CEMTEK Instruments- NH3 Analyzer Quick Start Manual

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1 CEMTEK Instruments- NH3 Analyzer Quick Start Manual November 2013

2 Table of Contents Section 1- General Overview 1.1- Overview Important Precautions Theory of Operation Performance Specifications Features Mechanical Specifications Electrical Specifications Section 2- Configuration and Operation 2.1- Pre-Setup Details Initial Setup Procedure Touch Screen Menu Navigation Calibration Modifying/Checking Analyzer Diagnostics Preventative Maintenance Section 3- System Description 3.1- Warnings/Alarms Troubleshooting Important System Components Appendix Controller Enclosure Mounting Dimensions i Controller Enclosure Layout ii Probe Enclosure Layout. iii Full System Layout iv ADAM wiring Layout v Cable Interconnect Wiring vi-vii Air Clean Up System Details.....viii-xi Contact Information xii 1

3 1.1- Overview The CEMTEK Instruments NH3 Hot/Wet Extractive NH 3 Analyzer is designed specifically for use in Combustion Process applications for Low NO x Burner Tuning and SCR Inlet/Outlet monitoring. NH 3 is measured using a Tunable Diode Laser. The system requires no sample conditioning and is simply heated throughout the sample s flow scheme to ensure NH3 is not lost from the sample gas Important Precautions Use dry, oil-free instrument air only Caution: This instrument will be damaged if used with instrument air that is not dry and oil-free. Ensure instrument air has 30 F dew point and has been filtered to remove all oil and particulates. Safety Notice This instrument operates from potentially lethal line voltage. In addition, certain components operate at high temperatures and can cause serious burns. Observe all precautions when using this device, and particularly be sure that all devices connected to the instrument are safely wired and properly grounded. Always disconnect power to the instrument before making any wiring adjustments. Caution: The analyzer should not be operated without each enclosure door shut and the fan fully functioning Theory of Operation With NH3 being a difficult compound to measure due to the physical properties created in combustion monitoring gas applications, our system looks to keep the sample gas at or above 190C throughout each component that our sampling system consists of, including most importantly, our high temperature tunable diode laser bench. In addition, we have a shortened sample flow scheme to lessen the chance of having our sample gas compromised, ensuring correct readings. 2

4 1.4- Performance Specifications Measurement technology Measurement range (adjustable) Zero noise Zero calibration drift Span noise Span calibration drift Linearity error Response time NH3 Tunable Diode Laser PPM PPM Better than ± 1 PPM < 1% of reading Better than ±2% of reading < ±2% of high calibration value across range from zero to full scale T90 < 30 seconds 1.5- Features Proven TDL technology for detection, accuracy, precision & long life span Simple Hot/Wet Extractive gas sampling system Automated Probe Enclosure climate control Front panel Touch Screen Display and Control Automatic Calibration mode option Automatic Calibration check option 4-20 ma analog output and Good Data Digital Circuit 1.6- Mechanical Specifications Probe Enclosure: NEMA 4 mounted directly to the flange 16 W x 12 D x 20 H Probe: SS with 3 ANSI 150lb flange Controller: Wall Mount NEMA4-12 W x 10 D x 16 H Total Weight: ~70 lbs depending on probe 3

5 1.7- Electrical Specifications AC input (supplied by customer): - Gauge wire: AWG VAC Output Contacts (supplied by customer): - Gauge wire: AWG Minimum rating 12V, 60mA Maximum rating 12V, 3.5A 2.1- Pre-Setup Details Getting started using your new CEMTEK Instruments analyzer should be quick and easy. In this section we have included the information needed for standard installations only. To ensure the quickest and most reliable startup, please follow the subsequent steps. The system consists of 3 major components: The Controller Enclosure which houses the majority of the electronics and pneumatic controls. The Probe Enclosure which contains the heated pump, laser bench, heated enclosure tube section, and heated probe. These components make up the sampling system. Enclosure Interconnects- Power cable, Signal cable, Calibration line, and Air line. 4

