50 mg org. C/m , for smaller ranges these only apply if they are factory-set per customer order. ≤ 2 % of measuring ranges to 10,000 mg org. C/m Linearity deviation , this value applies to one (calibrated) range ≤... -
Page 59: Index
Index Page Page Air injector cleaning Location Ambient temperature Materials supplied Analyzer data sheet Measurement principle Calibration Measurement range Calibration method Operating specifications Manual calibration Potential compensation connection Test gases Power supply Combustion air 115 / 230 VAC connection Combustion air conditioning 24 VDC connection Combustion gas Fuses... - Page 62 ABB. the information contained herein without notice. ABB has Sales & Customer Support expertise Printed in the Fed. Rep. of Germany (01.05) in over 100 countries worldwide.
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