—

ABB MEASUREMENT & ANALYTICS | COMMISSIONING INSTRUCTION | CI/ACX-EN REV. D

ACX
Advanced CGA Solutions

Analyzer System for Emission

Monitoring, Cement Applications
and Process Measurement

Measurement made easy

—
ACX Introduction Additional Information
ACX is a complete system solution for continuous Additional documentation on ACX is available for
gas analysis. download free of charge at www.abb.com/analytical.
Alternatively simply scan this code:
The ACX system includes everything from probe,
heated lines, sample conditioning to reliable and
time-tested analyzers of the Advance Optima
series. It can be operated from the outside.

The system is available in various variants tailored

to your measuring tasks - emission monitoring,
cement applications and process gas
measurements.
It is especially designed for easy service and
maintenance.
Advanced CGA Solutions
ACX
Analyzer System for Emission Monitoring, Cement Applications and
Process Measurement

Commissioning Instruction

Publication No. CI/ACX-EN

Revision D
Edition: February 2020

This operator’s manual is protected by copyright. The translation, duplication and distribution in any form, even in a
revised edition or in extracts, in particular as a reprint, by photomechanical or electronic reproduction or in the form of
storage in data processing systems or data networks are prohibited without the consent of the copyright holder and
will be prosecuted under civil and criminal law.
Table of Contents
Page

Foreword 6

Safety Information 7
Important Safety Information 7
Safety Tips for Handling Electronic Measurement Devices 8
Safety Tips for Handling the Analyzer System 9
Additional Safety Tips for Handling the Analyzer System with
Integrated VOC Analyzer 9
Safety Tips for Handling Corrosive and Acidic Substances 10
Safety Tips for Handling Harmful Gases 10
Notes on data safety 11

Installation Preparation 12
"Hydrogen Monitoring of the Analyzer Cabinet" option 12
Installing the Analyzer System 14
Choosing the Extraction Point, Wall Tube Installation 15
Analyzer System Installation Site Requirements 16
Sample Gas Inlet Conditions (at the Extraction Point) 17
Test Gas Connection at the Gas Sampling Probe or upstream of the Sample Gas
Cooler: Test Gas Inlet Conditions 17
AO2000-Magnos27: Test Gas Inlet Conditions 18
AO2000-Fidas24: Supply Gas and Test Gas Inlet Conditions 18
Back-Purging Unit: Installation Site and Air Supply Requirements 19
Power Supply Requirements 20
Weight, Sound Level 22
Items Delivered 23
Materials Needed for Installation (not supplied) 24

Sampling System Installation 25

Type 40 Probe Tube and Filter Unit Installation 25
Type 42 Probe Tube and Filter Unit Installation 26
Type 40W Probe Tube and Filter Unit Installation 27
PFE2 Filter Unit: Installation 29
PFE2 Filter Unit: Gas Connection 30
PFE3 Filter Unit: Installation 31
PFE3 Filter Unit: Gas Connection 32
Probe 2 Installation 33
Sample Gas Line Installation 35
Back-Purging Unit Installation 39

Gas Sampling with Automatic Back-Purging 40

In General 40
Components for Automatic Back-Purging Procedure 40

4 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D

 Start of the Back-Purging Procedure 41
Program Sequence 42
Cycle Time 44
Post-Purge Time 45
Adjustment of Cycle Time and Post-Purge Time 46

Analyzer Cabinet Installation 47

Installing the Analyzer Cabinet 47
Mounting Plate and Electrical Distribution Cabinet: Installation 48
Analyzer System with Integrated VOC Analyzer: Installing the Supply Gases
and Test Gases 49
AO2000-Fidas24: Connecting the Sample Gas Line 51
Analyzer Cabinet: Connecting the Electrical Leads 52

Analyzer System Start-Up 53

Prior to Analyzer System Start-Up 53
Transportation Restraints Release 54
Reagent Fill 55
Analyzer System Start-Up 56
AO2000-Fidas24: VOC Analyzer Start-Up 57
Warm-Up Phase 61
Analyzer System: Seal Integrity Check 62
AO2000: Air Pressure Correction 64
AO2000: Air Pressure Value Correction 65
Dynamic QR Code 66

Analyzer System Operation 68

Display/Control Unit 68
“Measured Values” Screen 69
“Control Panel” Screen 70
Menu Tree 72
Setting the Time Zone, Date and Time 74
Selecting User Interface Language 75
Changing the Password 76
Password Protection 77
Inhibit Operation 79
Release of communication via port 8001/tcp 80
Release of communication via Modbus® TCP/IP 82

Inspection and Maintenance 84

Safety Information 84

Analyzer System Shut-Down 85

Analyzer System Shut-Down 85
Packing the Analyzer Cabinet or System Components 86

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 5

Foreword

The Content of this This operator’s manual contains all the information you will need to safely and
Operator’s Manual efficiently install, operate and maintain the ACX Analyzer System.

This operator’s manual contains information on all the functional units in the analyzer
system. Your analyzer system as delivered may differ from the version described in this
operator’s manual.

System documentation The system documentation includes the following:

• Device Data Sheet

• Instructions in brief for installation, commissioning and operation
• Certificates
• Project-relevant CD-ROM with
• Set of drawings (arrangement diagram, piping diagram, interface diagram) as well
as
• Information on function block configuration as needed
• System CD-ROM ‘Continuous Gas Analysis – Software Tools and Technical
Documentation’
• CD-ROM ‘Spare Parts Catalog for Analyzer Technology’

Information on the Information on ABB Analytical products and services is available on the Internet at
Internet “http://www.abb.com/analytical”.

Service Contact If the information in this manual does not cover a particular situation, ABB Service is
prepared to supply additional information as needed.

Please contact your local service representative. For emergencies, please contact

ABB Service
Telephone: +49-(0)1805-222580, Telefax: +49-(0)621-38193129031,
E-mail: automation.service@de.abb.com

Symbols and indicates safety information to be heeded during analyzer system

Type Format in this operation in order to avoid risks to the user.
Operator’s Manual
identifies specific information on operation of the analyzer system as well
as on the use of this manual.

1, 2, 3, … identifies reference numbers in figures.

Display identifies a message in the display.

Input identifies a user entry

• either by pressing a soft key
• or by selecting a menu item
• or via the numeric keypad.

6 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D

Safety Information

Important Safety Information

Intended Conditions of The analyzer system is designed for continuous measurement of concentrations of
Use specific components in gases or vapor. Any other application is not compliant with the
specified use. Observation of this manual is also part of the specified use.

The analyzer system must not be used to measure flammable gases or combustible
gas/air or gas/oxygen mixtures. The analyzer system must not be installed in
hazardous locations.

The analyzer system interior remains free of explosive atmosphere during normal
operation. Therefore, the integration of explosion protection measures inside the
analyzer system is not required.

Requirements for Safe In order to operate in a safe and efficient manner, the analyzer system should be
Operation properly handled and stored, correctly installed and set-up, properly operated and
carefully maintained.

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

Special Information and These include

Precautions • The content of this manual,
• The safety labels affixed to the analyzer system,
• The applicable safety precautions for installing and operating electrical devices,
• Safety precautions for working with gases, acids, condensates, etc.

Safety Labels Affixed to Observe the safety labels affixed to the analyzer system or to the individual
the Analyzer System components:

Consult Documentation! Hot Surface! (Temperature > 60 °C)

Corrosive Material! Risk of Electric Shock!

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

Analyzer System Safety The analyzer system is designed and tested in accordance with EN 61010 Part 1/
and Safe Operation IEC 1010-1, “Safety Provisions for Electrical Measuring, Control, Regulation and
Laboratory Instruments” and has been shipped ready for safe operation.

To maintain this condition and to assure safe operation, read and follow the safety
information identified with the safety symbols in this manual. Failure to do so can put
persons at risk and can damage the analyzer system as well as other systems and
instruments.

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 7

Safety Tips for Handling Electronic Measurement Devices

Protective Lead The protective lead should be attached to the protective lead connector before any
Connection other connection is made.

Risks of a Disconnected The analyzer system can be hazardous if the protective lead is interrupted inside or
Protective Lead outside the analyzer cabinet or if the protective lead is disconnected.

Correct Operating Be sure the analyzer system voltage setting matches the line voltage before
Voltage connecting the power supply.

Risks Involved in Current-bearing components can be exposed when covers or parts are removed, even
Opening the Covers if this can be done without tools. Current can be present at some connection points.

Risks Involved in The analyzer system must be disconnected from all power sources before being
Working with an Open opened for any work. All work on an analyzer system that is open and connected to
Analyzer System power should only be performed by trained personnel who are familiar with the risks
involved.

Charged Capacitors The capacitors in the analyzer system can retain their charge even when it is
disconnected from all power sources.

Use of Proper Fuses Only fuses of the specified type and rated current should be used as replacements.
Never use patched fuses. Do not short-circuit the fuse holder contacts.

When safe operation If it is apparent that safe operation is no longer possible, the analyzer system should
can no longer be be taken out of operation and secured against unauthorized use.
assured …
The possibility of safe operation is excluded:
• if the analyzer system is visibly damaged,
• if the analyzer system no longer operates,
• after prolonged storage under adverse conditions,
• after severe transport stresses.

8 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D

Safety Tips for Handling the Analyzer System

CAUTION!

Do not open any gas paths in the analyzer system or in the integrated analyzers.
Doing so will damage gas path seal integrity.

If system-internal gas paths are opened, a seal integrity check must be performed
with a leak detector (thermal conductivity) when the device is reassembled.

Additional Safety Tips for Handling the Analyzer System with

Integrated VOC Analyzer

CAUTION!

The combustion gas path in the analyzer system and especially in the integrated
VOC analyzer must not be opened! The combustion gas feed path can become leaky
as a result!

If the system-internal combustion gas path is opened, a seal integrity check must be
performed with a leak detector (thermal conductivity) when the device is
reassembled.

The bulkhead connector with integrated flow limiter for connection of the
combustion gas line is a safety relevant part. It must not be removed, modified or
replaced!

It is recommended to check regularly the seal integrity of the combustion gas line
outside the analyzer system.

WARNING!

Combustion gas flowing out of leaks in the gas paths can cause fire and explosions
(even outside the analyzer system itself).

A shut-off valve must be installed in the combustion gas supply line to increase safety
in the following operating conditions:
• During shutdown of the gas analyzer,
• In the event of failure of the instrument air supply,
• Leakage in the combustion gas feed path inside the gas analyzer.
This shut-off valve should be installed outside the analyzer house in the vicinity of the
combustion gas supply (cylinder, line).

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 9

Safety Tips for Handling Corrosive and Acidic Substances

CAUTION!

When working with corrosive reagents note the hazard information and safety
precautions contained in the applicable material safety data sheets.

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

Safety Tips for Handling Harmful Gases

CAUTION!

Some of the gases measured with the analyzer system are harmful to health.

Therefore, the sample gas must not escape from the gas path during normal
operation and maintenance works.
A seal integrity check of the analyzer system has to be performed at regular
intervals.

The diluted exhaust gas must be drained out of the installation room of the analyzer
cabinet.

10 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D

Notes on data safety
Obligations of the This product is designed to be connected to a network interface and to communicate
owner information and data via this network interface.
It is the operator’s sole responsibility to provide and continuously ensure a secure
connection between the product and your network or any other network (as the case
may be).
The operator shall establish and maintain any suited measures (such as but not limited
to the installation of firewalls, application of authentication measures, encryption of
data, installation of anti-virus programs, etc.) to protect the product, the network, its
system and the interface against any kind of security breaches, unauthorized access,
interference, intrusion, leakage and / or theft of data or information.
ABB Automation Products GmbH and its affiliates are not liable for damages and / or
losses related to such security breaches, any unauthorized access, interference,
intrusion, leakage and / or theft of data or information.

Digital communication The ABB guidelines prevent communication through unsecured communication
protocols, provided that the operator does not explicitly allow this.
These communication protocols are blocked by default.
The device software has been supplemented with menu items through which the
operator can explicitly release communication.

