ABB ACF5000 Manual
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ABB ACF5000 Manual

ABB ACF5000 Manual

Multi-component ftir emission monitoring system
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A BB MEA SU RE ME NT & A NA L YT I C S | O PE R A TI N G I NS T RU C T I O N | OI / A C F 5 0 0 0-E N R E V. C
ACF5000
Multi-component FTIR emission monitoring system
—
Introduction
ACF5000
The ACF5000 continuous emissions
measurement system offers simultaneous
measurement of up to 15 components, including
water-soluble components, for precise
monitoring of exhaust gas composition.
The standard system design combines the
advantages of a FTIR spectrometer with flame
ionization (FID) technology and oxygen
measurement. The high resolution FTIR
spectrometer provides selective measurement of
infrared active gas molecules with high
sensitivity and stability.
Measurement made easy
Additional Information
Additional documentation on ACF5000 is available
for download free of charge at
www.abb.com/analytical.
Alternatively simply scan this code:

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  • Page 1 Measurement made easy — Introduction Additional Information ACF5000 The ACF5000 continuous emissions Additional documentation on ACF5000 is available measurement system offers simultaneous for download free of charge at measurement of up to 15 components, including www.abb.com/analytical. water-soluble components, for precise Alternatively simply scan this code: monitoring of exhaust gas composition.

  • Page 2: Table Of Contents

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Table of contents Installation .............. 31 Safety ................4 Safety instructions ............. 31 General information and instructions ....... 4 General Notes ..............31 System documentation ............4 Installing the analyzer cabinet ........... 32 Further documents ..............
  • Page 3 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C 12 Maintenance ............135 Safety instructions ............135 Visual inspection ............... 136 Cleaning the analyzer cabinet .......... 137 Seal integrity test.............. 137 FID – Leak and function tests .......... 138 Maintenance switch ............

  • Page 4: Safety

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C 1 Safety Further documents General information and instructions These instructions are an important part of the product and Title Doc. ID must be retained for future reference. ACF5000 Multi-component FTIR analyzer...

  • Page 5: Warranty Provisions

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Warranty provisions Improper use Using the device in a manner that does not fall within the scope The ACF5000 analyzer system must not be used for the of its intended use, disregarding this manual, using measurement of mixtures that could ignite during operation.

  • Page 6: Safety Instructions

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 1 Safety Safety instructions Requirements for safe operation Safety of the equipment and safe operation In order to operate in a safe and efficient manner the device The device was built and tested in accordance with should be properly handled and stored, correctly installed and EN 61010 Part 1 ‘Safety regulations for electrical measuring,...

  • Page 7: Safety Instructions For The Control Cabinet Fan

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Safety instructions for the control cabinet Risks involved in opening the covers Current-bearing components can be exposed when the covers or The analyzer system is supplied with a control cabinet fan as parts are removed, even if this can be done without tools.

  • Page 8: Safety Instructions For The Control Cabinet Cooling Unit

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 1 Safety Safety instructions for the FID analyzer Safety instructions for the control cabinet module cooling unit DANGER The analyzer system can be optionally equipped with a control cabinet cooling unit.
  • Page 9 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C As an additional safety measure, the analyzer system can be • The leak tightness of the combustion gas supply line supplied with the ‘Hydrogen monitoring of the analyzer cabinet’ outside the gas analyzer as well as the combustion gas option, see page 15.

  • Page 10: Safety Instructions For The Ftir Spectrometer Module

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 1 Safety Safety instructions for the FTIR spectrometer module Electric safety Laser safety The FTIR spectrometer has an unprotected metal housing that is Under normal conditions, the FTIR spectrometer can be connected directly to ground potential via the power cable and is operated completely safely (Class 1 laser product –...

  • Page 11: Cyber Security Disclaimer

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Cyber security disclaimer Services and ports on the Ethernet interface This product is designed to be connected to and to communicate information and data via a network interface. Port Description It is operator’s sole responsibility to provide and continuously...

  • Page 12: Design And Function

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C 2 Design and function Area of application and function of the analyzer system Application area Measurement principle The ACF5000 analyzer system is a multi-component analysis The analyzer system operates on the principle of FTIR system for continuous measurement of the concentration of spectrometry.

  • Page 13: Design

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Design Front view Side view right Front view open 1 Control cabinet cooler AU1 ACF5000 Electronics box AU2 Analyzer box 2 Analyzer cabinet AU3 Interferometer box 3 Cable entry for signal cable...

  • Page 14: Air Purifier

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 2 Design and function … Design Gas sampling Analyzer modules • FTIR spectrometer with heated measuring cell NOTICE • Oxygen sensor (Z sensor) Damage to components • Flame ionization detector (FID, optional) for measuring the...

  • Page 15: Hydrogen Monitoring Of The Analyzer Cabinet (Optional)

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Hydrogen monitoring of the analyzer cabinet (optional) Function Installation If an FID (VOC Analyzer) is installed, the analyzer system can be DANGER supplied with the ‘Hydrogen monitoring of the analyzer cabinet’...