6 Ensure all required services such as power supply, instrument air, and signal cabling are available on-site prior to installation. * Once the sample location has been identified, mount the probe at the sample port. * Next mount the controller appropriately so that the sample line can be run between the controller and probe enclosure without danger of being damaged upon completion of installation. ** A basic layout of the NH3 Analyzer System can be seen on the following page ** 5

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8 2.2- Initial Setup Procedure 1. Connect outer controller gas lines 1. Make sure that the analyzer is NOT powered on. 2. Connect instrument air and span calibration gas to inlets shown below via 3/8 and 1/4 Swagelok fittings respectively. a. Instrument air: must be dry, oil-free air, 8-10 SLPM at 60-70PSI. b. Calibration gas: Should be at 8-10 SLPM. * For the system, here are all the input pneumatic connections. All located going into the Controller Enclosure. 7

9 2. Ensure inner controller components and pneumatic lines are connected 1. Check to see if all internal wires are landed and in their correctly associated terminals and that there are no loose or exposed wires seen. 3. Connect analog and digital customer connections into correct ADAM module terminal locations 1. Connect analog and digital output signals that are brought in through the conduit labeled signal cable. (See below) Analog connector: ADAM-4021 (4-20mA Output) +IOUT, -IOUT Digital connector: Good Data (NORMALLY OPEN) - Good Data defined as analyzer is pulling sample with pump on, no temperature alarms, no pneumatic valves open. RL6 NO, RL6 COM (CLOSED = Bad Data) Analog Connection Digital Connection 8

10 2. Connect the 120 VAC power supply input (from customer) through the other ¾ conduit labeled AC IN into the proper locations on the power distribution terminal blocks. Analyzer Circuit Breaker: Switch up/down supplies/severs power to system. 4. Connect Enclosure Interconnect Cable and Gas lines 1. Connect the signal cable and power cable to their respective bulkheads. 2. Connect the 3/8 Air line and ¼ Calibration gas line to their respective tubing bulkheads. 9

11 5. Apply power and begin application specific analyzer setup 1. Apply power to the system by either flipping the circuit breaker and/or plugging the external power supply in. 2. After half a minute the NH3 concentration will be shown on the lock screen. This is the screen that should be seen once analyzer has gone through initial power up procedure. 3. Next go into the Temperature Setup screen and turn all heaters on. Let each heater begin to regulate at their associated temperature set points. The System Temperatures screen will show what each temperature set point is and what the high and low temperature alarms are set at. Adjust the temperature limits and set points accordingly in terms of your analyzer s application. Note: If set point temperatures are changed, check/adjust flow balance regulators and recalibrate analyzer. 10

The Main Menu Screen for analyzer set up and control. 4. Set the Full-scale value for the analyzer Full-scale value for the NH 3 channel can be set at any integer value between 1 and 500 ppm.

12 The Main Menu Screen for analyzer set up and control. 4. Set the Full-scale value for the analyzer Full-scale value for the NH 3 channel can be set at any integer value between 1 and 500 ppm. To adjust the output scaling, click on the Other Parameters button via the menu screen and then set the Full Scale to the appropriate value. Note: The analog output is scaled to the NH 3 full-scale of the analyzer. For example, if the full-scale of the analyzer is set to 50 ppm, then 20 ma will represent 50ppm. (0ppm=4mA) 5. Manually calibrate the analyzer After installation and at least a 1-hour warm up period, the analyzer can be calibrated following the procedure outlined in the "Calibration" Section of

13 2.3- Program Screen Navigation - When the analyzer is functioning the touch screen display makes it easy for the user to traverse to many different areas dealing with analyzer controls and diagnostics. Here is the program s runtime screen hierarchy. 12