The communication protocols are blocked again after software updates and must be
released once again.

Services and ports on Port Description

the Ethernet interface 22/tcp Used only for software updates.
No direct access to the device.
8001/tcp Binary proprietary protocol for:
• Remote HMI for operation
• AnalyzeIT program for continuous monitoring
• OPC Server, external OPC Server for ACX systems
501/tcp Used for Modbus/TCP.
The device allows connection to any Modbus client.

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 11

Installation Preparation

"Hydrogen Monitoring of the Analyzer Cabinet" option

Function If an FID (VOC Analyzer) is installed, the analyzer system can be supplied with the
‘Hydrogen monitoring of the analyzer cabinet’ option as an additional safety measure.
If a leak occurs in the hydrogen path inside the analyzer cabinet and hydrogen
accumulates inside the cabinet, both the hydrogen supply and the power supply are
shut off before the explosion limit is reached – at 40 % LEL. This prevents formation of
an ignitable mixture.

Scope of delivery Installed in the analyzer cabinet:

• in the upper area, an ATEX-certified gas sensor with connection socket,

• on the exterior on the right-hand side wall, a solenoid valve, connected with the
combustion gas input of the analyzer cabinet, which cuts off hydrogen supply in the
event of a failure of the power supply, or at 40 % LEL (H2safety valve).

Also supplied:

• a gas warning center for evaluating the gas sensor signal,

• a contactor for disconnecting the power supply to the analyzer cabinet,
• a contactor for disconnecting the UPS if the system is prepared for a UPS.

Installation The electric wiring of the gas sensor and the gas warning center to shut down the
power supply in the event of a fault is not installed in the analyzer system in the
factory-delivered condition.
The gas warning center must be installed outside the analyzer cabinet in a non-
hazardous area in a distribution cabinet or similar. It must be electrically connected to
the gas sensor (see the order-specific set of drawings in this regard).
The solenoid valve for disconnecting the hydrogen supply (H2) as well as the coils of
the contactors and relays for disconnecting the power supply and UPS (if present)
must be connected to a fault-signalling contact in the gas warning center. The fault-
signalling contact must be set so that the voltage is shut off at 40% LEL and the
contact itself latches.
The measuring signals (analog outputs and inputs), the status signals (digital outputs
and inputs) as well as the bus systems of the analyzer system are so designed that
after the power supply (and possibly the UPS) are disconnected no component in the
analyzer cabinet (contactor, relay, motor etc.) that could generate an ignition spark
can be actuated from the outside.
The measurement and status signals supplied potential-free as well as bus
connections must not be activated separately in the event of a gas alarm. If however a
non potential-free external signal is fed in, the operator should make sure that if a gas
alarm is triggered, it is activated via a cut-off relay, for example.

12 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D

 • The gas sensor installed in the analyzer cabinet is not factory calibrated; it is
inoperable without calibration. Calibration of the gas sensor is the responsibility of
the operator.
• Installation, commissioning, parameterization, operation, signal evaluation and
maintenance of the supplied gas warning center are the responsibility of the
operator.

WARNING!

If the above-mentioned instructions are not observed or the hydrogen monitoring of

the analyzer cabinet is installed incorrectly, a hydrogen explosion may occur in the
event of a malfunction.

Operation of this safety device should be checked during commissioning and at

regular intervals (min. 1 time a year).

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 13

Installing the Analyzer System

• We recommend having the analyzer system installed by ABB.

• When installing the analyzer system, in addition to this manual, comply with the
information contained in the drawings set.
• If there is shipping damage which points to improper handling file a damage claim
with the shipper (railway, mail or freight carrier) within seven days.
• Make sure the enclosed accessories are not lost (see the “Items Delivered” section,
page 23).
• Keep the packaging material for future shipping needs.

Installation – Overview Step Action Page

1 Prepare the gas sampling probe installation site. 15
2 Prepare the analyzer cabinet installation site. 16
3 Install the gas sampling probe and filter unit. 25
4 Install the sample gas line. 35
5 Install the back-purging unit (if applicable). 39
6 Install the analyzer cabinet. 47
7 Install the instrument air and test gas supply (if applicable). 49
8 Connect the gas lines to the analyzer cabinet. 51
9 Connect the electrical leads to the analyzer cabinet. 52

14 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D

Choosing the Extraction Point, Wall Tube Installation
Choosing the The extraction point must be suitable for extracting a representative specimen flow.
Extraction Point
In the case of emission monitoring systems the extraction point is specified by the
responsible technical inspection authority.

Wall Tube Installation • Install the wall tube with mounting flange (DN 65, PN 6, type A according to
DIN EN 1092-1; not supplied) at the extraction point in such a way that the sampling
probe tube can be easily installed and removed (see Figure 1).
• The sampling probe tube must be easily accessible to allow maintenance work to be
performed.
• Align the boreholes of the mounting flange in relation to the flow direction of the
process gas (see Figure 1).
Observe the separate instructions for installation of probe tube type 40W on page 27!

Figure 1
Brickwork Brickwork with metal sheeting
Wall Tube Installation
1 4 2 5 3 1 2 5 3
(Dimensions in mm)

Isolated sheet-metal channel Flow direction of process gas

1 2 5 3

Wall tube
Wall tube mounting flange DN 65, PN 6, Form A to DIN EN 1092-1
Gasket
Welded-on rectangular block
Sampling probe tube flange

Minimum distance xmin of the mounting flange (wall tube flange) from the wall
depending on mounting angle α:

α 10° 15° 20° 25° 30° 35°

xmin / mm 229 248 268 287 307 324

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 15

Analyzer System Installation Site Requirements

CAUTION!

The analyzer system must not be installed in hazardous locations.

Short Gas Paths The analyzer cabinet should be installed as close as possible to the sampling site. A
short sample gas line results in brief lead times.

The sample gas line length is limited to 60 meters with 230 VAC power supply and to
40 meters with 115 VAC power supply on account of pressure drop build-up in the line
and the required electrical fusing.

For fast measurement at preheater / CO monitoring of ESP, the sample gas line length
is limited to 10 meters.

The test gas cylinders should be installed as close as possible to the analyzer system.

Protection from Protect the analyzer cabinet against

Adverse Conditions • Water spray
• Contact with chemicals
• Strong sunlight and heat radiation
• Strong air currents
• Heavy dust load
• Corrosive atmospheres
• Vibration

Installation Indoors The sheet steel cabinet and the mounting plate are only suitable for installation
or Outdoors indoors. An air-conditioned room is recommended.

The GRP cabinet is suitable for installation indoors and outdoors. A weather
protection roof must be provided.

Ambient Temperature Operation: Mounting plate 0 to +35 °C

Sheet steel cabinet with ventilation fan 0 to +35 °C
with cooling unit 0 to +45 °C
GRP cabinet with ventilation fan –20 to +35 °C
with cooling unit –20 to +45 °C
Storage and transport: +2 to +60 °C
after draining and
drying parts in contact with condensate –25 to +60 °C

Relative Humidity Year-round average max. 75 %, short-term max. 95 %,

occasional slight condensation is permitted

Installation Site The maximum installation altitude is 2000 m above sea level.
Altitude

Continued on next page

16 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D

Analyzer System Installation Site Requirements, continued

Dimensions and Space Refer to the “Layout Plan” in the drawings set.
Requirement

Installation Site The installation site floor must be plane and capable of supporting the cabinets
Stability weight (see page 22).

The installation site wall must be capable of supporting the weight of the mounting
plate and the separate electrical distribution cabinet (see page 22).

Sample Gas Inlet Conditions (at the Extraction Point)

CAUTION!

The analyzer system must not be used for measurement of flammable gases and
ignitable gas/air or gas/oxygen mixtures!

In the case of toxic gases, the threshold limit value (TLV) must be complied with.

Application Temperature Pressure pabs Flow

Emission Monitoring max. 500 °C 850 to 1100 hPa (0.85 to 1.1 bar) max. 250 l/h
Kiln or Calciner Outlet (T > 900 °C) max. 1300 °C 850 to 1100 hPa (0.85 to 1.1 bar) 1) max. 100 l/h
Calciner max. 900 °C 850 to 1100 hPa (0.85 to 1.1 bar) max. 125 l/h
Wet Kiln Gas Outlet max. 300 °C 850 to 1100 hPa (0.85 to 1.1 bar) max. 250 l/h 2)
Preheater / CO Monitoring of ESP max. 450 °C 850 to 1100 hPa (0.85 to 1.1 bar) max. 250 l/h 3)
Coal Bunker, Coal Mill max. 500 °C 850 to 1100 hPa (0.85 to 1.1 bar) max. 250 l/h
Process Measurement max. 500 °C 850 to 1100 hPa (0.85 to 1.1 bar) max. 250 l/h

1) at the sample gas inlet of the analyzer system

2) max. 60 l/h with SO2 measurement
3) max. 300 l/h with probe F

Test Gas Connection at the Gas Sampling Probe or upstream of the

Sample Gas Cooler: Test Gas Inlet Conditions
CAUTION!

When handling test gases, the lower explosion limit (LEL)as well as the threshold
limit value (TLV) must be complied with.

Specification Pressure pe Flow

Test gases 1, 2, 3 Sample component or substitute gas 1000 ± 100 hPa 130 to 250 l/h
component in N2 or air (1.0 ± 0.1 bar)

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 17

AO2000-Magnos27: Test Gas Inlet Conditions

Characteristic Pressure pe Flow

Zero Gas N2 500 ± 50 hPa 130 to 250 l/h
Span Gas Air (= 0.5 ± 0.05 bar)

AO2000-Fidas24: Supply Gas and Test Gas Inlet Conditions

Characteristic Pressure pe Flow

1)
Instrument Air Based on ISO 8573-1 Class 2 4000 ± 500 hPa approx. 1500 l/h
(particle size max. 1 µm, particle density max. (4.0 ± 0.5 bar)
1 mg/m3, oil content max. 0.1 mg/m3, pressure
dew point at least 10 °C below the lowest
expected ambient temperature)
Combustion Air 2) Synthetic air or catalytically cleaned air with 1200 ± 100 hPa (1.2 max. 40 l/h
an org. C content of < 1% of the span ± 0.1 bar)
Combustion Gas 3) H2 (quality 5.0) 1200 ± 100 hPa (1.2 approx. 3 l/h
± 0.1 bar)
Zero Gas N2 (quality 5.0) or synthetic air or catalytically 1000 ± 100 hPa (1.0 130 to 250 l/h
cleaned air ± 0.1 bar)
Span Gas 4) Sample component or substitute gas 1000 ± 100 hPa (1.0 130 to 250 l/h
component in N2 or air ± 0.1 bar)

1) Provide a shutoff valve with a pe = 4.5 to 7 bar pressure gauge.

Instrument air is used as
• drive air for the air injector (if installed),
• combustion air,
• emergency purge air.
2) Separate combustion air supply is required if the analyzer system is not equipped
with a combustion air conditioning module (catalyst).
3) Recommendation: Provide two 40 l cylinders and a switchover station.
Note: For safety reasons, a flow limiter is integrated in the bulkhead connector
provided for connection of the combustion gas line to limit the combustion gas
flow to 10 l/h.
4) As the VOC analyzer only measures the number of carbons the concentration of the
span gas has to be calculated from ppm or mg/m3 CnHm to ppm or mg/m3 C.
• Perform regular inspections of the external combustion gas line.
• Install a pressure relief valve in the combustion gas line outside of the analyzer
cabinet
• Set the pressure relief valve to < 2 bar to securely limit the maximum supply
pressure.

Definition pe = pabs – pamb

with pe = positive pressure, pabs = absolute pressure, pamb = atmospheric pressure

18 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D

Back-Purging Unit: Installation Site and Air Supply Requirements

Design of the The back-purging unit consists of a protective cabinet with shut-off valve, 6 bar
Back-Purging Unit pressure reduction valve, solenoid valves for back-purging, pressure regulator and 5 l
compressed air receiver for effective pressure pulses also with lower airflow rate.

