Advance Cemas-NDIR Multi-component Measuring … · Advance Cemas-NDIR Multi-component Measuring...

Advance Cemas-NDIR Multi-component MeasuringSystem for Emission Monitoringand Process Control

Operator’s Manual 42/23-49-0 EN

2 Advance Cemas-NDIR Operator’s Manual 42/23-49-0 EN

Table of Contents

Page

Preface 3Important Safety Information 4

Chapter 1 Analyzer System OverviewApplication and Use 5Description 6

Chapter 2 Installing the Analyzer SystemUnpacking the Analyzer System 8Instructions for Selecting a Location 10Removing Transport Locks 11Installing the Gas Sampling Probe 12Installing Gas Lines 13Connecting the Signal Leads 14Connecting the Power Supply Lines 16

Chapter 3 OperationAnalyzer System Start-Up 18Adjusting and Calibrating the Analyzer System 20

Chapter 4 Inspection and MaintenanceSafety Precautions 21Cleaning and Inspecting the Analyzer System 22Checking Gas Path Seal Integrity 23Replacing Components 24

Chapter 5 TroubleshootingTroubleshooting 27

Chapter 6 Analyzer System Shut-DownAnalyzer System Shut-Down 29

42/23-49-0 EN Advance Cemas-NDIR Operator’s Manual 3

Preface

AdditionalDocuments

The following publications are available to supplement the Advance Cemas-NDIRAnalyzer System Operator's Manual:

Data Sheet Publication No. 10/23-8.20 ENSystem Description Publication No. 30/23-210 EN

The following publications are available for individual analyzer system components:

Advance Optima Operator's Manual Publication No. 42/24-10-1 ENSCC Cooler with SCM Gas SupplyModule Operator’s Manual Publication No. 42/23-50-0 ENCGO-K NO2/NO ConverterOperator’s Manual Publication No. 42/23-48-1 ENSample Gas Intake SystemComponents Data Sheet Publication No. 10/23-5.10 ENAcid Filter Service Bulletin Publication No. 43/23-341-2 XA

The applicable material safety data sheets are supplied with any reagentsdelivered.

Some of the publications referenced above are contained in the Advance Cemas-NDIR System Manual supplied with the analyzer system.

These publications can be ordered from your authorized Hartmann & Braunrepresentative or from

Hartmann & Braun Docu Service, Post Office Box 1552, D-61285 Bad HomburgFax (0 61 72) 92 80 47, Telephone (0 61 72) 92 80 55

Symbols in thisManual

Some symbols identify special information text:

☞ Identifies specific information on operation of the analyzer system as well ason the use of this manual.

Indicates safety information to be heeded during analyzer system operationin order to avoid risks to the operator.


Important Safety Information

Requirements forSafe Operation

In order to operate in a safe and efficient manner, the analyzer system should beproperly handled and stored, correctly installed and set-up, properly operated andcarefully maintained.

PersonnelQualifications

Only persons familiar with the installation, set-up, operation and maintenance ofcomparable systems and certified as being capable of such work should work onthe analyzer system.

Special Informationand Precautions

These include• the contents of this operator’s manual and the operator’s manuals for the

individual units• the safety labels affixed to the analyzer system and individual units• the applicable safety precautions for the installation and operation of electrical

devices• the applicable safety precautions for working with gases, acids and condensates

National Regulations The regulations, standards and guidelines cited in this operator's manual areapplicable in the Federal Republic of Germany. The applicable national regulationsshould be followed when the analyzer system is used in other countries.

Analyzer SystemSafety and SafeOperation

The analyzer system is constructed and tested in accordance with the applicablesafety requirements and left the factory in perfect safety condition.

To maintain this condition and to assure safe operation, read and follow the safetyinformation identified with the symbol in this manual. Failure to do so can putpersons at risk and can lead to analyzer system damage as well as damage toother systems and instruments.

AdditionalInformation

If the information in this operator's manual does not cover a particular situation,Hartmann & Braun is prepared to supply additional information as needed.

Contact your local Hartmann & Braun service representative or Hartmann & BraunService Center Europe, Post Office Box 93 02 09, D-60457 FrankfurtPhone (0 61 96) 8 00-46 00, Fax (0 61 96) 8 00-46 01.