14 2.4- Calibration After installation and at least a 1-hour warm up period, the NH3 channel can be calibrated via the Calibration Procedure as listed below: Initial Calibration: 1) Follow the Calibration Procedure outlined below which is executed from the Manual Calibration screen. 2) By utilizing the Trending NH3 Chart, the response time for zero and span gases can be timed, which assist in approximating the amount of time calibration gas should be run on the analyzer. 3) It may be necessary to do a second calibration to stabilize the analyzer after successfully completing the first procedure fully. Auto Calibration: 1) Setting up an auto calibration sequence can be accomplished through the Auto Cal Setup screen. Follow the steps as stated in section 2.5 Modifying/Checking Auto Cal Settings. Notes on Calibration Frequency * For normal process applications following the maintenance and calibration procedures listed in Section 2.6 will provide a level of accuracy acceptable for process monitoring. * For applications where the NH 3 value is being used as a feedback number for SCR control then calibrating at least on a weekly basis is recommended. * For applications whereby the NH 3 numbers are being utilized as a means of proving the process system s ability to meet the permitted limits (without the requirement for certification) calibration drift of the analyzer should be monitored- When readings obtained are outside the acceptable limits, a recalibration should be performed. 13

15 Calibration Procedure In order to calibrate the analyzer s zero and span values the user must click on the manual calibration button from the home screen. NOTE! * Before calibration of the analyzer ensure that the calibration gas bottle value saved is correct. * Make sure that the associated bottle value is within the range of the fullscale output value set. The screen displayed above shows the following: The calibration gas bottle value for its span calibration. The software s stored response value, which is shown and saved to provide a correctly calibrated Live NH3 PPM reading. The Raw Laser PPM value which is the raw response as outputted from TDL bench. 14

16 In order to perform a manual calibration, follow the procedure below starting with manually calibrating the zero gas (OFFSET), followed by performing a calibration with the span gas (SPAN) 1. Open the zero or span valve to initiate either the zero or span calibration of the analyzer. (make sure only one valve is open at a time) 2. Once the live response has settled (use the Trending NH3 screen to help determine this) you may select Calibrate Span/Zero. This will change the stored response value stored in the analyzer s software which is used to calculate the Live Response of the real-time sample gas. NOTE! Make note of the time it takes for the value to settle, as these will be used to set the automatic calibration sequence. (See Auto Calibration Setup Section 2.5) 3. After completing the calibration of the analyzer close the calibration gas valves and check to ensure the sample pump is on and Good Data is trending. NOTE! For the most accurate readings calibrate the zero and span of a gas back to back. 15

17 2.5- Modifying/Checking System Diagnostics Modifying/Checking Full Scale & NH3 Trend Chart- Menu Screen -> Trending NH3-> From this screen you can: Modify or check the trending graph s scale. See how the Live NH3 ppm has been trending. Navigate to the Manual Calibration or Chart Options screens. 16

18 Modifying/Checking Calibration values- Main Menu-> Manual Cal -> From this screen you can: Modify or check bottle or stored response values associated with the span and zero of the sampling gas. Open or close the span or zero gas valves. Capture the Span or Zero response, also known as manually calibrating the analyzer. View the raw or live response readings. Go to Trending NH3 screen. 17

19 Modifying/Checking Chart Options- Main Menu-> Trending NH3-> More Chart Options From this screen you can: Modify or check values associated with the number of rolling data points set for the Live Reading NH3 calculation. Modify or check the Charts time range hours and/or minutes. 18

Modifying/Checking Auto Calibration Settings Main Menu-> Auto Cal Settings-> From this screen you can: Modify or check the upcoming hour (0-24) to begin 1 st Auto Cal Run.