  • Page 16: Product Identification

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C 3 Product identification Name plate Note The name plates displayed are examples. The device identification plates affixed to the device can differ from this representation. The gas analyzer name plate is located on the exterior of the side wall of the system housing.

  • Page 17: Plates And Symbols

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Plates and symbols Note • All pictograms, signs and labels attached to the device must be complied with and maintained in a clearly legible state. • Damaged or illegible pictograms, signs and inscriptions must be replaced.
  • Page 18 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 3 Product identification … Plates and symbols Pos. Sign/Symbol Position/Meaning FTIR analyzer module (electronics box) CAUTION – Device has more than one power supply. Before any work on the device, switch off all power supplies...

  • Page 19: Scope Of Delivery

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Scope of delivery Standard scope of supply and delivery Analyzer data sheet • Analyzer cabinet (all components installed) The design of the gas analyzer that has been supplied is •...

  • Page 20: Transport And Storage

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C 4 Transport and storage Inspection Safety instructions Check the devices immediately after unpacking for possible WARNING damage that may have occurred from improper transport. Injury hazard due to heavy weight Details of any damage that has occurred in transit must be The analyzer system weighs approx.

  • Page 21: Packaging

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Packaging Refer to Packaging the analyzer system on page 158. Returning devices Use the original packaging or a secure transport container of an appropriate type if you need to return the device for repair or recalibration purposes.

  • Page 22: Preparation For Installation

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C 5 Preparation for Installation Selection of the sample gas extraction point and installation of the conduit pipe Selecting the sampling point Installation of the conduit pipe with mounting flange •...
  • Page 23 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Minimum distance between conduit pipe Figure 8: Installation of the conduit pipe Minimum distance x of the mounting flange on the conduit 1 Conduit pipe 3 Gasket pipe from the wall as a function of installation angle α:...

  • Page 24: Requirements For The Installation Site

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 5 Preparation for Installation Requirements for the installation site The analyzer system is intended for indoor installation only. The Climatic Conditions analyzer system must be protected from direct heat radiation, Transport- / Storage temperature heavy dust exposure, corrosive atmospheres and vibrations.

  • Page 25: Installation Location

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Dimensions, weights and noise level Dimensions Installation location See ‘Location diagram’ in the system documentation. DANGER Explosion hazard Weights Explosion hazard when setting up the analyzer cabinet in potentially explosive atmospheres.

  • Page 26: Power Supply

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 5 Preparation for Installation Power supply Main power supply Leakage current Input voltage • 230/400 V AC, ±10 %, 3 phases* or A leakage current of ≥ 9 mA can occur in the analyzer system •...

  • Page 27: Safety

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Safety In accordance with EN 61010-1 Power supply lines Note Overvoltage category When selecting the cable material, observe the applicable national safety requirements for installing and operating electrical equipment. Pollution degree Power supply 5 ×...

  • Page 28: Sample Gas Inlet Conditions

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 5 Preparation for Installation Sample gas inlet conditions … Material required for installation Signal Lines DANGER Note Explosion hazard When selecting the cable material, observe the applicable Explosion hazard when measuring ignitable gas / air or...

  • Page 29: Operating Gases And Test Gases

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Operating gases and test gases Definition of inlet pressure P FID – Flame ionization detector (option) − P Combustion air where P = overpressure, P = absolute pressure, Clean compressed air from the air purifier is used as = atmospheric pressure combustion air.

  • Page 30: Instrument Air

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 5 Preparation for Installation … Operating gases and test gases Compressed air for back-purge of the gas sampling Test gases probe (optional) Test Gases for Zero Calibration Compressed air is needed to clean the sampling filter and the...

  • Page 31: Installation

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C 6 Installation General Notes Safety instructions • It is recommended to have the analyzer system installed by WARNING ABB. Risk of injury due to heavy components • In addition to this operating instruction, refer to the order-...

  • Page 32: Installing The Analyzer Cabinet

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 6 Installation Installing the analyzer cabinet Providing the foundation Unpacking and transporting the analyzer system WARNING Risk of injury due to heavy components Improper handling of heavy components can lead to serious crushing, broken bones or even fatal injuries.
  • Page 33 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Setup of the analyzer system • Observe the requirements at the installation site , refer to page 24. • Provide the material required for installation, see page 27. • Observe the ‘Arrangement diagram’ in the system documentation.

  • Page 34: Installing The Gas Sampling Probe And Filter Unit

    Install the gas sampling probe and filter unit: 1. Observe the ‘Piping diagram’ in the system 1. Open the cover of the ACF5000 electronics box and take it documentation. out. 2. Make sure that the distance ‘X’ of the conduit pipe has 2.
  • Page 35 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Probe tube type 40 Gas connections to the PFE2 filter device Length of the probe tube 500 / 1000 / 1500 / 2000/2500 mm Figure 13: Dimensions of probe tube type 40 (dimensions in mm)

  • Page 36: Installing The Sample Gas Line

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 6 Installation Installing the sample gas line Note For detailed information on installing the heated sample gas Installation in ducts or shafts line, refer to the associated operating instructions, see Further...
  • Page 37 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Wall ducts Brackets Wrong Correct Wrong Correct Figure 22: Supports Figure 20: Wall ducts Make sure that the brackets or clamps do not compress the sheath of the heated sample gas lines in order to prevent The heated sample gas line must never be laid through wall damage to the sample gas line.