Distance to The distance between the back-purging unit and the sampling probe must not exceed
Sampling Probe 5 m (length of the steel-braided compressed-air hoses = 6 m).

Protection from Protect the back-purging unit against

Adverse Conditions • Water spray
• Contact with chemicals
• Strong sunlight and heat radiation
• Strong air currents
• Heavy dust load
• Corrosive atmospheres
• Vibration

Pressurized air supply • dry (dew point < 3 °C), oil- and dust-free
requirements • max. 6 bar for back-purging
• approx. 4 bar as control air (needed for 2-stage back-purging with Type PFE2 filter
unit and AO2000-Fidas24 VOC analyzer)
• Required air capacity approx. 100 m3/h
• Instrument air following ISO 8573-1 Class 2 (particle size max. 1 µm, particle density
max. 1 mg/m3, oil content max. 0.1 mg/m3, pressure dew point max. –20 °C)

CAUTION!

If the compressed air is not dry and clean, this will result in damage to the sample
conditioning components (valves, filters, sample gas cooler, sample gas feed unit) as
well as to the gas analyzer.

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 19

Power Supply Requirements

Operating Voltage 230 / 400 V AC or 120 / 208 V AC, ± 10 %, 48 to 62 Hz; 3∼, L1, L2, L3, N, PE.

Non-floating PEN conductor is forbidden.

Power Consumption Basic version 1000 W

Cooling unit + 940 W
Analyzer module AO2000-Fidas24 + 285 W
NO2 / NO converter + 350 W
Probe tube type 40W, partially heated (24 V AC) + 120 W
Probe tube type 42, heated + 800 W
Filter unit type PFE2 or PFE3, heated + 250 W
Probe 2, partially heated + 255 W
Probe F, partially heated + 400 W
Back-purging unit + 150 W
Sample gas line type TBL01-S, TBL01-C, heated regulated 180 °C + 90 W/m
self-regulating 100 °C + 35 W/m
self-regulating 30 °C + 15 W/m

Uninterruptible Prepared for Uninterruptible Power Supply (UPS), 400 W.

Power Supply
230 V AC or 120 V AC, ± 10 %, 48…62 Hz; L, N, PE.

Non-floating PEN conductor is forbidden.

Service Socket 230 V AC or 120 V AC, 48 to 62 Hz, max. 5 A.

The service socket is located

• in the cabinet light or
• mounted on a top hat rail in the separate electrical distribution cabinet.

Continued on next page

20 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D

Power Supply Requirements, continued

Fuses -F10 Power supply / leakage current indicator (option) 25 A / 30 mA

-F20 Power supply UPS / leakage current indicator (option) 25 A / 30 mA
-F01 Lighting, service socket, ventilation fan or cooling unit 6 A or 16 A
-F02 Heated probe tube, heated filter unit, back-purging unit, test 10 A or 16 A
gas connection valves or 6 A
-F03 Heated sample gas line 16 A
-F04 NO2 / NO converter 6A
-F05 AO2000-Fidas24, air catalyst 6A
-F06 Sample gas cooler, sample gas feed unit 6A
-F07 AO2000 central unit, power supply 6A
-F11 Temperature controller T2A
-F12 Temperature controller T2A
-F13 Temperature controller T2A
-F14 Emergency purging AO2000-Fidas24 T 0.5 A
-F17 Test gas valve 1 T 0,5 A
-F18 Test gas valve 2 T 0,5 A
-F19 Test gas valve 3 T 0,5 A
-F22 Filter unit 2nd sampling point 10 A or 16 A
-F23 Heated sample gas line 2nd sampling point 16 A

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 21

Weight, Sound Level

Weight of the Individual Sheet steel cabinet max. 430 kg

System Components GRP cabinet max. 370 kg
Mounting plate max. 170 kg
Separate electrical distribution cabinet max. 065 kg
Probe tube type 40, unheated 500 mm 1 kg
1000 mm 2 kg
1500 mm 3 kg
Probe tube type 40W, partially heated 3500 mm 13 kg
4000 mm 15 kg
4500 mm 17 kg
Probe tube type 42, heated 1000 mm 8 kg
1500 mm 10 kg
2000 mm 12 kg
Probe 2 with protective case 1200 mm 17 kg
Probe F 1200 mm 10 kg
Filter unit type PFE2, heated, with protective case 20 kg
Filter unit type PFE3, heated, with protective case 17 kg
Back-purging unit 70 kg
Sample gas line type TBL01-S or TBL01-C, heated 1 kg/m

Sound Level Ventilation fan 50 Hz 59 dB(A)

60 Hz 61 dB(A)
Cooling unit < 64 dB(A)

22 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D

Items Delivered

Standard Equipment Quantity Description

1 Analyzer cabinet or
Mounting plate with separate electrical distribution cabinet
System documentation (provided in a ring binder, see page 6)

Additional Items Quantity Description

Delivered Per Order 1 Gas sampling probe tube
Type 40 (unheated) or
Type 40W (partially heated) or
Type 42 (heated) or
Gas sampling probe
Type 2 optionally with separate protective case or
Type F
1 Filter unit type PFE2 or PFE3 with ring heater or heating sleeve
1 Sample gas line type TBL01-S or TBL01-C (heated)
1 Back-purging unit 1-stage or 2-stage with compressed-air hoses
1 Hydrogen switch-over station with cylinder pressure reducers on
mounting plate (for AO2000-Fidas24)
1 Reagent supply bottle
1 Condensate collection bottle
1 Wear parts set

‘Hydrogen monitoring of Quantit Description

the analyzer cabinet’ y
option 1 Unipoint gas warning center
1 Contactor for disconnecting the power supply to the analyzer cabinet
1 Contactor for disconnecting the UPS if the system is prepared for a UPS.
1 Unipoint Multilingual Manual CD
1 Sensepoint Manuals CD

The gas sensor and the H2safety valve are securely installed in or on the analyzer
cabinet.

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 23

Materials Needed for Installation (not supplied)

Gas Sampling • Wall tube with mounting flange (DN 65, PN 6, Type A to DIN EN 1092-1, see Figure 1,
page 15)

Gas Lines • Sample gas (unheated line) PTFE pipe 4 / 6x1 mm

• Sample gas outlet PTFE pipe 4 / 6x1 mm

• Test gas N2 PTFE pipe 4 / 6x1 mm

• Test gases 1, 2, 3 PTFE pipe 4 / 6x1 mm

• Instrument air Stainless steel pipe, 8 mm O.D., or compressed-air

hose (plus pressure gauge and shut-off valve)

• Fidas24 combustion air PTFE pipe 4 / 6x1 mm

• Fidas24 combustion gas Purified stainless steel pipe (SS316), 6 mm O.D.

• Fidas24 zero gas PTFE pipe 4 / 6x1 mm

• Fidas24 span gas PTFE pipe 4 / 6x1 mm

• Fidas24 exhaust gas Stainless steel pipe, 12 mm O.D.

• Condensate collecting bottle PVC tube 4 / 6x1 mm

Input Wiring • Input wiring

• 5 x 6 mm2 (5 x AWG 8)
• If applicable, uninterruptible power supply wiring 3 x 2.5 mm2 (3 x AWG 14)
• Cables to connect the heated gas sampling probe, filter and sample gas line to the
analyzer cabinet (if applicable, in a heat-resistant version; note the power
requirements of these components, page 20)
• Grounding cable with cross section ≥ 10 mm2 (≥ AWG 8)

Signal Leads • Shielded cable for analog outputs (current outputs)

• Cable for digital outputs
• Cable for data lines (Modbus, Profibus, Ethernet)
• Cable for the Pt100 resistance thermometers of the heated components

When selecting conductor materials, follow all applicable national safety regulations
for the installation and operation of electrical devices.

Mounting • Screws and nuts to secure the analyzer cabinet to the floor
or
• Screws and nuts (stud bolts if applicable) to secure the mounting plate and the
electrical distribution cabinet to the wall
For details regarding the size of the screws and nuts see the “Layout Plan” in the
drawings set.

24 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D

Sampling System Installation

Type 40 Probe Tube and Filter Unit Installation

CAUTION!

The weight of the probe tube with filter unit amounts to approx. 18–20 kg! Two
persons are needed for transportation and mounting!

Before the Installation • Observe the “Piping Plan” in the drawings set.
• Make sure that the wall tube is installed at the extraction point (see page 15).

Figure 1
Special Steel Material No. 1.4571 (max. 500 °C)
Type 40 Probe Tube

L1=500/1000/1500 mm
12,6 ø

(Dimensions in mm) 17,2 ø G3/4

L1
16

Type 40 Probe Tube and Step Action

Filter Unit Installation 1 Screw the probe tube into the internal thread of the filter unit.
2 Insert the pre-assembled probe tube with filter unit in the wall tube and
screw the flange of the filter unit to the flange of the wall tube. Use the
green seal from the accessories pack to seal the space between the
flanges of wall tube and filter unit.
3 Mount the heating sleeve or the ring heater on the filter unit.

4 If applicable, install the compressed-air hoses between the filter unit and
the back-purging unit (see page 39).

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 25

Type 42 Probe Tube and Filter Unit Installation

CAUTION!

The weight of the probe tube with filter unit amounts to approx. 28–32 kg! Two
persons are needed for transportation and mounting!

Before the Installation • Observe the “Piping Plan” in the drawings set.
• Make sure that the wall tube is installed at the extraction point (see page 15).

Figure 2
40

Type 42 Probe Tube 160 1000/1500/2000 mm

(Dimensions in mm)

Type 42 Probe Tube and Step Action

Filter Unit Installation 1 Insert the probe tube in the wall tube and screw the probe tube flange to
the wall tube flange. Use the green seal from the accessories pack to seal
the space between the flanges.
2 Screw the filter unit to the flange of the probe tube. Use the green seal
from the accessories pack to seal the space between the flanges of probe
tube and filter unit.
3 Mount the heating sleeve on the filter unit.
4 If applicable, install the compressed-air hoses between the filter unit and
the back-purging unit (see page 39).

26 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D

Type 40W Probe Tube and Filter Unit Installation

CAUTION!

The weight of the probe tube with filter unit amounts to approx. 50 kg!
Two persons are needed for transportation and mounting!

Before the Installation Observe the “Piping Plan” in the drawings set.

Vertical Installation The type 40W probe tube must be installed in the smoke chamber almost in vertical
orientation (see Figure 3, page 28).

Protection Pipe for The probe tube must be installed in a protection pipe with the following character-
Type 40W Probe Tube istics:

Material: Mild steel

Length: 3.0 m (for protection of the heated part of the probe tube)
Inner diameter: 50 mm or 100 mm for probe tube without or with prefilter
Flange: for connection to the flange of probe tube, location min. 300 mm
above the roof of the smoke chamber or its platform

Due to the probe tube’s length (normally 3.5 m, 4.0 m or 4.5 m), it can be necessary to
make a hole in the roof above the smoke chamber in order to install the probe tube as
well as the protection pipe.

Installation of the protection pipe is preferably carried out during a shut down of the
kiln. The opening should be closed with a blind flange until the installation of the probe
tube takes place.

Type 40W Probe Tube Step Action

and Filter Unit 1 Remove the blind flange from the protection pipe and lay on a flange seal
Installation on the protection pipe flange.
2 Insert the probe tube from above in the protection pipe.
Do not damage the electrical connection (porcelain terminals) of the
probe tube heating at the probe tube flange!
3 Lay on the supplied flange seal on the probe tube flange and mount the
filter unit.
4 Interconnect the 3 flanges with bolts and nuts.
5 Mount the heating sleeve on the filter unit.
6 Connect the cable of the heating sleeve to the terminals in the terminal
box of the filter unit.
7 Connect the cable of the probe tube heating (2 x 2.5 mm2) to the 26 VDC
connection of the transformer in the back-purging unit.