20 Modifying/Checking Auto Calibration Settings Main Menu-> Auto Cal Settings-> From this screen you can: Modify or check the upcoming hour (0-24) to begin 1 st Auto Cal Run. Modify or check the number hours between Auto Cals. Check the time and date in which the next Auto Calibration will run. Modify or check the Duration in minutes that the span and zero valves will be open. Enable or Disable the Auto Calibration mode. 19

Modifying/Checking System Temperatures- Main Menu-> System Temperatures-> From this screen you can: Modify or check the over values under values, and/or set point values of each component

21 Modifying/Checking System Temperatures- Main Menu-> System Temperatures-> From this screen you can: Modify or check the over values under values, and/or set point values of each component s temperature limits. Check the Live Temperature Readings of each heater component. Check the Ambient Outside air temperature and inside controller temperature. Turn on/off each heater. 20

Modifying/Checking System Parameters- Main Menu-> Other Parameters-> From this screen you can: Modify or check the heater regulating temperature

22 Modifying/Checking System Parameters- Main Menu-> Other Parameters-> From this screen you can: Modify or check the heater regulating temperature range, temperature set points, offset value, span value, and Full Scale output value. Check Heater Power Relay functioning. Go to Software Tags screen. 21

23 Modifying/Checking Software Tags- Main Menu-> Other Parameters-> Software Tags From this screen you can: Check Laser bench parameters. Override the pump, laser controls, and Good data variables. Change Cooler Valve Set point, Cal Wait Time, or Laser Range Filter values. 22

24 2.6- Preventative Maintenance Once the analyzer is correctly configured and functioning as intended, it is crucial to implement periodic checks to avoid problems causing analyzer down time. The type and amount of maintenance required varies upon application. It is dependent on the concentration of the measured gas, particulate loading, moisture, and other sorts of relevant flue gas constituents. Yearly basis: Check/Clean/Replace as necessary the calibration shroud and probe tip-end filter. Check Linearity of TDL bench by running a mid-range gas value after a calibration procedure is performed. -Contact CEMTEK if sensor linearity procedure must be done. Replace/Check sample lines for contamination. Quarterly basis: Check the amount of air/gas flow while instrument air/cal gas is flowing through the analyzer. Adjust the flow balance regulators as necessary. Check/Clean the Exhaust orifice at the probe enclosure. Monthly/weekly basis (application dependent): Check for alarms and system abnormalities. Check Air and Calibration gas system pressures. Run analyzer calibration check. Manually recalibrate the analyzer if necessary. ** On the following page are acceptable log sheets that can be used to carry out monthly/weekly, quarterly, and yearly preventative maintenance checks. 23

25 NH3 Analyzer MONTHLY/WEEKLY CHECKS Alarms? YES NO Plant inlet air pressure(psi) psi psi OK Air cleanup panel psi(exit) psi psi OK Calibration Gas Bottle pressure >150psi psi OK *must recalibrate analyzer if pressures and/or flows are changed. NH3 zero air check value (PPM) 0 Pass/Fail NH3 zero stored % value % NH3 span check value (%) Bottle Val: Pass/Fail NH3 span stored % value % NH3 Analyzer QUARTERLY CHECKS CALIBRATION GAS FLOWS: NH3 span gas flow 3 LPM lpm OK NH3 zero gas flow 3 LPM lpm OK ANALYZING SAMPLE GAS: Calibration gas flow 0 LPM lpm OK Probe Temperature see set point C OK Enclosure Section Temperature see set point C OK Pump Temperature see set point C OK Enclosure Temperature see set point C OK Check/Replace Probe Filter Check/Clean Pump Exhaust Check/Clean Enclosure Section line OK OK OK *must recalibrate analyzer if flows, parts, or temperatures are altered. 24

26 8000 NOX-O2 PROBE YEARLY CHECKS Check/Clean all lines for contamination Check/Clean as necessary the calibration shroud and probe tipend filter Check Linearity of TDL bench by running a mid-range gas value of NH3 after a calibration procedure is performed. Contact CEMTEK if sensor linearity procedure must be done OK OK OK *must recalibrate analyzer if sensor parts or lines are cleaned. 25

3.1- Warnings/Alarms Warnings and Alarms are displayed atop each screen (as shown below). PUMP OFF- There is no sample being drawn through the analyzer.