  • Page 38: Operating Gases And Test Gases

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 6 Installation Operating gases and test gases … Installing the sample gas line Connect the sample gas line to the analyzer system Installing the instrument air supply • Observe the requirements at the installation site, refer to page 30.
  • Page 39 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Combustion gas supply for the flame ionization detector Waste gas (FID) NOTICE DANGER Leaks in the gas discharge line due to condensation Explosion hazard Corrosive condensates can cause leaks in the gas discharge Explosion hazard due to incorrect connection of the hydrogen line.

  • Page 40: Electrical Connections

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 6 Installation Electrical connections Description of the signal inputs and outputs Modbus® interface Analog outputs 9-pin Sub-D socket connector or 5-pin M12 socket connector. 4 to 20 mA, common negative pole, galvanically isolated, can be grounded as required, max.
  • Page 41 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Connecting the Signal Lines • Lay the signal lines separately from the power supply lines. • Lay analog and digital signal lines separately from each other. • Carefully plan the combination of signal lines in cables, including for the purpose of feeding through the cable glands.

  • Page 42: Commissioning

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C 7 Commissioning Initial commissioning Safety instructions The analyzer system is essentially commissioned by the NOTICE authorized personnel of the manufacturer or of the supplier. Damage to the gas analyzer Damage to the gas analyzer due to condensing sample gas Note during commissioning.

  • Page 43: Start Of The Measurement

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C FID Recommissioning Heating-up phase, connect supply gases 4. The analyzer system starts to heat up automatically. 1. Select the ‘Controller values’ menu item: • The assemblies in the analyzer cabinet reach their target ‘MENU / Diagnostic/Information / Module specific /...

  • Page 44: Igniting The Flame

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 7 Commissioning … FID Recommissioning Igniting the flame 4. During the heating phase, the following status messages are 7. Flame ignition is automatic. displayed: Message Description Temperature Status message:...

  • Page 45: Operation

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C 8 Operation General The gas analyzer can be operated via several user interfaces: On initial commissioning of the gas analyzers, it may occur that, • Local operation on the gas analyzer via the integrated depending on the position of the combustion gas line, there is LCD display (‘local HMI’).
  • Page 46 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 8 Operation … General Priority of a user interface Operation via the web interface The analyzer system can only be operated from one single HMI. Functions Some functions are only accessible via the web interface. The...

  • Page 47: Lcd-Indicator

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C LCD-indicator LCD display The backlit graphics has a 320 x 240-pixel resolution. The screen is divided into three panels: • Menu line • Information field • Softkey line The menu line The menu line appears at the upper edge of the screen.

  • Page 48: Status Leds

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 8 Operation … LCD-indicator In addition, the user can configure display elements that allow Display of status messages Messages from the gas analyzer are also displayed in the softkey Enter values, see Value Input on page 109.

  • Page 49: Numeric Keypad

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Numeric keypad Softkeys The numeric keypad is located to the right of the screen, under The six buttons under the screen and the softkey line at the the status LED’s.

  • Page 50: Entering Text

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 8 Operation … LCD-indicator The Softkeys in Menu Mode Entering text In menu mode, a series of softkeys appears on the softkey line, When text, such as sample components or user names, needs to...

  • Page 51: Selecting And Changing Parameters

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Selecting and changing parameters Value Input Softkeys in Edit Mode Numeric and alphanumeric parameter values can be entered The softkeys in the edit mode have the following functions: directly via the keyboard using the value input.

  • Page 52: Password Protection

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 8 Operation Password protection … Selecting and changing parameters Key Entry Note We strongly recommend to change all passwords from their Using the key entry, preset parameter values can be selected default value.

  • Page 53: Factory Setting

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Factory setting Duration of the change privilege The change privilege therefore refers to the limited User Group Access to password level Password authorization to make changes to the menu items. By contrast,...

  • Page 54: Menu Structure

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 8 Operation Menu structure For reasons of clarity, only the suitable parameters and functions are presented; the menu links onward at most menu items, e.g. to the various sample components or to the selection and settings of values.

  • Page 55: Process Display

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Process display Notification on the LCD display F00853 Figure 30: Process notification on the LCD display Each display page shows the measured values of six measuring components. • The ‘>>’ key allows the operator to scroll to the next display page.

  • Page 56: Adjusting The Analyzer System

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C 9 Adjusting the analyzer system Note Manual adjustment The descriptions in this section refer to the adjustment of the Definition analyzer module FID and oxygen sensor. Manual adjustment means: Zero point and end point are adjusted separately using the keys on the LCD display of the analyzer system.
  • Page 57 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Automatic adjustment Definition Starting and canceling automatic adjustment Automatic adjustment means: Start Cancel Adjustment of the zero point and end point runs automatically Controlled by interval: after start. If the ‘Activation’ parameter is set to By appropriate configuration of the ‘on’...