Chapter 1: Analyzer System Overview

Application and Use

Use According toRegulations

The Advance Cemas-NDIR multiple component analyzer system is intended forcontinuous quantitative determination of gas concentrations in emissionsmeasurement per 17. BlmSchV, 13. BlmSchV and TA-Luft.

The analyzer system is also used for process monitoring of flue and exhaust gases,filter monitoring and other process technology applications.

The analyzer system is primarily intended for the measurement of SO2, NO, CO,CO2 and O2.

The analyzer system may not be used to measure highly toxic and highly corrosivegases.

Analyzer SystemTasks

The tasks of the analyzer system are• Sample gas intake• Sample gas supply• Sample gas cooling• Condensate removal• Sample gas analysis

Notes on ExplosionSafety

The analyzer system should not be used• To measure operationally ignitable gas/air or gas/oxygen mixtures• To measure combustible gases that can form an explosive mixture with air or

oxygen• In explosive atmospheres and in explosion hazard areas


Description

Components The Advance Cemas-NDIR analyzer system consists of the• Intake system (optional)

• Probe tube• Filter• Sample gas line• Probe and sample gas line supply unit

• Sample gas preparation• Advance SCC sample gas cooler• SCM gas supply module• Condensate trap• NO2/NO converter (optional)

• Advance Optima gas analyzer(s)• O2 module (optional)• Analyzer cabinet

Continued on next page


Description, continued

Figure 1

Analyzer Cabinet

1 Advance Optima Gas Analyzer2 Solenoid Valve3 Acid Filter4 Reagent Container

(not shown)5 Condensate Collector6 Blower7 Sample Gas Cooler with

Gas Supply Module8 Flowmeter with Needle valve to

Adjust Sample Gas Flow Rate9 Switching Units

10 Transport Lock for 19-InchPivoting Racks

11 Terminal Strip -X140for Current Output Signals

12 Terminal Strip -X120for Status and Limit Value Signals

13 Terminal Strip -X100for Power Supply

14 Main Switch15 Overload Breakers16 Light with Movement Indicator


Chapter 2: Installing the Analyzer System

Unpacking the Analyzer System

☞ We recommend having the analyzer system installed by Hartmann & Braun.

When installing the analyzer system follow the instructions contained in theindividual unit operator’s manual, bulletins and specifications sheets in addition tothe instructions contained in this operator’s manual.

WARNING!

The analyzer cabinet weighs approx. 300 kg! A crane with a suitable supportdevice is required for unpacking and handling.

The crane cable must be long enough to have an angle of at least 60° relativeto the top of the cabinet when under tension (see Figure 2). If this is not donethe cabinet can be warped.

Figure 2

Transporting theAnalyzer Cabinet

☞ If there is shipping damage which points to improper handling file a damage claimwith the shipper (railway, mail or freight carrier) within seven days.

☞ Make sure that none of the enclosed accessories are lost during unpacking (see“Items Included” below). Keep the shipping box and packaging material for futureshipping needs.



Unpacking the Analyzer System, continued

Items Included The equipment normally supplied with the analyzer system includes:

Quantity Description

1 Analyzer cabinet with• Advance Optima gas analyzer(s) including Accessories• Advance SCC cooler with SCM gas supply module, including

Accessories• NO2/NO converter (optional)• Condensate collector• Reagent container (optional)

1 Intake system (optional) with• Sample tube with filter• Sample gas line• Probe and sample gas line service module• Protective housing

1 Floor fastening set

2 Cabinet keys

2 Service switch keys

1 Double-bit key for 19-inch pivoting rack

Reagent concentrate (optional)

WARNING!

The reagent concentrate is packaged separately.

When working with corrosive or combustible reagents note the hazardinformation and safety precautions contained in the applicable materialsafety data sheets.


Instructions for Selecting a Location

Short Gas Paths Install the analyzer cabinet as close as possible to the measurement site.Short sample gas lines result in short lag times.

Foundation Erect a foundation in accordance with the “Assembly Plan” drawing in the systemdocumentation.

☞ Consider the additional space requirement for the filter blower as well as foropening the cabinet door and to swing out the pivoting rack according to the “LayoutPlan” drawing in the system documentation.