27 3.1- Warnings/Alarms Warnings and Alarms are displayed atop each screen (as shown below). PUMP OFF- There is no sample being drawn through the analyzer. The sample pump may be turned off or a temperature alarm thrown. TEMP ALRM- Alarm displayed when a heater temperature is either over or under a specified limit or not turned on. See touch screen menu navigation section to view alarm details. Many need to troubleshoot. VALVE OPEN- States that the Span or Zero gas valve is open, should be seen during manual or automatic calibrations. See touch screen menu navigation section to close and open this valve. AC- States that system has been placed in Auto Calibration Mode. See Auto Calibration Section on how to configure this mode. M- States that the system has been placed in Maintenance mode. Must be placed in this mode to signal Good Data is NOT being transmitted at the time and to place the system in/out of Auto Calibration mode. 26

28 3.2- Troubleshooting Once the analyzer has been set up correctly through the Initial Setup Procedure and has been functioning acceptably beyond start up issues, situations in which the analyzer is not functioning properly may arise. Below are descriptions of possible issues that may be experienced and the correct steps to take in troubleshooting them. Analyzer Touch screen not powering on: Blank Touch screen - Check wiring to analyzer and into back of HMI display. - Check analyzer circuit breaker switch. - Replace screen. Unresponsive NH3 reading: When a change in NH3 ppm value should be seen (such as when switching from zero to span gas during a calibration check) - Check flow scheme for leaks and loose fittings. - Make sure there is some type of range between the stored % response of the zero and span calibration values on the manual calibration page. - Validate proper calibration gas input conditions as specified in the initial set up section. - Check that the pneumatic block solenoid valves are all functioning correctly. a. While monitoring the flow meters, manually open/close the span and zero valves via the touch screen on the calibration page. - Check state of filters in filter assembly. -Check pump exhaust flow at probe. a. If there is not sufficient air flow out of the pump there may be a problem with your pump or a clogged line (within sampling system up at probe). Blow out all exhaust lines. 27

29 Over/Under Temperature Alarm: Will be seen atop the main screen - Go to system temperature page and confirm set points for alarms and regulating points are correct. - Check Heater lines to main board wiring connections. - Check ADAM relay heater wiring connections. - Check Probe Enclosure wiring connections. 28

The bench outputs a RS-485 protocol which communicates with the Advantech Touchscreen through signal cabling.

30 3.3- Important System Components PROBE ENCLOSURE COMPONENTS 1. Heated TDL Bench Rectangular black TDL bench assembly mounted inside Probe Enclosure in between the Enclosure Heated Line Section and Heated Sample Pump. The bench outputs a RS-485 protocol which communicates with the Advantech Touchscreen through signal cabling. See Component Manuals folder on disc manual for more information concerning troubleshooting and servicing this component further. 24VDC into bench serial port and 120VAC into bench heater power supply supplying 2 12VDC lines running into green bench heater connector 2. Heated Extraction Probe Assembly Probe Assembly connected via flange protruding out of the Probe Enclosure into the gas stream that the analyzer is looking to pull sample from. The probe assembly consists of sampling orifice, probe filter, coil heater, and filter bushing assembly. 120VAC Coil Heater 29

Heated Sample Pump Heated Sample Pump that is temperature controlled and responsible for

31 3. Enclosure Heated Line Section Heated line that is temperature controlled located between the heated filter bushing assembly and heated TDL Bench. 120 VAC line heater 4. Heated Sample Pump Heated Sample Pump that is temperature controlled and responsible for drawing a heated sample gas through the analyzer s sampling system. 120 VAC heater power and 120 VAC pump power 30

32 5. Vortex Air Cooler The Vortex Air Cooler assists in controlling the Probe Enclosure s temperature set point. It will produce a cooled stream of air when a pressurized air stream is fed through its port via a controlling solenoid valve. 6. Enclosure Fan Assembly Cross ventilating fan that pulls air through Probe Enclosure to regulate the enclosure s temperature to a specified set point. Fan works in conjunction with lower louver plate vent. 120VAC fan power 31

CONTROLLER ENCLOSURE COMPONENTS 1.24 Vdc Power Supply This component supplies the Vdc power to the entire system. The input voltage supply is typically 120 Vac.