  • Page 58: Adjustment Methods

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 9 Adjusting the analyzer system … Principles Adjustment methods The common adjustment has no effect on the other measuring One or more (gas) components, each with one or more components of the analyzer module.
  • Page 59 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Overview The following table presents the adjustment methods at a glance. Quantity Adjustment Method To be configured ... To be adjusted ... The adjustment affects ... Sample gas/ the zero point and the final point in...

  • Page 60: Fid - Conversion Of Concentration Data

    ) is equal to 1.00 in accordance with the definition. The FID analyzer in the ACF5000 is used exclusively for the measurement of total hydrocarbons (VOC). The table of response factors is therefore only necessary for required conversions of concentrations.
  • Page 61 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Relevant variables Molar mass Molar volumes = 12.011 g/mol = 22.414 l/mol for 0 °C and 1013 hPa = 1.008 g/mol = 24.05 l/mol for 20 °C and 1013 hPa...

  • Page 62: Configuration

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 9 Adjusting the analyzer system Configuration Configuring the FTIR Automatic Reference Function For the FTIR spectrometer, the automatic recording of the reference can be configured. Menu Path ‘Menue / Configure / Adjustment data / Automatic Reference’...
  • Page 63 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Automatic Adjustment Check (AAC) – Configuring the Duration (optional) Note Contact ABB Service to have this option retrofitted. Function Optionally, the cycle that automatically monitors the adjustment (Automatic Adjustment Check – AAC) of the FTIR spectrometer under QAL3 monitoring can be configured.
  • Page 64 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 9 Adjusting the analyzer system … Configuration Implementation Parameter Explanation Enable: The AAC is only completed when it is activated. AAC cycle runs The run mode of the AAC must be set.
  • Page 65 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Automatic Adjustment Check (AAC): settings and export of the QAL3 data Function The settings for the cyclical ‘Automatic Adjustment Check’ are to be made in the web interface. Menu Path ‘ACF5000 Settings / QAL3’...
  • Page 66 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 9 Adjusting the analyzer system … Configuration Export Components The AAC results for all measuring components are combined in a text file that can be exported in the Export Components submenu.
  • Page 67 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Settings F00859 • Whether the analyzer system transmits a status signal according to the limit values criteria on the CUSUM control chart or the Shewhart control chart, or according to both control charts, can be selected in the ‘Settings / Available options for QAL3 control chart’...
  • Page 68 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 9 Adjusting the analyzer system … Configuration Configuring the Automatic Drift Check (ADC) Function On the analyzer system, the cyclical drift check with automatically connected test gases can be configured as an option. The ‘Automatic Drift Check’...
  • Page 69 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Configuring the gas port F00862 Select the gas inlet that will connect to the test gas in the ADC menu and press ‘ENTER’ to call up inlet configuration. Parameters Explanation Enable: The cyclical automatic drift check (ADC) is only completed when it is activated.
  • Page 70 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 9 Adjusting the analyzer system … Configuration Configuring the ADC operating mode Call up operating mode configuration in the ADC menu by selecting ‘ADC MODE’. F00863 Operating mode Explanation ACF5000 runs the ADC The ports are controlled as configured.

  • Page 71: Adjustment Method

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Configure Manual Adjustment Note The descriptions in this section refer to the adjustment of the analyzer module FID and oxygen sensor. Menu Path ‘MENUE / Configure / Adjustment data / Manual adjustment / ...’...
  • Page 72 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 9 Adjusting the analyzer system … Configuration Configure Automatic Adjustment of the FID Function For the FID, an automatic adjustment with test gas at the zero and final point can be configured.
  • Page 73 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Implementation Parameter Explanation Enable: Automatic adjustment is completed only when it is activated. Cycle time: The cycle time shows the time intervals over which automatic adjustment is completed. Recommended setting: 21 days Next adj.
  • Page 74 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 9 Adjusting the analyzer system … Configuration Configure Automatic Adjustment of the Oxygen Sensor Function For the oxygen sensor, an automatic adjustment with test gas at the zero and final point can be configured.
  • Page 75 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Implementation Parameter Explanation Enable: Automatic adjustment is completed only when it is activated. Cycle time: The cycle time shows the time intervals over which automatic adjustment is completed. Recommended setting: 14 days Next adj.
  • Page 76 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 9 Adjusting the analyzer system … Configuration Check time conflicts of the automatic processes Automatic processes in the analyzer system The following automatic processes can be configured in the analyzer system: The automatic reference (see Configuring the FTIR Automatic Reference on page 62), •...
  • Page 77 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Operation Creating manual reference Output Current Response Function Menu Path A manual reference can be created for the FTIR spectrometer. ‘MENUE / Configure / Adjustment data / Output current You first need to set in ‘Menue / Maintenance/Test / System / response / ...’...
  • Page 78 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 9 Adjusting the analyzer system … Configuration 2. If the measured value is stable, start recording the manual Manual reference – Show status of the last reference reference by pressing ‘ENTER’.
  • Page 79 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Manual reference – Display diagnostic values of the Manual reference – Saving the reference as initial reference measurement reference Function Function The last reference measurement's diagnosis values for the FTIR After recording the manual reference, it can be saved as an initial spectrometer can be displayed on the HMI.
  • Page 80 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 9 Adjusting the analyzer system … Configuration Start Automatic Adjustment Check (AAC) manually AAC duration ‘continuous’ or ‘continuous with reference’ Function The automatic cyclical check of the adjustment of the FTIR spectrometer (Automatic Adjustment Check –...
  • Page 81 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Carry out manual adjustment Note End point adjustment: The descriptions in this section refer to the adjustment of the 8. Select Span Gas. analyzer module FID and oxygen sensor. 9. Turn on the span gas.