Continued on next page

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 27

Type 40W Probe Tube and Filter Unit Installation, continued

Figure 3

Type 40W Probe Tube

Installation in the
Smoke Chamber

28 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D

PFE2 Filter Unit: Installation

Figure 4

PFE2 Filter Unit:

Mounting of Probe X
Protective Case

Minimum distance xmin of the mounting flange (wall tube flange) from the wall
depending on mounting angle α:

α 10° 15° 20° 25° 30° 35°

xmin / mm 229 248 268 287 307 324

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 29

PFE2 Filter Unit: Gas Connection
Figure 5
16 17 18 1
PFE2 Filter Unit:
Gas Connections (with
Back-Purging) 2
D
B
3
A

15 4

14

13
5

12 6

11 8

10 9

1 Pilot Operation Valve Cleaning Filter -Y2.1

2 Diaphragm Valve Cleaning Filter -Y2.2
3 Pilot Operation Valve Pulsed Instrument Air -Y1.1
4 Diaphragm Valve Pulsed Instrument Air -Y1.2
5 Instrument Air Inlet Bulk Head Union 12 mm
6 Test Gas Inlet Bulk Head Union 6 mm
7 Control Air Inlet Bulk Head Union 6 mm
8 Pt100 Connection
9 Heated Sample Gas Line -E13
10 Power Supply
11 Heated Check Valve -Y5
12 Solenoid Valve Aeration -Y4
13 Diaphragm Valve Cleaning Filter Surface and Probe Tube -Y3.2
14 Pilot Operation Valve Cleaning Filter Surface and Probe Tube -Y3.1
15 Protection Box
16 Terminal Box
17 Filter Unit
18 Check Valve
A Back Purging Filter Inlet G 1/2″
B Back Purging Filter Surface / Probe Tube Inlet G 1/2″
C Sample Gas Outlet G 1/4″
D Test Gas Inlet G 1/4″

30 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D

PFE3 Filter Unit: Installation

Figure 6

PFE3 Filter Unit:

Mounting of Probe
Protective Case

(Dimensions in mm)

min. 680
min. 150

270
330

25°

Minimum distance xmin of the mounting flange (wall tube flange) from the wall
depending on mounting angle α:

α 10° 15° 20° 25° 30° 35°

xmin / mm 229 248 268 287 307 324

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 31

PFE3 Filter Unit: Gas Connection

Figure 7

PFE3 Filter Unit:

Gas Connections (with
Back-Purging)

(Dimensions in mm)

1 Tube Test Gas, VA 1.4571, 6x1 mm

2 Tube Compressed Air, CU, 15x1 mm
3 Terminal Box -X1 IP66
4 2 x M12x1.5 Cable Connectors
5 3 x M20x1.5 Cable Connectors
6 2 x M20x1.5 Cable Connectors
7 Tube Compressed Air, CU, 15x1 mm
A Test Gas Connection with Check Valve, Bulkhead Fitting 6 mm
B Back-purging of Filter (max. 6 bar), Bulkhead Fitting 18 mm
C Back-purging of Filter Surface / Probe Tube (max. 6 bar), Bulkhead Fitting 18 mm
D Sample gas connection, male fitting 6 mm

32 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D

Probe 2 Installation
Probe 2 Delivery Form Probe 2 is supplied in various partially pre-assembled component parts:

• Gas sampling probe with flange and internal heating rod

• Ceramic inlet filter (inner filter)
• Installation set for mounting the ceramic inlet filter (4 bolts M12 x 70 with nuts,
spring washers and washers)
• Harting connector, degree of protection IP55
• Protective box (option), degree of protection IP54

CAUTION!

Danger of breakage! The ceramic inlet filter of probe 2 is fragile.

Assembly of the First of all, assemble the ceramic inlet filter as shown in Figure 8. Please note that the
Ceramic Inlet Filter compression spring 4 has to be compressed by approx. 15 mm.

Figure 8

Probe 2: 7 6 5 4 3 2 1 2
Ceramic Inlet Filter

1 Filter Element
2 Sealing Gasket
3 Bush
4 Compression Spring
5 Pressure Disk
6 Bush
7 Screw

Continued on next page

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 33

Probe 2 Installation, continued
Figure 9

Probe 2 Installation
L1
(Dimensions in mm)

2
1

α 180

650

1 Mounting for the Ceramic Inlet Filter

2 Inlet Filter (Inner Filter) with Internal Heating Rod
3 Gas Sampling Tube
4 Wall Tube with Inlet Flange
5 Sample Gas Outlet and Test Gas / Purge Air Inlet G 1/4
L1 Fitting Length
Lx Length of the Gas Sampling Tube (approx. 400 mm)

Minimum distance xmin of the mounting flange (wall tube flange) from the wall
depending on mounting angle α:

α 10° 15° 20° 25° 30° 35°

xmin / mm 133 138 143 147 151 153

Probe 2 Installation Step Action

1 Align the probe so that the protection shield is directed towards the
process gas flow.
2 Insert the probe in the wall tube and screw it to the wall tube flange with
the enclosed screws M12 x 70.
3 Connect the sample gas line to one of the two gas ports 5 by means of a
clamp ring screw fitting.
4 If 1-stage probe back-purging is available, connect the compressed-air
hose to the other of the two gas ports 5. Please note the maximum
permissible air pressure of 6 bar.

Probe 2 Step Action

Electrical Connection 1 Connect the cables of the current
lead to the connector as shown in PE
the connector pin assignment. 1 N
2 Connect the connector to the 2 L1
power supply. 3–6 not assigned

34 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D

Sample Gas Line Installation

Installing the Sample • Observe the “Piping Plan” in the drawings set.
Gas Line • Connect the sample gas line to the filter unit / gas sampling probe.
• Route the sample gas line through the opening provided in the right wall of the
cabinet.

When a VOC analyzer is installed in the analyzer system no fat or grease should be used
when installing the sample gas line (see page 51). Otherwise the measurement values
would drift for a prolonged period of time.

Fundamentals for Do not lay the heated sample gas line in a

Laying the Sample Gas thermowell.
Line

When laying the sample gas line, avoid the

formation of water locks, particularly at the
sampling points.

Do not lay the heated sample gas line in a

cable tray together with other electrical or
pneumatic lines, especially not in an enclosed
cable tray.

When laying the heated sample gas lines on

exposed C-profiles with BBS cable clips:
Do not overtighten the cable clips, in order to
prevent damage to the sample gas line
through crushing.

Continued on next page

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 35

Sample Gas Line Installation, continued

Procedures for Laying Incorrect Correct

the Sample Gas Line

Do not lay the heated sample gas lines Ensure that the hoses do not touch.
directly side-by-side in an enclosed duct Maintain a distance of 25 mm.
or shaft. This results in heat Provide adequate ventilation. Heat can
accumulation. be conducted away as a result.

Prevent powdery substances, adhesives If soiling occurs, clean the materials and
or other thermally insulating materials remedy the cause. Heat can be
from soiling the heated sample gas line. conducted away again as a result.
Otherwise, overheating will occur at
these points.

Avoid heat accumulation through Do not wrap the sample gas line. Ensure
wrapping the heated sample gas line that the area near the temperature
with other materials, otherwise the sensor is exposed.
sample gas line will overheat at these This results in error-free temperature
points. Do not cover the area near the measurement.
temperature sensor, otherwise the rest
of the sample gas line will cool down.

Continued on next page

36 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D

Sample Gas Line Installation, continued

Procedures for Laying Incorrect Correct

the Sample Gas Line
(continued)

Do not lay the heated sample gas line in When laying the heated sample gas line
wall break-throughs which are through a wall break-through, use
subsequently sealed with a sealing bulkhead plates with conduit thread
compound under any circumstances. cable glands, in order to provide
The sample gas line will be destroyed by adequate cooling of the sample gas line.
overheating in this case!

Avoid bundling or laying several heated Lay several heated sample gas lines
sample gas lines, so that they touch separately with a distance of at least
each other. This results in overheating 2.5 cm and provide adequate ventilation.
at the contact points. Heat can be conducted away as a result.

Do not squeeze the heat insulation in Tighten the BBS cable clips sufficiently
mounting brackets tightly together, so but not excessively, in order to prevent
that the outer braiding is pressed on to damage to the protective braiding and
the heat conductor. If you disregard the heated sample gas line.
this, damage to the protective braiding
and the heated sample gas line may
occur.

Continued on next page

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 37

Sample Gas Line Installation, continued

Permissible Values for Characteristic Permissible value

Laying the Sample Gas Maximum line length see table below
Line
65 m for version with anti-frost heater
Minimum bending radius 300 mm
Maximum clip distance 1.2 m with horizontal laying
3.5 m with vertical laying
Lowest laying temperature –10 °C
Temperature of the sheathing max. 60 °C

Application Ambient Sample Type of Length of

Temperature Components Sample Gas Line Sample Gas Line
Emission Monitoring heated, Type TBL01-S, 230 / 400 V AC 1):
regulated heating, 3-phase max. 60 m
200 °C, heating power 1-phase max. 35 m
approx. 90 W/m 120 / 208 V AC 1):
3-phase max. 40 m
1-phase max. 15 m
Kiln or Calciner Outlet, > 0 °C w/o SO2, NO unheated (PTFE) max. 20 m
Calciner with SO2, NO heated, Type TBL01-C, (recommended)
< 0 °C self-regulating, 100 °C
Wet Kiln Gas Outlet > 0 °C w/o SO2, NO unheated (PTFE) max. 10 m (recommended)
with SO2, NO heated, Type TBL01-C,
< 0 °C self-regulating, 120 °C
Preheater / > 0 °C w/o SO2, NO unheated (PTFE) max. 10 m (must not be
CO Monitoring of ESP with SO2, NO heated, Type TBL01-C, exceeded!)
< 0 °C self-regulating, 120 °C
Coal Bunker, Coal Mill > 0 °C unheated (PTFE) max. 20 m
< 0 °C heated, Type TBL01-C, (recommended)
self-regulating, 100 °C
Process Measurement heated, Type TBL01-S, 230 / 400 V AC 1):
regulated heating, 3-phase max. 60 m
200 °C, heating power 1-phase max. 35 m
approx. 90 W/m 120 / 208 V AC 1):
3-phase max. 40 m
1-phase max. 15 m
heated, Type TBL01-S, max. 60 m
self-regulating heating,
100 °C, heating power
approx. 30 W/m
unheated (PTFE) max. 25 m

1) with “measuring point switch-over” option (2 measuring points):

230 / 400 V AC, only 1-phase allowed, length max. 35 m per measuring point
120 / 208 V AC, only 1-phase allowed, length max. 15 m per measuring point

38 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D

Back-Purging Unit Installation

Before the Installation Observe the “Piping Plan” in the drawings set.

Installation Site The distance between the back-purging unit and the sampling probe must not exceed
5 m (length of the steel-braided compressed-air hoses = 6 m).

Connecting the Com- Connect the compressed-air hoses for purge air and control air to the respective ports
pressed-air Hoses to at the PFE2 filter unit (see Figure 5, page 30).
PFE2 Filter Unit

Connecting the Com- Connect the compressed-air hoses for purge air (filter and filter / probe tube) to the
pressed-air Hoses to respective ports at the PFE3 filter unit (see Figure 7, page 32).
PFE3 Filter Unit

Connecting the Com- Connect the compressed-air hose for purge air to one of the two gas ports at Probe 2
pressed-air Hose to (see Figure 9, page 34).
Probe 2

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 39

Gas Sampling with Automatic Back-Purging

In General

Filter Plugging During operation of the ACX analyzer system the dust which is contained in the sample
gas will accumulate in the probe filter of the gas sampling system. This is uncritical if
dust concentration is low and only requires a cleaning of the filter periodically in longer
time intervals.

But if the dust concentration is high, the dust accumulation in the filter will cause an
increasing pressure loss, and the gas feed of the sample gas pump decreases and also
the sample gas flow, and finally the filter is blocked in an extreme case.