See Component Manuals folder on disc manual for more information concerning troubleshooting and servicing this component further. 120VAC power input 2.

33 CONTROLLER ENCLOSURE COMPONENTS 1.24 Vdc Power Supply This component supplies the Vdc power to the entire system. The input voltage supply is typically 120 Vac. And the output voltage of the component is 24Vdc. Located in the controller. See Component Manuals folder on disc manual for more information concerning troubleshooting and servicing this component further. 120VAC power input 2. ADAM 4069 Module These two components provide the logical switching between different states of the programmed heating/switching functions within the system. See Component Manuals folder on disc manual for more information concerning troubleshooting and servicing this component further. 24VDC power input 32

3. ADAM 4019+ Module The module that is responsible for receiving each thermocouple pair from system heater components and relaying their signals to the

24VDC power input 4. ADAM 4021 Module ADAM module that is programmed to transmit a 4-20mA output signal of the NH3 ppm reading.

34 3. ADAM Module The module that is responsible for receiving each thermocouple pair from system heater components and relaying their signals to the Advantech Touchscreen. See Component Manuals folder on disc manual for more information concerning troubleshooting and servicing this component further. 24VDC power input 4. ADAM 4021 Module ADAM module that is programmed to transmit a 4-20mA output signal of the NH3 ppm reading. Module communicates with the Advantech Touchscreen. See Component Manuals folder on disc manual for more information concerning troubleshooting and servicing this component further. 24VDC power input 33

5. Advantech Touch Screen HMI Touchscreen HMI that is responsible for configuring each analyzer s programmable settings. Found on the outer face of the Controller Enclosure s hinged front door.

35 5. Advantech Touch Screen HMI Touchscreen HMI that is responsible for configuring each analyzer s programmable settings. Found on the outer face of the Controller Enclosure s hinged front door. See Component Manuals folder on disc manual for more information concerning troubleshooting and servicing this component further. 24VDC power input 6. Calibration Assembly Assembly that consists of the calibration flow meter, span/zero calibration valves, and various stainless steel fittings located in the controller enclosure. 120VAC valve power 34

36 7. System Air Pressure Regulator A pressure regulator that is responsible for setting and adjusting the incoming system air pressure. 8. Power Distribution DIN rail Assembly DIN rail which system circuit breaker, power supplies, and terminal blocks are mounted on. 35

37 APPENDIX APPENDIX CONTROLLER ENCLOSURE MOUNTING DIMS i

38 APPENDIX CONTROLLER ENCLOSURE LAYOUT ii

39 APPENDIX PROBE ENCLOSURE LAYOUT iii

40 APPENDIX Full System Layout iv

41 APPENDIX ADAM Wiring Layout v

42 APPENDIX Cable Interconnect Wiring Layout vi

43 APPENDIX vii

44 APPENDIX Cemtek Air Clean Up System (Box) - Type 1 viii

45 APPENDIX Cemtek Air Clean Up System (Panel) - Type 2 ix

46 APPENDIX Cemtek Air Clean Up System (with Heatless Dryer) - Type 3 x

47 APPENDIX Air Clean Up System Information Scrubber 1- Activated Carbon (black) Scrubber 2- Activated Aluminum (white) Scrubber 3- Purafil Media (purple) *See Supplied Material Safety Data Sheets for more information on these substances LB canisters contain each of these media - May need to be changed out due to the quality of the compressor plant air used (input air should be clean and dry). - Based on each specific application; media and air clean up components should be monitored accordingly. xi

48 APPENDIX Contact Information: CEMTEK INSTRUMENTS Telephone: (732) hr. Emergency Service: xii

Section 55 Chapter 6

Section 55 Chapter 6 REMOTE HYDRAULICS CONTROLLER Calibration and Fault Codes 6-12880NH TABLE OF CONTENTS REMOTE HYDRAULICS CONTROLLER CALIBRATION... 55-5 Requirements For Calibration... 55-5 Aux Set Main