  • Page 82: Automatic Adjustment

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 9 Adjusting the analyzer system … Configuration Manual start of automatic adjustment Note The descriptions in this section refer to the adjustment of the analyzer module FID and oxygen sensor.

  • Page 83: Configuration

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C 10 Configuration M e s sk o m p o n e n t e n - s p e z i f i s ch e Fu n k ti o n e n...
  • Page 84 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 10 Configuration … Sample component functions Change number of decimal places Add measuring range Menu Path Note ‘MENU / Configure / Component specific / Measurement Adding measuring ranges is only possible with the FID analyzer range / Select component / ...’...
  • Page 85 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Delete measuring range Automatic measuring range switching Note Menu Path Measuring ranges can be deleted only with the FID analyzer ‘MENU / Configure / Component specific / module. Autorange / Select component / ...’...

  • Page 86: Configure Filter

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 10 Configuration … Sample component functions Status Configure filter Automatic measuring range switching can be activated or Menu Path deactivated. „MENU / Configure / Component specific / Filter / Select component / ...’...

  • Page 87: Standard Configuration

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Active component selection Limit Value Monitor Parameterization Menu Path Menu Path ‘MENU / Configure / Component specific / ‘MENU / Configure / Component specific / Limit values / Active component’...
  • Page 88 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 10 Configuration … Sample component functions Configuring FTIR limit value monitoring Implementation Function The monitoring of the FTIR measured values can be configured Parameters Explanation to detect down-scale of the limit values.
  • Page 89 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Configuring dry base and O reference Implementation Measurement value corrections The measurement gas concentrations can be converted to dry Parameter Description waste gas or normal conditions. The measurement gas Watercorrection for meas.

  • Page 90: System Functions

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 10 Configuration System functions … Sample component functions Setting the time zone, date and time Changing module name Menu path Menu Path ‘MENU / Configure / System / Date/Time’...
  • Page 91 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Selecting the user interface language Change password Menu Path Note ‘MENU / Configure / System / Language’ We strongly recommend to change all passwords from their default value. All passwords can be changed by the user. It is...
  • Page 92 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 10 Configuration … System functions Block operation Setting System Modules Menu Path Menu Path ‘MENU / Configure / System / Change password’ ‘MENU / Configure / System / Setup system modules’...
  • Page 93 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Add System Module Unknown System Module Note If a system module shows the ‘Unknown’ status in menu item As long as there is no system module configured in the gas ‘Setup system modules’, there are several possible causes for...
  • Page 94 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 10 Configuration … System functions Replacing the System Module Replace an existing system module (analyzer module or I/O Uninstallation and reinstallation of the same system module device) with another system module If an existing system module has been uninstalled and (e.g.after...
  • Page 95 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Delete System Module Save Configuration Menu Path Sequence when removing system modules ‘MENU / Configure / System / Save configuration’ When removing system modules from the gas analyzer, the following sequence must always be applied: Automatic saving of the configuration 1.

  • Page 96: Analog Outputs

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 10 Configuration Analog outputs … System functions Changing Analog Output Current Range Configure Status Signals Menu Path Menu Path ‘MENU / Configure / Function blocks / Outputs / Analog ‘MENU / Configure / System / Status signals’...

  • Page 97: Digital Communication

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Digital communication Configure the Ethernet connection Menu Path Adresses ‘MENU / Configure / System / Network / TCP/IP Network’ The IP address, IP address screen and IP gateway address need to be queried from the system administrator.
  • Page 98 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 10 Configuration … Digital communication Release of communication via port 8001/tcp 3. Select the ‘Unsecure Protocol’ menu item and set the In ACF5000, a proprietary protocol has been implemented on parameter to ‘Allowed’.
  • Page 99 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Configure Modbus Connection Release of communication via Modbus® TCP/IP In the ACF5000, communication via Modbus® TCP/IP is blocked Note on all Ethernet interfaces (X8 / X9) by default. The Modbus® protocol is an unsecured protocol (in terms of IT...
  • Page 100 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 10 Configuration … Digital communication 3. Select the ‘Modbus TCP access’ menu item and set the parameter to ‘Allowed’. 4. Confirm the information field by selecting ‘BACK’. 5. Communication via the Modbus® TCP/IP protocol has now...
  • Page 101 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Configure PROFIBUS® Connection Note The PROFIBUS® protocol is an unsecured protocol (in terms of IT and cyber security), as such the intended application should be assessed to ensure that this protocol is suitable before implementation.
  • Page 102 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 10 Configuration … Digital communication Configuring Bus I/Os Menu Path Parameters ‘MENU / Configure / System / Network / Bus IO’ Parameter Function Read Write Example Bus AI Bus analog inputs...