Protection fromAdverse Conditions

Protect the analyzer cabinet from• Water spray• Contact with chemicals• Strong sunlight and heat radiation• Strong air currents• Heavy dust• Corrosive atmospheres• Severe shock

EnvironmentalConditions

The following table summarizes the permissible ambient temperature ranges for thevarious cabinets.

Average annual relative humidity ≤ 75 %.

Cabinet Design Ambient Temperature Range

Sheet steel cabinet 0 to +35 °C

Fiberglass-reinforced plastic cabinet –20 to +35 °C

Fiberglass-reinforced plastic cabinet with cooler –20 to +50 °C


Removing Transport Locks

Calibration Cells inthe Advance OptimaUras 14 Gas Analyzer

The Uras 14 analyzer module is fitted with calibration cells. At the factory thecalibration cells are protected from shipping damage by a hose placed over thecalibration unit guide rods.

See the Advance Optima Gas Analyzer Operator’s Manual

WARNING!

In any case, the Uras 14 calibration cell transport locks must be removedbefore the analyzer system is powered up.

19-Inch Pivoting Rack

(see Figure 3)

The 19-inch pivoting rack transport lock is located in the lower left corner.

Proceed as follows to remove the transport lock:

Step Action

1 Remove screw 2.

2 Loosen screws 5.

3 Remove angle bracket 4.

4 Place cover cap 1 in opening 3.

Figure 3

19-Inch Pivoting RackTransport Lock

(Example:Sheet steel cabinet)

☞ Keep the transport locks for future shipping needs.


Installing the Gas Sampling Probe

Mounting Flange A tube with a DN 65, PN 6, Form B mounting flange per DIN 2573 must be installedfor the gas sampling probe at the intake site.

Installing the Probe Install the probe on the mounting flange with the 4 M12 screws and nuts supplied.

☞ Refer to the installation plan in the “Sample Gas Intake Components” data sheet.


Installing Gas Lines

Sample Gas LinePlacement

Place the sample gas line so that there is no tapering of the line cross-section atany point. Avoid excessive narrowing, bending, kinking and crossing of other lines.The smallest possible sample gas line bend radius is 20 cm.

Condensate RunoffSlope

The sample gas line from the gas sampling probe to the analyzer cabinet should besloped and, if possible, run along a separate route.

☞ The heatable sample gas line should never be run through walls where there is apossibility of subsequent closure with sealing compound. This will damage thesample gas line.

No Protective Tube Do not run the heatable sample gas line in a protective tube. Maintain a distance ofat least 2.5 cm between multiple parallel sample gas lines (there is a risk of over-heating).

Route LinesSeparately

Insofar as possible, the heatable sample gas line should not be located togetherwith other electric lines in a cable run – especially not in an enclosed cable run. Ifthere is no provision for adequate ventilation, these lines can overheat and bedamaged.

Evacuate ExhaustGases

Connect the exhaust line to the connection port on the right side wall of the cabinet.

Exhaust gas should be routed to the atmosphere or to an exhaust pipe directly orvia the shortest possible large-diameter line.

WARNING!

Exhaust gas can be corrosive, toxic or inflammable!

Take the appropriate precautions when routing exhaust gas and follow theprescribed measures for disposal.

EvacuateCondensates

Connect the condensate line to the connection port on the right side wall of thecabinet and allow pressure-free outflow of condensates to an overflow point.

WARNING!

Condensates are often acidic.

Take the appropriate precautions when routing condensates and follow theprescribed measures for disposal.


Connecting the Signal Leads

WARNING!

Follow local regulations on installing and connecting electrical wiring.

☞ The analyzer cabinet is delivered completely wired.

☞ When choosing conductor material and when placing signal leads, follow therequirements of VDE 0100 “Determinations for Setting-Up High Current Systemswith Rated Voltages Up to 1000 V”.

☞ Locate the signal leads separately from the power supply lines.

Locate the analog and digital signal leads separately from each other.

Carefully plan the signal lead arrangement in cables.

Use the device voucher and “Wiring Plan” and “Terminal Strip Plan” drawings in thesystem documentation.

What Materials areNeeded?

Selection of the required conductors depends on:• Line length• Planned current load

The maximum conductor cross-section for signal leads is 1.5 mm2.