Pump Suction Increase At first this effect can be compensated by occasional adjustment of the sample gas
flow, which increases the suction of the sample gas pump.

The pump is strong enough, but if the fouling continues, the needed suction for
keeping up the required gas flow will increase to such a high value, that several
unfavorable effects will emerge and can finally be accepted no longer.

Filter Cleaning If the suction exceeds a limit of about 300 mbar (accordingly the absolute pressure
falls below 700 mbar), the sampling system filter has to be cleaned. The PFE2 and PFE3
filter units can be cleaned automatically by a back-purging procedure with
compressed air. To control this procedure a function block program is used.

Components for Automatic Back-Purging Procedure

Components for To carry out the automatic back-purging of the filter unit, components are integrated
Automatic Back- in the ACX analyzer system as follows:
Purging Procedure • the PFE2 filter unit with valves combination for back-purging or
• the PFE3 filter unit and separate back-purging unit with integrated compressed-air
conditioning components and
• the control program.

Control of the The back-purging procedure is integrated into the main control program of the ACX
Automatic Back- analyzer system. The manual handling is carried out with softkeys on the system’s
Purging Procedure display and control unit.

40 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D

Start of the Back-Purging Procedure

Start of the Back- The start of the back-purging procedure can be carried out
Purging Procedure • Controlled by time
• Controlled by event
• Manually controlled.

Start After a cycle time has run down, the back-purging procedure will start automatically.
Controlled by Time The cycle time can be adjusted individually (see section “Adjustment of Cycle Time and
Post-Purge Time”, page 46). A cycle time of 4 hours is factory-set.

Start A flow fault during normal measuring operation will start the automatic back-purging
Controlled by Event procedure. After back-purging was started by event, the procedure will run only once.
If the procedure is finished (waiting time 30 sec) and the starting event (flow fault) is
still active, the back-purging procedure will not start again, even not controlled by
time, and a status message “Probe or line is plugged” will be generated. However, the
back-purging procedure can be started manually.

Manually Controlled The manual start of back-purging procedure can be executed locally by softkey “Start
Start Purge” on the system’s display and control unit (see section “Control Panel Screen”,
page 70) or remote-controlled via Modbus-DI or Profibus-DI.

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 41

Program Sequence

PFE2 -D08 -D08 -D08 -D08 -D08 -E05 Status

Digital output: DO2 DO3 DO1 DO4 DO5 MV1 Display signal
Valve: -Y1.1 -Y2.1 -Y3.1 -Y4 -Y5 6) -Y01 Message
Impulse Filter Tube Sample Position “Purge
Compr. Back- Back- Gas Calibr. back Maint.
Step Duration Function Air purging purging Venting Valve Valve 5) active“ Mode
0 4 hrs 1) Measure closed closed closed open open Measure off off
Back-purging
1 10 sec 8) probe filter Impulse open closed closed closed Calibrate on on
Back-purging
2 14 sec 9) probe tube Impulse closed open closed closed Calibrate on on
3 6 sec Venting closed open closed open closed Calibrate on on
2)
4 150 sec Post-purging closed closed closed open open Measure on on
1)
0 4 hrs Measure closed closed closed open open Measure off off

PFE3, Probe 2, -A01 -A01 -A01 -E05 Status

Probe F, Probe Digital output: DO1 DO2 DO3 MV1 Display signal
Tube 40W Valve: -Y12 7) -Y11 -Y07 -Y01 Message
Filter Tube Position “Purge
Back- Back- Calibr. back Maint.
Step Duration Function purging purging Venting Valve 5) active“ Mode
0 4 hrs 1) Measure closed closed closed Measure off off
1 2 sec Switch over closed closed closed Calibrate on on
Back-purging
2 4 sec 3) probe filter open closed closed Calibrate on on
Back-purging
3 8 sec 4) probe tube closed open closed Calibrate on on
4 6 sec Venting closed closed open Calibrate on on
2)
5 150 sec Post-purging closed closed closed Measure on on
0 4 hrs 1) Measure closed closed closed Measure off off

1) Cycle time factory-set to 4 hours

2) Post-purging time factory-set to 150 sec. For an analyzer system with Probe F,
this period must be as short as possible (to be determined during start-up)
3) 1x pressure impulse 2 sec, 1x interrupt 2 sec
4) 1x pressure impulse 2 sec, 1x interrupt 2 sec, 1x pressure impulse 4 sec
5) Calibration valve on = “Measure”, calibration valve off = “Calibrate”
6) Only in version with VOC analyzer AO2000-Fidas24:
open = sample gas path open, closed = relaxation against atmosphere
7) not in a system with Probe 2, Probe F
8) 3x interrupt 2 sec, 2x pressure impulse 2 sec
9) 3x interrupt 2 sec, 2x pressure impulse 2 sec, 1x pressure impulse 4 sec

Continued on next page

42 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D

Program Sequence, continued

Switch Over At first the calibration valve -Y01 1) is switched over to position “Calibrate”. This
separates the sample gas conditioning system and the analyzer system from the
sampling system and protects it against the back-purging pressure. At the same time
the status “Maintenance mode” is activated and all analog outputs and limits are set
on hold. The display reports “Purge Back is active”.

Back-Purging The back-purging procedure continues with the back-purging of the probe filter. To
Probe Filter increase the cleaning effect, the compressed air is applied not continuously but by two
2 sec pressure impulses alternating with a 2 sec interval each.

Back-Purging After this the probe tube is purged back in the same way with two pressure impulses.
Probe Tube A single pressure impulse of 4 sec is followed, to blow out the remaining dust from the
tube.

Venting and Next the pneumatic system is vented for 6 sec and finally the calibration valve -Y01 1) is
Switch Over switched back from position “Calibrate” to position “Measure”. This venting time
removes an internal remaining pressure which might be still present in the pneumatic
system and so avoids a damage of the analyzer’s measuring cell.

Post-Purging Period The calibration valve switch back to position “Measure” will not finish the back-
purging procedure, because first the actual sample gas must flow through the
pneumatic system to purge it, and the analyzer must adjust to the new actual
measuring value. This post-purge time must be adjusted individually according to the
given conditions (see section “Adjustment of Cycle Time and Post-Purge Time”,
page 46). A purge time of 150 sec is factory-set.

End of the Back-Purging The back-purging procedure is not finished until the purge time has expired. Now the
Procedure analog outputs and limits are set free again and they will take over the actual values.
The message “Purge back active” in the display as well as the status signal
“Maintenance Mode” will vanish.

1) In system version with VOC analyzer AO2000-Fidas24, the sample gas path is
blocked and unblocked with the valve -Y5 which is built-in in the PFE2 filter unit.

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 43

Cycle Time

Cycle Time Duration The cycle time is given as the time interval between two automatic starts of the back-
purging procedure. The higher the dust concentration in the sample gas and the
higher the sample gas flow, the shorter this time interval must be set, to avoid a
blocking of the gas sampling probe filter.

Cycle Time Factory The parameter “Cycle time” is factory-set to 4 hours.

Setting
The parameter “Next event time” is factory-set to 08:00 / 12:00 / 16:00 / 20:00 / 00:00
/ 04:00 o’clock.

Optimum Cycle Time The cycle time should not be adjusted shorter than needed, because during the back-
Setting purging procedure (approx. ca. 28 sec) and especially during the post-purge time
(factory-set to 150 sec) no measurement can be made. The optimum time will have to
be found out by operational experience.

Cycle Time Minimum The cycle time should not be below a lower limit. The back-purging procedure with
Value cold compressed air causes a cooling of the heated probe filter, and the filter
temperature regulation needs some time to correct this temperature decrease. As the
filter heating regulation is a rather slow control loop, this time will be relatively long.
Therefore the cycle time should not fall below approx. 60 min.

Event-controlled Start Should despite the time controlled back-purging a probe filter blocking occur caused
of the Back-purging by temporary larger amounts of dust, with the result of a sample gas flow decrease
Procedure by Filter beneath the admissible limit, an additional back-purging procedure is started as a
Plugging result, and the probe filter is purged free in between.

44 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D

Post-Purge Time

Post-Purge Time The post-purge time at the end of the back-purging procedure must be such, that the
Duration complete pneumatic system is flushed with the actual sample gas and the analyzer
gets time to take over the actual measuring value again. The needed post-purge time
depends on the respective layout of the system (i.e. the length of the sample gas line)
and will have to be adjusted individually. A post-purge time of 150 sec is factory-set.

Guide for the A guide for the needed post-purge time is given in the table below. Please add the
Post-Purge Time times for the pneumatic system, the analyzer and the sample gas line.

Response time (3 x T90, approx.) for sample gas flow

60 l/h 100 l/h 200 l/h
(Bypass)
Pneumatic system without sample gas line 45 sec 27 sec 20 sec
plus analyzer Uras26 23 sec 20 sec 23 sec
plus for each 10 m sample gas line I.D. = 4 mm 8 sec 5 sec 2.5 sec
plus PFE2 / PFE3 with probe tube 40, length = 1 m 75 sec 45 sec 23 sec

Example For an ACX analyzer system with filter unit PFE2 / PFE3 and 15 m sample gas line at
60 l/h sample gas flow the post-purge time is calculated as follows:

Post-purge time = 45 sec + 23 sec + 1.5x 8 sec + 75 sec = 155 sec

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 45

Adjustment of Cycle Time and Post-Purge Time

Adjustment of Cycle To adjust the cycle time or post-purge time you must change the parameters of
Time and Post-Purge function blocks.
Time
WARNING!

Only changes as described below may executed! Changes of function block

parameters inappropriately executed may affect the complete function of the
function blocks program!

Procedure Step Action

1 Push Softkey MENU.
The window MAIN MENU is shown.
2 Select menu Configure.
The window CONFIG: is displayed.
3 Select menu Functions blocks.
The window CONFIG: FUNCTION BLOCK is displayed.
4 Select menu Miscellaneous and after this menu Timer.
The window CONFIG.: TIMER is displayed.
To adjust the cycle time:
5 Select timer Zycl..
The window CONFIG: TIMER CYCL. is shown with the parameters
of this function block.
6 Select the parameter Low time.
The window PASSWORD ENTRY is shown, if the password is not
already active.
7 Enter the password, using the numeric keys. The factory-set password is
325465.
The window CONFIG: TIMER CYCL. with indication of the
parameter Cycle time is shown.
8 Change the shown value (factory-set = 4 hrs) to the new value required.
9 Return to normal measuring operation using the key MEAS.
To adjust the post-purge time:
5 Select timer DELAY.
The window CONFIG: TIMER DELAY is shown with the parameters
of this function block.
6 Select the parameter Low time.
The window PASSWORD ENTRY is shown, if the password is not
already active.
7 Enter the password, using the numeric keys. The factory-set password is
325465.
The window CONFIG: TIMER DELAY with indication of the
parameter Low time is shown.
8 Change the shown value (factory-set = 150 sec) to the new value required.
9 Return to normal measuring operation using the key MEAS.

46 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D

Analyzer Cabinet Installation

Installing the Analyzer Cabinet

Installing the • Observe the installation site requirements, see page 12

Foundation • Observe the “Layout Plan” in the drawings set.

CAUTION!

The analyzer cabinet weighs approx. 370 to 430 kg.

A suitable lifting device (crane, block and tackle, lifting
truck, etc.) is required for transport, setting upright and
installation!

Use the handling lugs provided to connect any lift cables

to the analyzer cabinet.

The lift cable must be long enough to have an angle of at

least 60° relative to the top of the cabinet when under
tension (see the illustration).
If this is not done the handling lugs can be bent or the
analyzer cabinet can be warped.

It is strongly recommended that the analyzer cabinet is

• transported by a specialist firm
• transported in a horizontal position as far as possible and
• not set upright until immediately before the installation!

Unpacking the Analyzer • Lift out the analyzer cabinet from the shipping box.
Cabinet Do not remove the plastic sheet in which the analyzer cabinet is wrapped.
Unpacking a cold analyzer cabinet can lead to condensation.