  • Page 103: Lcd Display

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C LCD display Display Features In measurement mode, the LCD display of the gas analyzer is The following table shows the standard system page layout in a freely configurable. A standard layout is configured on each gas analyzer with no more than six sample components and delivered unit.

  • Page 104: Display Overview

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 10 Configuration … LCD display Display Overview Display element positioning on the page The display elements can be represented in two sizes. • A maximum of three large and six small display elements can be represented on a page.

  • Page 105: Page Overview

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Page overview Parameter The page overview contains the following information: Page number and status ‘On’ or ‘Off’ Name Name of the page Usage Page Assignment Type System: page configured by the system with...

  • Page 106: Parameter Overview

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 10 Configuration … LCD display Parameter Overview Parameter The display parameters have the following functions: Parameter Description Name The name of the display element set by the system cannot be changed.
  • Page 107 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C User Page Configuration Moving a Display Element from One Page to Another Perform the following steps to configure a user page: Display elements can be moved between the pages. Peform the 1.
  • Page 108 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 10 Configuration … LCD display Moving a Display Element within a Page Configuring the bargraph or dot display Display elements can be moved within a page. Perform the following steps to move a display element: 1.
  • Page 109 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Value Input 7. Select the ‘Position’ parameter. • The nine possible positions are graphically represented; free positions are identified by the position number. 8. Select the position with the corresponding number key.
  • Page 110 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 10 Configuration … LCD display Configuring Value Input 1. Select the ‘Display’ menu item. 11. Select the function block created in Step 8, enter the name 2. Start configuration of the new display element with the and unit, and link the function block to an application via its ‘NEW’...

  • Page 111: Key Entry

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C 1 5 5 Key Entry Parameters For the display element ‘Key input’, the following parameters should be configured: Parameter Description No of keys The number of keys (1 to 6) – the keys are assigned...
  • Page 112 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 10 Configuration … LCD display 8. Select the ‘Keys’ display type. • This creates a ‘Constant’ function block; the system- issued name 'Value page-position' is displayed in the ‘Source’ parameter.

  • Page 113: Diagnosis / Troubleshooting

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C 11 Diagnosis / Troubleshooting The Dynamic QR Code Safety instructions Application WARNING Dynamic QR Code is a unique feature for displaying dynamically Risk of injury generated QR codes on the gas analyzer display.
  • Page 114 The QR code is accessed in the Diagnostic Menu of the gas Recommended QR code scanner apps analyzer and indicated on the display. To be able to use the full service, ABB recommends using the website My Measurement Assistant: The website opened on the mobile device scans the QR code that is displayed.

  • Page 115: Process And Device Status

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Process and device status The Process status provides information on measurement values Instrument status and the status of the process, which is monitored by the gas Status messages analyzer. The following components and modules generate status...
  • Page 116 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 11 Diagnosis / Troubleshooting … Process and device status Status messages are shown in the LCD display Status Signals As soon as a status message is received, the message indicator Overall or Individual Status flashes on the LCD display and the ‘STATUS MESSAGE’...

  • Page 117: Status Message Categories

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Status Message Categories There are three categories of status messages: Individual Status by Analyzer Module or Sample Component • Status messages not requiring acknowledgment In principle, the individual status signals apply to the entire gas •...
  • Page 118 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 11 Diagnosis / Troubleshooting … Status Message Categories Overview Status messages requiring acknowledgment and intervention In the status message overview, the status messages requiring acknowledgment and intervention are marked as follows.

  • Page 119: Possible Status Messages

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Possible status messages Legend for the ‘Status messages’ table Column in ‘Status messages’ table The status message number appears in the detailed display in the menu line. Note Message numbers ≥ 10000 are exclusive messages of a function block application.
  • Page 120 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 11 Diagnosis / Troubleshooting … Possible status messages Text Reaction/Comment System controller (continuation) The profibus module is installed on a wrong slot! see message text The profibus interface is therefore not functional.
  • Page 121 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Text Reaction/Comment System bus (continuation) The analyzer module has an internal Notify Service. communication error! The analyzer module has an internal program Notify Service. error! The analyzer module could not be found.
  • Page 122 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 11 Diagnosis / Troubleshooting … Possible status messages Text Reaction/Comment Analyzer module (continuation) The pressure regulator works erroneously. see status message of the relevant pressure controller The pressure correction for this component was...
  • Page 123 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Text Reaction/Comment Pressure regulator No new measured values from the analog/digital Notify Service. converter. The measured value exceeds the value range of Notify Service. the analog/digital converter. A calculation error occurred while calculating the Notify Service.
  • Page 124 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 11 Diagnosis / Troubleshooting … Possible status messages Text Reaction/Comment Measured value The measured value exceeds the value range of Measured value > +130% MRS; not in the logbook the measuring range.
  • Page 125 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Text Reaction/Comment Adjustment (continued) A combination of the following errors has Calibrate the detector displayed manually at the zero point and span point. occurred: Drift half, drift, reinforcement or delta drift.
  • Page 126 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 11 Diagnosis / Troubleshooting … Possible status messages Text Reaction/Comment Adjustment (continued) The adjustment was canceled, as no raw measured values can be entered. The adjustment was canceled, as the pushbutton only with Fidas24 did not detect calibration gas.