Figure 4

ConnectionArrangement

-X120 Advance Optima gas analyzer current output signals-X140 Status, limit value and digital interface signals



Connecting the Signal Leads, continued

Connecting theSignal Leads

Proceed as follows to connect the signal leads:

Step Action

1 Move main switch -F01 to “0”.

2 In the sheet-steel cabinet, remove the cover from the front or rearcabinet opening (depending on the cable opening) and slide the cabinetcenter bottom plate forward.

3 Pass cables through the openings in the bottom (sheet-steel cabinet) orthrough the cable screw connections (fiberglass reinforced plasticcabinet) and route them upwards in to the left rear corner. Pass thecables through the safety clips and secure them.

4 Connect the signal leads to terminal strips -X120 and -X140 (see figures4 and 5):1. Insert a screwdriver to the stop in the corner actuating opening of the

spring clips.2. Insert stripped conductors in the round clip points.3. Remove the screwdriver. The conductor is securely clamped.

5 Proceed to “Connecting the Power Supply Lines” (see followingsection).

Figure 5

Spring Clips


Connecting the Power Supply Lines

WARNING!

Follow all applicable national safety regulations for the preparation andoperation of electrical devices as well as the following safety precautions.

The analyzer system voltage must be set to match the line voltage before thepower supply is connected.

The protective lead should be attached to the protective lead connectorbefore any other connection is made.

The analyzer system can be hazardous if the protective lead is interruptedinside or outside the analyzer cabinet or if the protective lead isdisconnected.

Service Module Rated current: 16 to 20 A (set to 20 A)

Feed: Motor protection switch Mbs 28.

☞ Use the device voucher and “Wiring Plan” and “Terminal Strip Plan” drawings in thesystem documentation.

Analyzer System Connect the analyzer system to the local power source.

What Materials areNeeded?

Select the conductors required based on rated voltage:

RatedVoltage

RatedFrequency

Number ofWires

Rated WireSection

Main Fuse(Adjustable)

230 V 50 Hz 3 (L, N, PE) 2.5 to 6 mm2 16 to 25 A

115 V 60 Hz 3 (L, N, PE) 2.5 to 6 mm2 16 to 25 A



Connecting the Power Supply Lines, continued

Connecting thePower Supply

Proceed as follows to activate the power supply:

Step Action

1 Make sure the analyzer system power supply is set to the properline voltage (see the device voucher).

2 Make sure the power supply leads have an adequately dimensionedprotective device (breaker).

3 Move main switch -F01 to “0”.

4 Pass cables through the openings in the bottom (sheet-steel cabinet) orthrough the cable screw connections (fiberglass reinforced plasticcabinet) and route them upwards in to the left rear corner. Pass thecable through the safety clips and secure it.

5 Connect the signal leads to terminal strip -X100 (see figures 4 and 6):1. Insert a screwdriver to the stop in the corner actuating opening of the

spring clips.2. Insert stripped conductor in the round clip point.3. Remove the screwdriver. The conductor is securely clamped.

6 In the sheet-steel cabinet, reattach the cabinet opening cover.

Figure 6

ConnectionArrangement


Chapter 3: Operation

Analyzer System Start-Up

☞ We recommend having the analyzer system placed in service by Hartmann &Braun.

When starting up the analyzer system follow the instructions contained in theindividual unit operator’s manual, bulletins and specifications sheets in addition tothe instructions contained in this operator’s manual.

Reagent Fill Fill the reagent container (optional) with the reagent needed for the measurementtask.

WARNING!


Reagents Depending on the measurement task involved, reagents can be used to eliminateinterfering gas components or to stabilize the desired sample components.

Mixture Ratio Reagents (concentrate) can be ordered from Hartmann & Braun service using thespare parts list. They are used in following mixture ratios:

Phosphoric Acid (H3PO4) Hydrogen Peroxide (H2O2)

Concentration 85% 30%

Mixture ratio(in 10-liter container)

½ liter phosphoric acid9½ liters water1

1 liter hydrogen peroxide9 liters water1

Solution sufficient for 2 fills 1 fill

1 e.g. distilled water or water from an ion exchanger.

Test Seal Integrity Check the analyzer system seal integrity (see page 23).



Analyzer System Start-Up, continued

Adjusting the SupplyUnit

Follow the wiring diagrams and operator's manuals of the individual control andmonitoring devices.

WARNING!

Before activating the power supply check once again that the operatingvoltage setting matches the line voltage.