• Do not remove the plastic film until just before the analyzer cabinet will be
connected and it has reached room temperature. This takes at least 24 hours.

Setting Up the Analyzer • Installation site requirements, see page 12

Cabinet • Material required, see page 24
• Follow the “Layout Plan” in the drawings set.
• Ground by means of the central grounding screw, route the grounding cable
(≥ 10 mm2 / AWG 6) through the M16 cable gland.

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 47

Mounting Plate and Electrical Distribution Cabinet: Installation

Preparing the • Observe the installation site requirements, see page 12

Installation Site • Observe the “Layout Plan” in the drawings set.
• Mounting on a rack or wall. The loading capacity must be high enough to bear the
weight of the mounting plate and electrical distribution cabinet (see page 22).
• Attachment with M8 bolts or studs.

ATTENTION!

The mounting plate weighs approx. 170 kg! The electrical distribution cabinet weighs
approx. 65 kg! A suitable lifting device (crane, block and tackle, lifting truck, etc.) is
required for transport, setting upright and installation!

It is strongly recommended that the mounting plate and the electrical distribution
cabinet are
• transported by a specialist firm
• transported in a horizontal position as far as possible and
• not set upright until immediately before the installation!

Unpacking the System • The system components are shipped in two separate transport crates.
Components (Mounting • Open the transport crates and lift out the system components.
Plate and Electrical Do not remove the plastic foil in which the system components are shrink-
Distribution Cabinet) wrapped! Unpacking cold system components could cause condensation.

• Do not remove the plastic foil until the system components have reached room
temperature. This takes at least 24 hours.

Installing the • Installation site requirements, see page 12

System Components • Material required, see page 24
• Follow the “Layout Plan” in the drawings set.
• Hang the electrical distribution cabinet on the left of the mounting plate.
The distance is predetermined by the length of the prepared cables which are
connected to the modules on the mounting plate. The cables are tied together in
bundles for transport.
• Connect the ground lead (green-yellow, ≥ 10 mm2 / AWG 6) to the central ground-
terminal screw of the mounting plate and pass it through the provided M16 screwed
cable gland to the ground-terminal screw in the electrical distribution cabinet.
• Connect the prepared cables to the electrical distribution cabinet:
• Open the sliding cable entry plate on the underside of the cabinet (knurled screws)
• Insert the ready-made cables
• Attach the cable connectors to the appropriate terminal strip as per the wiring
diagram and
• Close the cable entry plate

48 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D

Analyzer System with Integrated VOC Analyzer: Installing the Supply
Gases and Test Gases

• Gas inlet conditions, see page 18

• Material required, see page 24
• Observe the “Piping Plan” in the drawings set.
• Pay special attention to complete cleanliness when connecting the gas lines. Gas
inlets, outlets, fittings, tubes and pipes must be free of dust and grease.
Contaminants can enter the gas analyzer and damage it or lead to false
measurement results.
• Follow the fitting manufacturer’s instructions. Be sure to use a backup wrench when
tightening gas line bulkhead connections (gas ports).
• Heat the gas lines if there is a danger of frost.

CAUTION!

The pertinent safety regulations for handling combustible gases must be followed.

Installing the • Connect the instrument air line to the bulkhead connector provided for this purpose
Instrument Air on the right wall of the cabinet.
Supply • Install a shutoff valve with a pe = 4.5 to 7 bar pressure gauge in the instrument air
supply system.

Installing the • Clean the combustion gas line: Pump cleaning agent (alkaline cleaner, solvent,
Combustion Gas Supply stainless steel pickling fluid) through the tube. Purge tube thoroughly with distilled
water. Purge tube for several hours at a temperature above 100 °C with synthetic air
or nitrogen (10 to 20 l/h). Close off tube ends.
• Connect the combustion gas line: Connect two-stage pressure-reducing valve (for
ultra-pure gases) with flow limiter to the combustion gas cylinder. Connect the
combustion gas line to the bulkhead connector provided for this purpose on the
right wall of the cabinet.
Note: For safety reasons, a flow limiter is integrated in this bulkhead connector to
limit the combustion gas flow to 10 l/h.
• Check combustion gas line seal integrity: Adjust the high-pressure stage of the
pressure-reducing valve of the combustion gas cylinder to pe = 1200 ± 100 hPa (1.2 ±
0.1 bar) and purge the combustion gas line. Check seal integrity of the combustion
gas line with a leak detector (measuring principle: thermal conductivity). Close
combustion gas cylinder.

Continued on next page

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 49

Analyzer System with Integrated VOC Analyzer: Installing the Supply
Gases and Test Gases, cont’d

Setting Up the Test Gas • Comply with permissible ambient temperatures and the warning labels on the
Cylinders pressure reducers.
• Fit the test gas cylinders with pressure reducers and place them near the analyzer
cabinet. Short test gas lines result in short lag times.
• Connect the test gas lines to the bulkhead connectors provided for this purpose on
the right wall of the cabinet.

Installing the • Connect the exhaust gas line to the bulkhead connector provided for this purpose
Exhaust Gas Line on the right wall of the cabinet (using the shortest possible line with an I.D. ≥ 8 mm).
Allow the exhaust air to pass freely and do not install reduction sections or shutoff
valves. The diameter of the exhaust gas line should be widened at the shortest
possible distance outside the cabinet to prevent any backpressure due to long line
length.

50 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D

AO2000-Fidas24: Connecting the Sample Gas Line

CAUTION!

Before start-up of the gas analyzer it is imperative to remove any plastic sealing
stopper inserted in the sample gas inlet at the factory.

Sample Gas Line Connect the heated sample gas line directly to the sample gas inlet of the AO2000-
Connection Fidas24 VOC analyzer (see Figure 10). Make sure that the O-rings are properly seated
and the sample gas line is fully inserted in the sample gas port.

Fittings and O-Rings The required fittings and O-rings are supplied in the accessory kit.

Figure 10
4 3 2 1
Sample Gas Line
Connection on AO2000-
Fidas24 Heated Sample
Gas Port

1 Heated Sample Gas Line (tube with 4/6-mm ID/OD)

2 O-Ring 6.02 x 2.62
3 Fitting
4 O-Ring 12.42 x 1.78

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 51

Analyzer Cabinet: Connecting the Electrical Leads

Connecting the • Material required, see page 24

Electrical Leads • Observe the “Interface Plan” in the drawings set.
• When routing the electrical lines, follow all applicable national safety regulations for
the installation and operation of electrical devices.

Connecting the • Route the signal leads separately from the power supply lines.
Signal Leads • Locate the analog and digital signal lines separately from each other.
• Carefully plan the arrangement of signal leads in the cables as well as the use of
openings for cable connectors.
• Connect the signal leads to the terminal strips.
• Cable shielding should be connected according to local regulations. Differences in
potential and signal interference must be taken into consideration.

Connecting the • Power supply requirements, see page 20

Input Wiring • Before connecting the power supply, make sure the analyzer system operating
voltage is set to match the line voltage.
• The protective lead connector and protective lead should be connected before any
other connection is made. The analyzer system can be hazardous if the protective
lead is interrupted inside or outside the system or if the protective lead is
disconnected.
• Connect
• the input wiring of the analyzer cabinet
• the input wiring of the heated sample components (temperature-resistant as
needed)
• the Pt100 resistance thermometer leads
• the input wiring of the back-purging unit (solenoid valves)
to the terminal strips.

52 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D

Analyzer System Start-Up

Initial startup of the analyzer system should be performed by trained personnel of the
manufacturer or the supplier.

Prior to Analyzer System Start-Up

WARNING!

The analyzer system must stand in its operating position for about 24 hours prior to
start-up.

Purge the Combustion Purge the combustion gas line before analyzer system start-up. This should ensure that
Gas Line the combustion gas line is free of impurities – especially containing hydrocarbons –
that could lead to erroneous measurement values. Purge the combustion gas line for
approx. 20 seconds with a nitrogen flow of approx. 100 l/h.

Transportation see “Transportation Restraints Release” section, page 54

Restraints Release

Reagent Fill see “Reagent Fill” section, page 55

Check Analyzer System see “Analyzer System: Seal Integrity Check” section, page 85
Seal Integrity

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 53

Transportation Restraints Release

Transportation Step Action

Restraints Release Sample Gas Feed Unit SCC-F: Diaphragm Pumps Transportation Restraints:
(see Figure 11) 1 Using a Ph2 crosshead screwdriver, loosen the two M6x25 screws 1 in the
base plate.
Retain the screws in case the unit needs to be transported again in
the future.
Sample Gas Cooler SCC-C: Compressor Transportation Restraints:
2 Using a Ph2 crosshead screwdriver, turn the two screws counterclockwise
through the holes 2 in the base plate to the point at which resistance can
be felt.
In case that the “Zero Air Generator” (catalyst for combustion air
conditioning) is mounted underneath the sample gas cooler use an
offset screwdriver to release the transportation restraints.
If no offset screwdriver is at hand the “Zero Air Generator” must be
dismounted according to the following instructions.
1 Loosen the nuts of the hose fittings on the left and right side of
the “Zero Air Generator” and pull the hoses out of the fittings.
2 Loosen the mounting screws (2 above, 1 below) and lay the “Zero
Air Generator” on the cabinet floor.
3 Release the transportation restraints as described above.
4 Mount the “Zero Air Generator” to the cabinet rear wall.
5 Insert the hoses into the hose fittings as far as they will go and
hand-tighten the nuts. Perform this step carefully in order to
ensure leak-tightness of the hose connections.

Figure 11

Transportation
Restraints
left: SCC-F
Sample Gas Feed Unit
right: SCC-C
Sample Gas Cooler

54 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D

Reagent Fill

CAUTION!

When working with corrosive reagents note the hazard information and safety
precautions contained in the applicable material safety data sheets.

Reagents should be purchased from a local chemical distributor in order to keep the
route of transport as short as possible!

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

Reagent Fill Fill the reagent supply bottle (optional) with the reagent needed for the measurement
task.

Mixture Ratio Reagents (concentrate) are used in the following mixture ratios:

Phosphoric Acid (H3PO4) Hydrogen Peroxide (H2O2)

Concentration 85 % 30 %
Mixture ratio ½ liter phosphoric acid 1 liter hydrogen peroxide
(in 10-liter bottle) 9½ liters water 1) 9 liters water 1)
Solution sufficient for 2 fills 1 fill

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

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 55

Analyzer System Start-Up

CAUTION!

Before activating the power supply check once again that the analyzer system
operating voltage is set to match the line voltage.

Power Supply Activation Step Action

1 Make sure that all fuse switches are deactivated.
2 Turn on the analyzer system power supply with main switch -Q10 and -Q20
if applicable.
3 Activate the ground fault circuit interrupters -F10 or -F20 if applicable.
4 Activate the fuse switches of the individual modules one after the other:
-F01 Lighting, service socket, fan or cooling unit
-F02 Heated probe tube, heated filter unit, back-purging unit,
test gas connection valves
-F03 Heated sample gas line
-F04 NO2 / NO converter
-F05 AO2000-Fidas24, air catalyst
-F06 Sample gas cooler, sample gas feed unit
-F07 AO2000 central unit, power supply

Function Check The following events will occur after the power supply is turned on:

Phase Description
1 The three “Power”, “Maint” and “Error” LEDs light up.
2 The different booting phases are displayed on the screen.
Also the software version is displayed.
3 After a brief time the screen switches to measurement mode.
STATUS
MESSAGE
4 The softkey appears on the screen. This indicates the possibility of
a temperature or flow problem during the warm-up phase (see page 61).
By pressing the softkey the user can recall the status message summary
and view status message details.

Date and Time Check A correct date and time setting is required for proper operation of functions such as
automatic calibration and time / date logging of error messages.

Step Action
1 Select the Date/time menu item:
MENU → Configure → System → Date/Time
2 Check and, if necessary, correct the date and time (for more information
see “Setting the Time Zone, Date and Time”, page 74).