  • Page 127: Possible Status Messages - Ftir

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Possible status messages – FTIR Legend for the ‘status messages’ table Column in ‘Status messages’ table The status message number appears in the detailed display in the menu line. Note Message numbers ≥...
  • Page 128 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 11 Diagnosis / Troubleshooting … Possible status messages – FTIR Text Reaction/Comment 2004 OFFLINE Check sample gas concentration. Alarm state: OFFLINE Notify Service. 2005 MAINTENANCE Check sample gas concentration.
  • Page 129 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Text Reaction/Comment 2505 Auto ref. Error Enter manual reference Automatic zero point reference failed. Notify Service if this occurs again. 2506 High alarm For information High alarm triggered by the components:...
  • Page 130 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 11 Diagnosis / Troubleshooting … Possible status messages – FTIR Text Reaction/Comment 2527 Emergency purging See message text Temperature error on the emergency purging is active. To end the emergency purging, please select the menu: Service/TestSelect emergency purging.

  • Page 131: Troubleshooting

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Troubleshooting The measured value display flashes Temperature Problem The measuring signal exceeds the limits of the measuring Analyzer system still in the warm-up phase range • The assemblies in the analyzer cabinet reach their target Note temperatures after approx.

  • Page 132: Fid - Troubleshooting

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 11 Diagnosis / Troubleshooting FID – Troubleshooting Pressure regulator fault Temperature Problem Unstable pressure values Connection leads of the temperature sensor or the heater • Check the inlet pressures of the operating gases.

  • Page 133: Notify Service

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Notify Service FID in fail-safe status Who should you contact for further help? If a fatal error occurs in the analyzer module, the analyzer module Please contact your local service representative. For will be set to the fail-safe status;...

  • Page 134: Returning Devices

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 11 Diagnosis / Troubleshooting Returning devices Use the original packaging or a secure transport container of an appropriate type if you need to return the device for repair or recalibration purposes.

  • Page 135: Maintenance

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C 12 Maintenance Safety instructions WARNING Note Only persons familiar with the maintenance of comparable Risk of injury analyzer systems and who possess the qualification required for Risk of injury due to maintenance work being carried out such work are allowed to work on the analyzer system.

  • Page 136: Visual Inspection

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 12 Maintenance Visual inspection Figure 35: Internal view of the analyzer cabinet Pos. Component Test / set point – External instrument air regulator 5.5 to 7 bar – External gas cylinder pressure reducer: Zero point gas O analyzer (3 vol.% O...

  • Page 137: Cleaning The Analyzer Cabinet

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Cleaning the analyzer cabinet Note Simplified seal integrity test of the sample gas path The door of the analyzer cabinet must be closed at all times Note during operation! The simplified seal integrity test is not suitable for testing the overall analyzer system for seal integrity.

  • Page 138: Fid - Leak And Function Tests

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 12 Maintenance FID – Leak and function tests … Seal integrity test Simplified seal integrity test using FID NOTICE CAUTION The seal integrity check and function tests described in this...
  • Page 139 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Combustion gas supply from a central unit Combustion gas line 1. Switch off the gas analyzer power supply. Ensure that the The seal integrity of the combustion gas feed line must be shut-off valve in the combustion gas supply line is open.

  • Page 140: Maintenance Switch

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 12 Maintenance Maintenance switch … FID – Leak and function tests Function Function test of the H safety valve The analyzer system can be set permanently to the ‘Maintenance’...

  • Page 141: Emergency Purging

    (no. 2527). message (no. 2534). Ending emergency purging manually The digital output 4 of a digital I/O module with the ‘ACF5000 Once all temperatures have risen above the threshold, cabinet status’ functional block application is set. As a result, the...

  • Page 142: Connecting Gas Paths And Inserting Validation Cells

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 12 Maintenance Connecting gas paths and inserting validation cells Function The gas path in the analyzer system can be connected manually, e.g. to emit test gases. The menu can be exited without waiting for the purging times and any necessary switchover of the measuring model.

  • Page 143: Adjustment Reset

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Adjustment reset Basic adjustment Note Note The adjustment reset is only possible for the FID and oxygen Basic adjustment is only possible for the FID and oxygen sensor sensor analyzer modules.

  • Page 144: Fid - Standby / Restart

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 12 Maintenance FID – Standby / Restart Menu Path ‘MENU / Maintenance/Test / Analyzer spec. adjustm. / Definitions of the statuses Standby/Restart FID’ Standby mode means: Heater on, combustion gas valve closed, combustion air valve...