Power SupplyActivation

Turn on the analyzer system power supply system with main switch -F01.

Warm-Up Phase During the warm-up phase the analyzer system screen displays a blinking “STATUSMESSAGE” and the “Power” and “Error” LEDs are lit. Depending on the devicestatus the “Maint” LED may also be lit.

After pressing the “STATUS MESSAGE” softkey, the “Condens. &Cooler”temperature message appears.

The warm-up time is approx. 1-2 hours. It ends when the temperature messagegoes away.

OperatingTemperatures

After end of the warm-up phase, the following operating temperatures are reached:

Component Operating Temperature

Gas analyzer Approx. +60 °C

Sample gas line +160 °C

Cooler +3 °C

Converter +300 °C

Readiness At the end of the warm-up period the analyzer system is ready for operation.

Sample Gas Supply The analyzer system automatically activates the sample gas supply at the end ofthe warm-up phase.


Adjusting and Calibrating the Analyzer System

When should theanalyzer system becalibrated?

The analyzer system should be calibrated at regular intervals (weekly, in general).

According to 17. BImSchV, the zero-point should be calibrated daily and the end-point weekly. Follow regulatory authority rules.

Depending on the application, the interval between calibration processes can beshortened or extended.

No Test Gas Required The analyzer system is calibrated with purified outside air. The outside air must notcontain any sample components.

Analyzer SystemCalibration

See the Advance Optima Gas Analyzer Operator’s Manual

☞ The system should only be calibrated if the warm-up phase has ended and allcomponents have attained their respective operating temperatures.

Analyzer System inMeasurement Mode

The analyzer system is in measurement mode after the gas analyzer is calibrated.

Sample Gas FlowRate Adjustment

The sample gas flow rate is adjusted with the needle valve in the SCM gas supplymodule and indicated on the flowmeter. See the “Piping Plan” drawing in the systemdocumentation for required values.


Chapter 4: Inspection and Maintenance

Safety Precautions

WARNING!

The tasks described in this chapter require special training and under somecircumstances involve working with the analyzer system open and poweredup. Therefore, they should only be performed by qualified and speciallytrained personnel.

If it is apparent that safe operation is no longer possible, the analyzer systemshould be taken out of operation and secured against unauthorized use.

The possibility of safe operation is excluded:• If the system is visibly damaged• If the system no longer operates• After prolonged storage under adverse conditions• After severe transport stresses

☞ We recommend having the analyzer system maintained by Hartmann & Braun.

☞ Main switch -F01 can be secured with a lock to prevent inadvertent activation of theanalyzer system.

☞ During maintenance operations the service switch key should be turned from thevertical “Operation” position to the horizontal “Service” position to produce the“Operational Checkout” status message.

The “Operational Checkout” status message indicates that the currentmeasurement value is not unconditionally valid (e.g. in the associated standbymode).

The maintenance switch should not be turned to “Service” if operations not affectingmeasurement values are being carried out. This includes operations such aschanging blower filter elements.


Cleaning and Inspecting the Analyzer System

Cleaning the ViewingPort

The analyzer cabinet viewing port is made of safety glass and can be cleaned withcommercially available window cleaning products.

Routine VisualInspections

In case of a problem, the “STATUS MESSAGE” softkey appears on the AdvanceOptima gas analyzer display. On a regular basis, e.g. daily, inspect• Analyzer system operational status• Condensate trap fill level• Reagent container fill level• Flowmeter reading in the SCM gas supply module• Cooler temperature reading

Inspections AsRequired

As required, inspect• Status messages• Heating and temperature set-points in the probe and sample gas line service

module• Functions of all devices and units• System seal integrity

Condensate andReagents

Empty the condensate trap and fill the reagent container (optional) when theapplicable status messages are displayed.

WARNING!


Condensates are often acidic. Neutralize condensates and follow theprescribed measures for disposal.


Checking Gas Path Seal Integrity

When should gaspath seal integrity bechecked?

Gas path seal integrity should be checked periodically.

It should be tested after the analyzer system gas paths are opened.

Testing Seal Integrity To test the seal integrity of the gas paths, follow the instructions in the AdvanceOptima gas analyzer operator's manual.

☞ • The peristaltic pump paths should not be opened to the surrounding atmosphere.