The analyzer system is factory-set to the GMT+1 time zone.

56 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D

AO2000-Fidas24: VOC Analyzer Start-Up

VOC Analyzer Start-Up Step Action

Procedure Turn on supply gases
1 Select the Controller values menu item:
MENU → Diagnostic/Information → Module specific →
Controller values
The variables for the temperature regulators are indicated under this
menu item:
T-Re.D Detector temperature
T-Re.E Heated sample gas port temperature
The temperature values will rise slowly after the power supply is
activated.
2 Turn on instrument air, combustion air and combustion gas (H2). Using
the appropriate external pressure regulator, adjust the initial pressure to
the value specified in the analyzer data sheet.
The pressure values shown on the gas port labels and in the
“Supply Gas and Test Gas Inlet Conditions” section (see page 18)
are only typical values. Only the factory-determined values shown
in the analyzer data sheet of the analyzer module are applicable for
safe operation.
3 In the Controller values menu item also the variables for the
internal pressure regulators are indicated; set the supply gas pressures by
means of the variables:
Input Instrument air at combustion-chamber inlet
Output Instrument air at combustion-chamber outlet
Air Combustion air
H2 Combustion gas (H2)
Random values may be displayed at first for the variables. The
values are updated for the first time approx. 30 seconds. after
selection of the menu item and thereafter approx. every 30
seconds. Pressure control continues to run in the background.
Depending on the pilot pressure setting, pressure setting times
can be long.
If the operator does not press any key for more than five minutes
while in menu operation, the analyzer switches automatically to
measuring operation to display of sample values (“time out”).
4 As soon as the temperature of the detector has reached the threshold
value (150 °C) the appropriate solenoid valve in the analyzer module
automatically connects the instrument air. The vacuum and combustion
air controllers work to keep pressures at the applicable set points.
Sample gas begins to flow through the analyzer as soon as the
instrument air is connected.
5 After the pressures are at the applicable set points, the associated
solenoid valve in the analyzer module automatically starts the combustion
gas supply. The combustion gas controller attempts to establish the set
point pressure value.

Continued on next page

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 57

AO2000-Fidas24: VOC Analyzer Start-Up, continued

Step Action
Adjust the variables for the internal pressure regulators
Steps 6 to 8 should only be performed if the analyzer module does not
automatically start operation at the pressure values indicated on the
analyzer data sheet. If the internal pressure controller values do not
match these values, the pilot pressures must be changed.
6 Instrument air: Use the external pressure regulator to set the Output
variable to approx. 60 % (max. 70 %).
Variable too large ⇒ reduce pressure.
Variable too small ⇒ raise pressure.
(The Input variable depends on the sample gas flow rate.)
7 Combustion air: Use the external pressure regulator to set the Air
variable to approx. 50 % (max. 60 %).
Variable too large ⇒ raise pressure.
Variable too small ⇒ reduce pressure.
8 Combustion gas: Use the external pressure regulator to set the H2
variable to approx. 35 % (max. 40 %).
Variable too large ⇒ raise pressure.
Variable too small ⇒ reduce pressure.

Continued on next page

58 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D

AO2000-Fidas24: VOC Analyzer Start-Up, continued

Step Action
Flame ignition (automatic)
9
Adjust supply-gas pressures
to set points

Combustion air pressure

set to start value

Ignition coil switched on

Combustion air pressure

raised steadily

Ignition coil switched off

Yes
Flame on?

No

Yes
Number of ignition attempts
= 10?
No

Combustion gas pressure Combustion gas pressure and

raised one step combustion air pressure are
reset to operating values

Analyzer module goes

into stand-by mode

Menu → Maintenance/Test
→ Analyzer spec. adjustm.
→ Restart FID

Warm-up phase
continues

Flame ignition may take up to 10 minutes, depending on the number of

ignition attempts.
The flame temperature is displayed in the Flame parameter under the
Auxiliary raw values menu item; it must be at least 30 °C higher
than the detector temperature.
Actual start-up of the analyzer is complete when the flame ignites.

Continued on next page

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 59
AO2000-Fidas24: VOC Analyzer Start-Up, continued

Initial Heating Phase The initial heating phase covers the period after the power supply has been turned on
until the detector temperature reaches the threshold value (150 °C).

Status Messages The following status messages are present during the initial heating phase:

Short Text Description

Working temperature The detector temperature has not yet reached the
threshold value.
Flame fault The flame is not yet lit.
Temperature limit The temperature of the detector (T-Re.D) and
value 1, 2 possibly of the heated sample gas port (T-Re.E) is
above or below the upper or lower limit value 1 (2).
Pressure limit The pressure at one of the internal pressure
value 1, 2 regulators for instrument air (Input, Output),
combustion air (Air) or combustion gas (H2) is
above or below the upper or lower limit value 1 (2).

Reading The reading and ––E–– flash alternately, signaling that the displayed measurement
value is not valid.

CAUTION!

Never pull the 115 / 230 VAC power supply plug connectors for the detector heater
and the heated sample gas port while the power is on.

CAUTION!

The heated sample gas port cover is hot during operation. Its temperature is higher
than 70 °C.

60 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D

Warm-Up Phase

Warm-Up Phase The warm-up time is approx. 2 to 4 hours.

The warm-up phase can take longer if the analyzer system was not brought to room
temperature before the power supply was activated.

During the warm-up phase measurement values can be outside the ranges specified in
the data sheet.

End of the The warm-up phase is over when the temperature and flow status messages are gone
Warm-Up Phase and the measured value drift is acceptable. The latter depends on the size of the
measurement range.

Readiness, At the end of the warm-up phase the analyzer system is ready for operation and
Sample Gas Supply automatically activates the sample gas supply.

Calibration Calibration should only be started after the warm-up phase (see “Analyzer System
Calibration” chapter, page 80).

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 61

Analyzer System: Seal Integrity Check
CAUTION!

Prior to performing any maintenance works on the analyzer system be sure to

activate the “Maintenance Mode” on the “Control Panel” screen (see page 70) thus
setting the “Maintenance Mode” status signal.

Be sure to reset this setting after finishing the maintenance work.

When is the seal The seal integrity check must be performed regularly. It must be performed in any
integrity check needed? event when the respective status message is displayed.

The seal integrity check methods differ depending on whether a VOC analyzer
(AO2000-Fidas24) is installed in the analyzer system.

Seal Integrity Check of The seal integrity check should be performed according to the pressure-drop method
Analyzer System using a U-tube manometer when no VOC analyzer is installed in the analyzer system.
without VOC Analyzer

Step Action
1 Interrupt the sample gas supply.

2 Close the sample gas outlet.

3 Disconnect the sample gas line from the sample gas inlet and connect a
tee fitted with a shut-off valve.
4 Connect a U-tube manometer half filled with water to the free end of the
tee.
5 Blow air or nitrogen through the shutoff valve to a gauge pressure of pe ≈
100 hPa (= 1000 mm water column).
6 Close the shut-off valve. The pressure should not change measurably in
1 minute (pressure drop ≤ 1 hPa). A sharp pressure drop is a sign of a leak.

Seal Integrity Check of When a VOC analyzer is installed in the analyzer system,
Analyzer System • disconnect the sample gas line which runs to the other gas analyzers from the
with VOC Analyzer AO2000-Multi-FID14 sample gas connection and
• perform the seal integrity check for the analyzer system without the AO2000-Fidas24
according to the pressure-drop method described above.
The sample gas path in the AO2000-Fidas24 cannot be checked for seal integrity.

Continued on next page

62 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D

Analyzer System: Seal Integrity Check, continued

Seal Integrity Check of Check seal integrity of the combustion gas line in the analyzer system with a leak
Combustion Gas Path in detector (measuring principle: thermal conductivity). Leak rate < 2 × 10–4 hPa l/s. Do
an not use leak detection spray!
Analyzer System
It is recommended to check regularly the seal integrity of the combustion gas line
with VOC Analyzer
outside the analyzer system.

The combustion gas path inside the VOC analyzer is checked for leaks at the factory.
No seal integrity testing is required during normal operation.

Seal Integrity Check Step Action

of Back-Purging Unit 1 Close the water precipitator outlet (part of the pressure regulator
combination).
2 Connect instrument air with operating pressure = 6 bar to the back-
purging unit inlet.
3 Spray the complete compressed-air path with leak detection spray.

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 63

AO2000: Air Pressure Correction
Air Pressure Effect A specific amount of change in air pressure will result in a specific change in a
measurement value, depending on the measurement principle employed by the
analyzer module.

Measures to Minimize Air pressure effect can be minimized by:

Air Pressure Effect • Installing a pressure sensor in the analyzer module (this can only be done at the
factory) or
• Entering the current atmospheric pressure as a correction value.

In which analyzer Analyzer module Pressure sensor

modules is a pressure Uras26, Limas21, Magnos206, Magnos28 installed ex works
sensor installed?
Magnos27, Fidas24 cannot be installed

Use the MENU → Diagnostic/Information → System overview menu

item and select the appropriate analyzer module to determine if a pressure sensor is
installed.

Air Pressure Values Operating Altitude Mean Air Pressure

meters above mean
sea level hPa (mbar) psi mm Hg (Torr) in Hg
–200 1037 15.04 778 30.63
–100 1025 14.87 769 30.28
±0 1013 14.69 760 29.92
+100 1001 14.52 751 29.57
200 989 14.34 742 29.21
300 977 14.17 733 28.86
400 965 14.00 724 28.50
500 955 13.85 716 28.19
600 943 13.68 707 27.84
700 932 13.52 699 27.52
800 921 13.36 691 27.21
900 909 13.18 682 26.85
1000 899 13.04 674 26.54
1100 888 12.88 666 26.22
1200 877 12.72 658 25.91
1300 867 12.57 650 25.59
1400 856 12.42 642 25.28
1500 845 12.26 634 24.96
1600 835 12.11 626 24.65
1700 825 11.97 619 24.37
1800 815 11.82 611 24.06
1900 804 11.66 603 23.74
2000 793 11.50 595 23.43

64 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D

AO2000: Air Pressure Value Correction

An incorrect air pressure value will produce erroneous measurement values.

When should the air The air pressure value must be checked and readjusted as required in the following
pressure value be set? cases:

• If the analyzer system’s operating site altitude has changed since the last calibration
• If the air pressure effect on the measured value is too high.

Limas21 and Uras26 A pressure sensor is installed as standard equipment in the Limas21 and Uras26
with Integral Pressure analyzer modules. The pressure sensor is calibrated to 1013 hPa. This is the reference
Sensor and Calibration pressure for the test gas concentration when measuring the calibration cells.
Cells
If the air pressure value needs to be changed, the following items are also required
• Calibrate the sample components with test gases and then
• Measure the calibration cells

Air Pressure Value The current atmospheric pressure can be entered as a correction value for each
Correction analyzer module or for all analyzer modules as a group.

Menu Path For one analyzer module:

MENU → Maintenance/Test → Analyzer spec. adjustm. →
Atm. press. anlz → …
For all analyzer modules as a group:
MENU → Maintenance/Test → System → Atm. pressure

If the pressure sensor is connected to the sample gas output line, the sample gas flow
must be interrupted while calibrating the pressure sensor so that the sample gas
pressure does not distort the measured pressure.

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 65

Dynamic QR Code

Application Dynamic QR Code is a unique feature to display dynamically generated QR codes on

the gas analyzer screen.

The QR code contains static information for device identification as well as

dynamically generated information on system configuration and gas analyz-er health
status .

Static data for device • Production number

identification are
among other data: • Production date
• Software version
• Serial numbers of built-in analyzer modules and components
Dynamic data for error • Status messages
diagnosis are among
other data: • Measured values
• Temperature, pressure and flow values
• Drift values
• Analyzer-specific values
In combination with mobile devices (smartphone, tablet, etc.) Dynamic QR Code
represents an innovative way of customer’s communication which allows, for instance,
improved case-specific support by ABB resulting in an increased availability of analyzer
assets.