  • Page 145: Configure Saving Of Ftir Spectra

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Configure saving of FTIR spectra FID in fail-safe status Function If a fatal error occurs in the analyzer module, the analyzer module It can be configured whether the FTIR spectra are saved in the will be set to the fail-safe state;...

  • Page 146: Configure Automatic Back-Purging Of The Gas Extraction Probe

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 12 Maintenance Configure automatic back-purging of the gas extraction probe Recommended program sequence for back-purging ‘ ‘ 1. In the Timer“ menu select the Blow back MGE1 on/off’ function block.
  • Page 147 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C ‘ 4. In the selected Constant“ function block, switch on back- purging: • „FB value“ = 0 Back-purging is switched off. • „FB value“ = 1 Back-purging is switched on.

  • Page 148: Replacement Of Wear Parts

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 12 Maintenance Replacement of wear parts Replacement cycle CAUTION Risk of burns Wearing parts Replacement cycle Risk of burns on the sample gas extraction components Filter on the gas extraction probe At least every 12 months, depending (temperature approx.

  • Page 149: Replacing Filter On The Gas Sampling Probe

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Replacing filter on the gas sampling probe Wearing parts Cleaning or replacing filters CAUTION Wearing parts Item no. Replacements Risk of burns Stainless steel filter with two 8329410 At least every 12 months, depending...

  • Page 150: Replacing Sample Gas Filter In The Asp Block

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 12 Maintenance Replacing sample gas filter in the ASP … Replacing filter on the gas sampling block probe Wearing parts Or replace filter Wearing parts Item no. Replacement, comment...

  • Page 151: Removing The Filter

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Removing the filter Fitting the filter 1. Open analyzer box AU2. 1. Use the degreased tool to grip the new filter at the spring 2. Undo three fixing screws (4 mm hexagonal spanner).

  • Page 152: Replacing Filter In The Compressed Air Main Regulator (-J85)

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 12 Maintenance Replacing filter in the compressed air main regulator (-J85) Wearing parts Replacing the filter element Wearing parts Item no. Replacements Filter in the 990048 Every 12 months...

  • Page 153: Replacing Filters In The Sample Gas Pressure Controller

    Replacing the filter 1. Loose 5 screws and remove the cover of the ACF5000 electronics box AU1. The paper filters in the sample gas pressure regulator are located on the right-hand side in the ACF5000 electronics box.

  • Page 154: Replace Filter Cartridges In Air Purifier Au5

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 12 Maintenance Replace filter cartridges in air purifier AU5 Wearing parts 4. Loosen four hexagonal screws at the top and bottom on Wearing parts Item no. Replacements one of the filter cartridges.

  • Page 155: Replacing Filter Pad In The Fan

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Replacing filter pad in the fan Replacing the system controller battery Wearing parts Wearing parts Wearing parts Item no. Replacements Wearing parts Type Replacements Filter pad in the inlet and...

  • Page 156: Replace Pressure Equalization Screws

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 12 Maintenance Replace pressure equalization screws Wearing parts Wearing parts Item no. Replacements Pressure equalization screw 8329416 Every 12 months connection Replace pressure equalization screws 1. Loosen the counter nut in the top of the cabinet and remove the screw upwards.

  • Page 157: Decommissioning

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C 13 Decommissioning Shutting down the analyzer system Safety instructions WARNING Shutting down the analyzer system temporarily 1. Switch the gas flow control on ‘zero gas probe’ (zero air Risk of injury due to live parts!

  • Page 158: Packaging The Analyzer System

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C … 13 Decommissioning Packaging the analyzer system Vacuum pack the analyzer system in foil. WARNING 1. Lay out dessicant in the transport crate. Use an amount of Injury hazard due to heavy weight desiccant that is appropriate for the packing volume and the The analyzer system weighs approx.

  • Page 159: Recycling And Disposal

    15 Specification Note Note Products that are marked with the adjacent symbol The device data sheet is available in the ABB download area at may not be disposed of as unsorted municipal waste www.abb.com/analytical. (domestic waste). They should be disposed of through separate collection of electric and electronic devices.

  • Page 160: Appendix

    ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C 16 Appendix Return form Statement on the contamination of devices and components Repair and/or maintenance work will only be performed on devices and components if a statement form has been completed and submitted.
  • Page 161 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Trademarks Modbus is a registered trademark of Schneider Automation Inc. PROFIBUS and PROFIBUS DP are registered trademarks of PROFIBUS & PROFINET International (PI)
  • Page 162 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Notes...
  • Page 163 ACF5000 MULTI-COMPONENT FTIR EMISSION MONITORING SYSTEM | OI/ACF5000-EN REV. C Notes...
  • Page 164 We reserve all rights in this document and in the subject matter and illustrations contained therein. Any reproduction, disclosure to third parties or utilization of its contents – in whole or in parts – is forbidden without prior written consent of ABB. © ABB 2024...

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