• The solenoid valve should be in the “Measurement” mode.Press the “Meas” button. The solenoid valve is in the “Measurement” mode whenmeasurement values appear in the Advance Optima gas analyzer display.

• No automatic calibration should occur during the seal integrity test.Determine when the next automatic calibration is to take place:1)29�→�'SRJMKYVI�→�'EPMFVEXMSR�HEXE�→�%YXSQEXMGGEPMFVEXMSR�→�2I\X�GEP��HEXI�ERH�SV�2I\X�GEP�XMQIIf necessary, postpone the %GXMZEXMSR value for the duration of the sealintegrity test.


Replacing Components

Probe Head OutletFilter

Replace the outlet filter in the probe head as necessary. At the same time insertnew sealing washers.

☞ Leaks and dust penetration will plug the gas analyzer sample gas capillary tubes.This leads to failure of the analyzer system.

Filter ElementReplacement

(see Figure 7)

Proceed as follows to replace the filter element:

Step Action

1 Remove the insulation casing cover (Velcro fastener).

2 Open the filter by turning locking handle 1 counterclockwise.

3 Turn guide 2 counterclockwise so that it can be pulled over pins 3.

4 Turn removable washer 4 counterclockwise so that it engages screws5.

5 Pull out the entire filter element with flange 7 using the locking handle.

6 Change the filter element and O rings 6.

7 Reverse the disassembly steps to assemble the filter unit.

Figure 7

Filter

1 Locking Handle2 Guide3 Pin4 Removable Washer5 Screws6 O Rings7 Filter Element with Flange



Replacing Components, continued

Disposable Filter Examine the SCM gas supply module and the gas analyzer in the gas module everymonth. Replace the filter if it is stained and definitely replace the filter if theminimum sample gas flow can no longer be adjusted with the needle valve.

See the “Advance SCC Cooler with SCM Gas Supply Module” operator’s manual42/23-50-0 EN and/or “Advance Optima” 42/24-10-1 EN.

Acid Filter Inspect the acid filter element monthly. Replace if stained.

See the “Acid Filter” service bulletin 43/23-341-2 XA.

WARNING!

Acid is corrosive! Take the appropriate safety precautions.

Condensate Drain,Reagent Metering

Depending on the operating cycle, the peristaltic pump hoses should be replacedevery 6 months.

See the “Advance SCC Cooler with SCM Gas Supply Module” operator’s manual42/23-50-0 EN.

☞ Use only original hoses and follow the color coding.

WARNING!

The media supplied (condensate and acid) can be corrosive and toxic. Takethe appropriate safety precautions.

NO2/NO Converter Replace the catalyst material as required.

See the “CGO-K NO2/NO Converter” operator’s manual 42/23-48-1 EN.



Replacing Components, continued

Filter Blower inAnalyzer Cabinet

The analyzer cabinet vent has an inlet and an outlet filter.

Check filter screens monthly. Replace if stained, e.g. by dust.

The analyzer cabinet inlet filter is at the bottom of the left side wall and the outletfilter is at the top of the right side wall.

☞ To change the filters it is not necessary to actuate the maintenance key switchbecause this action has no effect on measurement results.

Filter Replacement Proceed as follows to replace the filter:

Step Action

1 Turn off the blower with switch -F02.

2 Pull the filter cover off of the analyzer cabinet side wall.

3 Replace the old filter with a new one.

4 Reinstall the cover. The plates will have to be pressed down to do this.

5 Turn on the blower with switch -F02.


Chapter 5: Troubleshooting

Troubleshooting

Screen Messages Problems will be indicated by the “Error” and “Maint” LEDs on the Advance Optimagas analyzer.

Clear text-messages can be accessed using the “STATUS MESSAGES” softkeythat appears at the lower right of the screen.

• Advance Optima-specific problems are identified in the “Advance Optima”operator’s manual (42/24-10-1).

• System-specific problems are shown in the table below.

System Reaction The following messages cause the system to be switched to the zero gas andinterrupt automatic calibration:

• “Condens. &Cooler”• “Condensate Level”• “Conv. Overall Status”• “Intk. Overall Status”

The following messages cause automatic calibration to be interrupted:

• “Min. Gas Flow Rate”

It the Advance Optima fails, the system is switched to the zero gas.

Short Message/Problem

Cause Corrective Action

Error: “Error” LED lights“Condens. &Cooler” Cooler temperature not in set range Cooler temperature range must be in the

green zone (see cooler operator’smanual).Wait for warm-up phase to end(approx. 0.5 to 1 hour)

“Condens. &Cooler”

Check the status ofER 144 switch unit(on left side of analyzercabinet)• “Condensate” LED

on È problem.• “Sensor Line” LED

on È problem.

Condensate penetration of a gas path.• Peristaltic pump pressure too low• Peristaltic pump motor blocked• Peristaltic pump motor failure• Defective hose• Increased condensate level• Sensor/line break

Eliminate the cause of condensatepenetration, e.g.• Increase pump pressure• Replace peristaltic pump• Replace hose• Check the cooler if condensation is

excessive• Clean and dry the flow chamber• Replace the sensor• Change sensor leads

After eliminating the problem, press theER 144 reset button.



Troubleshooting, continued

Short Message/Problem

Cause Corrective Action

Error: “Error” LED lights“Condensate Level”

Check the status of theSNG-220AC-K switchunit(s) (on left side ofanalyzer cabinet)• “OUT” LED off È

problem.

Condensate buffer container full insample gas cooler.• Peristaltic pump pressure too low• Peristaltic pump motor blocked• Peristaltic pump motor failure• Defective hose• Increased condensate level

Eliminate the cause of elevatedcondensation, e.g.• Increase pump pressure• Replace peristaltic pump• Replace hose• Check the cooler if condensation is

excessive• Clean and dry the downstream

components as required.“Conv. OverallStatus”

Converter Overall Status active Check the converter (see converteroperator’s manual).

“Intk. Overall Status” Overall status of the probe and samplegas line service module active (samplingproblem message)

Check the probe and sample gas lineservice module.

Maintenance needed: “Maint” LED lights“Empty Cond. Cont.” Condensate trap full Empty the condensate trap and clean

and dry the downstream components asrequired.

Follow safety precautions!

“Fill Reag. Cont” Reagent container empty Fill the reagent container Follow safety precautions!

“Min. Gas Flow Rate”

Check the status of theS3D2-CK-US switchunit (on left side ofanalyzer cabinet)• “Line Power” LED onÈ OK

• “IN1” LED on È FlowRate 1 OK.

• “IN2” LED on ÈFlow Rate 2 OK.

• “OUT” LED on Èproblem (this signalis activated if “IN1” or“IN2” report aproblem for 10seconds)

The problem can be caused by thefollowing:• Intake filter plugged

• Gas lines contaminated or plugged

• Gas lines kinked

• Disposable filter contaminated orplugged

• Gas path frozen in the sample gascooler

• Replace filter element

• Separate the gas lines from the gasanalyzer and clear them mechanicallyor with compressed air.

• Route gas lines directly.

• Replace the disposable filter.

• At ambient temperatures < 5 °C theanalyzer cabinet should be heated.Maintain the operating specifications.

Operational Checkout:“Serv. Key” Service key switch on “Service” Return key switch to “Operation” after

maintenance work is finished.

“Backflush” Probe flush active Deactivate backflush.


Chapter 6: Analyzer System Shut-Down

Analyzer System Shut-Down

WARNING!

Before being shut down the analyzer system should be purged in order toprevent condensation and condensate deposits in the individual units.

Shutting Down theAnalyzer System

Proceed as follows:

Step Action

1 Flush the intake probe, filter and sample gas line, e.g. by drawingoutside air from the intake probe.

2 Place gas analyzer Advance Optima on “Zero Gas” and purge theanalyzer system for 30 minutes.

3 Turn off the analyzer system with main switch -F01.

Emptying theCondensate Trap

Empty the condensate trap and dispose of condensates according to applicableregulations.

Disposing ofReagents

Empty the (optional) reagent container and dispose of reagents according toapplicable regulations.

WARNING!


Condensates are often acidic. Neutralize condensates and follow theprescribed measures for disposal.

☞ Make sure the analyzer system is free of residual moisture that can freeze if lowtemperatures are encountered during shipping and storage.

Returning theAnalyzer System toService

See the “Starting-Up the Analyzer System” chapter.

Subject to technical changesPrinted in the Fed. Rep. of Germany

42/23-49-0 EN 09.97

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