Dynamic QR Code is compatible with the ABB application "my Installed Base" as well as
with standard QR code scanner applications.

Handling The QR code is selected in the gas analyzer's diagnosis menu and displayed on the gas
analyzer's screen.

There is a direct link from the status messages overview to the diagnosis menu. In
addition, the QR code can be selected in Remote HMI and scanned from the computer
screen.

The displayed QR code is scanned using the QR code scanner application installed in
the mobile device. The resulting text information displayed on the mobile device's
screen is then sent by e-mail or a suitable messenger service to the local service
representative defined in the "Measurement Care" agreement.

As an alternative, a photo of the displayed QR code can be sent to the ser-vice

representative.

66 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D

Select QR code

Menu path Menu → Diagnosis/Info. → QR Code Display

Vorgehensweise 1 Select system overview or specific analyzer module.
2 Select QR code with ENTER.
3 Scan QR code.
4 Return to selection with Back.
The diagnosis menu can be selected directly from the status messages overview.

The QR code can also be selected in Remote HMI and scanned from the computer
screen.

Recommended QR code ABB recommends the use of the following QR code scanner applications (available free
scanner applications of charge for iOS and Android):

"my Installed Base" by Download in App Store: Download in Google Play:

ABB

"QR Scanner" by Download in App Store: Download in Google Play:

Kaspersky

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 67

Analyzer System Operation

Display/Control Unit
Figure 12

Display/Control Unit
Status LED’s

Numeric
Keypad

Softkeys Cancel Keys

Status LED’s Power Green LED: The power supply is on.

Maint Yellow LED: The “Maintenance Request” status signal is on.

The measured value is valid.

Error Red LED: The “Error” status signal is on.

The measured value is no longer valid.

Cancel Keys Back

Allows the operator to cancel a function or menu item and to return to the previous
menu level.

Meas
Allows the operator to cancel a function or menu item and to return to the measured
value display in measurement mode.

Only entries confirmed with ENTER are stored; unconfirmed items are not accepted.

Softkeys Allows the operator to scroll to the next display “page”. This key only allows forward
scrolling.

STATUS Appears in measurement mode if an “Error” or “Maintenance request” condition arises.

MESSAGE
This key allows the operator to call up the status message log and view the status
messages. The operator can also call up a detailed display for any message in the log.

68 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D

“Measured Values” Screen

Figure 13

“Measured Values”
Screen

Indication Values measured by the analyzer system are displayed on the “Measured Values”
screen. Up to six measured values are displayed on one page. The actual number of
pages depends on the number of measurement components configured in the
analyzer system.

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 69

“Control Panel” Screen

Figure 14

“Control Panel” Screen

Indication The “Control Panel” screen offers controls for various functions of the analyzer system.

Functions activated manually are indicated by means of a filled rectangle below the
function’s name (see the following example).

“Maintenance Mode” deactivated (off)

“Maintenance Mode” activated (on)

Operation The controls are operated in the following manner:

Press the number key that corresponds to the position of the control and is indicated
above the control. In the following screen, press the corresponding function key.
Thereby, the system switches back to the control panel screen, and the function just
activated is indicated by means of a filled rectangle.

Password Protection All control panel functions except the “Maintenance control” are password protected.

Changing the password is described on page 76.

Continued on next page

70 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D

“Control Panel” Screen, continued
Purge Control MAINT. Operate this key before
MODE starting and after finishing
maintenance work
(“Maintenance Key Switch”)

START Start back-purging manually

PURGE

PURGE Disable back-purging

OFF

MPS Control (Measuring AUTOM. Automatic measuring point

Point Switchover) switchover

MP 1 Select measuring point 1

manually

MP 2 Select measuring point 2

manually

Gas Control SAMPLE Sample gas supply

(normal operation)

PROBE Test gas supply at the probe

CABINET Test gas supply at the analysis

cabinet

Test Gas Control TESTGAS Select test gas 1

1

TESTGAS Select test gas 2

2

TESTGAS Select test gas 3

3

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 71

Menu Tree

Menu Tree The following table summarizes the analyzer system menu tree.

For reasons of brevity only the top level parameters and functions are shown; the
menu branches more extensively at most menu items, e.g. into the various
measurement components or into the selection and adjustment of values.

Some menu items are analyzer-specific, i.e. they only appear when particular analyzer
modules are integrated into the analyzer system.

Password Levels For each menu item its password level (0, 1, 2, 3) is shown in the table.

For some menu items, individual sub-menu items are on a higher password level.
These applies especially to those sub-menu items which allow access to function block
applications.

Note: The “Change password” menu item is not assigned to a specific password level.
To change a password the old password of the respective level must be entered (see
“Changing the Password” section, page 76).

Continued on next page

72 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D

Menu Tree, continued

Menu
 ↓
_ Calibrate  _ Maintenance/Test
   
  __ Manual calibration 0   __ System
     _ Atm. pressure 2
  __ Automatic calibration 0    _ Display test 0
    _ Keyboard test 0
_ Configure  
    __ Analyzer spec. adjustm.
  __ Component specific   _ Pump 1
   _ Measurement range 0   _ Atm. press. anlz 2
   _ Filter 1   _ Calibration reset 1
   _ Pressure controller 2   _ Basic calibration 2
   _ Autorange 1   _ Measure cal. cell 1
   _ Alarm values 1   _ Optical adjustm. 2
   _ Active component 0   _ Phase adjustm. 2
   _ Module text 2   _ Relinearization 2
    _ Amplification optimization 2
  __ Calibration data   _ Cross sensitivity adjustm. 2
   _ Manual calibration 1   _ Carrier gas adjustm. 2
   _ Automatic calibration 1   _ Electr. zero cal. FID 2
   _ Ext. controlled cal. 1   _ Restart FID 1
   _ Output current response 1 
   _ Diagnostics/Information
  __ Function blocks 
   _ Miscellaneous 3  __ System overview 0
   _ Inputs 3 
   _ Outputs 3  __ Module specific
   _ Mathematics 3   _ Raw values 0
   _ Multiplexer/Demultiplexer 3   _ Auxiliary raw values 0
   _ Measurement 3   _ Status 0
   _ Sample system 3   _ Controller values 0
   _ Calibration/Correction 3   _ Lamp intensity 0
    _ Uras26 Status 0
  __ System 
  _ Date/Time 2  __ Logbook 0
  _ Language 2
  _ Change password
  _ Setup system modules 2
  _ Save configuration 1
  _ Status signals 2
  _ Network 2
  _ Display 2
↓

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 73

Setting the Time Zone, Date and Time

Menu Path MENU → Configure → System → Date/Time

Procedure Parameter Explanation

Time zone The time zone can be selected either from the GMT (Greenwich Mean
Time) values or from the continent / country / city list.
Date Date must be entered in month/day/year format.
Enter year with 4 digits.
Time Time must be entered in hour:minute:second format.
Enter seconds, too.

Daylight Savings Time The analyzer system is automatically set to daylight savings time.

Note: This applies only when the time zone has been selected from the
continent / country / city list and not from the GMT values list.

Factory Setting The analyzer system is factory-set to the GMT+1 time zone.

Accept the Press the softkey SET TIME to accept the modified time settings.
Time Settings

74 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D

Selecting User Interface Language

Menu Path MENU → Configure → System → Language

Language Selection The user interface languages English and German are factory-configured (per order) in
the analyzer system. In the menu item Language the user can switch between these
two languages.

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 75

Changing the Password
Menu Path MENU → Configure → System → Change password

Password Protection See page 77 for basic information on “Password Protection”.

We strongly recommend to change all passwords from their default value.

Factory Setting User group Access to Password levels Password

Every user 0 None
Maintenance team 0, 1 471100
Specialist team 0, 1, 2 081500
Function block specialist 0, 1, 2, 3 325465

Procedure Select the Change password menu item, select the user group, enter the old
password, enter the new password (6 digits), re-enter the new password, leave the
menu item with Back.

Password level 0 is not displayed in the Change password menu item.

CAUTION!

After entering the password for password level 3, you can access all of the function
block applications. When configuring function blocks, existing applications with
their configurations and links can be damaged or destroyed.

76 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D

Password Protection
Elements of Password Password protection consists of three elements:
Protection • Password level
• User group
• Password

Password Level Each menu item is assigned an password level. Password levels are numbered
0, 1, 2 and 3.

Menu items are assigned to different password levels in order to assure that specific menu
items can only be changed by authorized users.

User Group The members of a user group are authorized to access a specific password level, i.e. to
change the menu items at that level.

Some user groups are set-up at the factory.

A user group can be made up of one or more users.

Password Every user group set-up in the system has a password.

The password consists of six digits which can be entered via the numeric keypad.

Passwords are pre-assigned for the factory-set user groups.

Factory Setting User group Access to password levels Password

Every user 0 None
Maintenance team 0, 1 471100
Specialist team 0, 1, 2 081500
Function block specialist 0, 1, 2, 3 325465

CAUTION!

After entering the password for password level 3, you can access all of the function
block applications. When configuring function blocks, existing applications with
their configurations and links can be damaged or destroyed.

Technical Bulletin “AO2000 Function Blocks – Descriptions and Configuration”

(publication no. 30/24-200 EN) contains complete information on the “Function Block”
concept as well as detailed descriptions of the individual function blocks.

Continued on next page

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 77

Password Protection, continued

Viewing Menu Items All users can view all menu items, regardless of password level, without entering a
password.

Changing Menu Items All users can execute all password level 0 menu items without entering a password.

Password level 1, 2 and 3 menu items can only be changed if the user belongs to the
group authorized for that level and after the user’s password has been entered.

Note Entering the main menu and thus switching to the menu mode can be password
protected (see the “Inhibit Operation” section, page 79).

Change Privilege After entering the password the user is authorized to change any menu items
accessible at the user’s level.

Duration of the Change The change privilege remains in effect until:

Privilege
• The analyzer automatically switches to measurement mode if the user has not
pressed a key for more than about 5 minutes (time out).
• Or the user presses the “Meas” key twice in succession.

The change privilege remains in effect if the user presses the “Meas” key only once to
return to measurement mode. This is indicated by the “Password active” status
message.
In this manner the user does not have to re-enter a password to change a menu item if
he or she returns to the menu mode within approximately 5 minutes.

Note The change privilege thus refers to a temporary authorization to change menu items.
In contrast, the access privilege refers to a fundamental and configurable authorization
to change menu items at certain password levels.

78 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D

Inhibit Operation

Menu Path MENU → Configure → System → Change password

Inhibit Operation Operation of the analyzer system, i.e. entering the main menu and thus switching to
the menu mode, can be password protected.

After inhibition the analyzer system can only be operated when the level 1 password
has been entered.

The level 3 password must be entered to configure the password protection.

Procedure Press the MENU ACCESS softkey in the “Change password” menu item and set the
password protection.

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 79

Release of communication via port 8001/tcp
In ACX, a proprietary protocol has been implemented on port 8001 for communication
with remote clients:
• In the ACX, communication is blocked on all Ethernet interfaces (X8 / X9) by default.

When communication is blocked, a corresponding message is issued on the Remote

HMI.
Image 1

Message on the Remote

HMI (example)

Release communication Implement the following steps to release communication via the proprietary protocol:
via the proprietary 1. Select the ‘…\Configure\Network\TCP/IP Network’ menu.
protocol
2. Select the ‘Unsecured protocol’ menu item

80 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D

 3. Select the ‘Unsecured protocol’ menu item and set the parameter to ‘Permit’.

4. Confirm the information field by selecting <BACK>.

• Communication via the proprietary protocol has now been released.

The proprietary protocol via port 8001/tcp is an unsecured protocol (in the meaning of
IT security or cybersecurity).

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 81

Release of communication via Modbus® TCP/IP
In the ACX, communication via Modbus® TCP/IP is blocked on all Ethernet interfaces
(X8 / X9) by default.
Release communication Implement the following steps to release communication via Modbus® TCP/IP:
via Modbus® TCP/IP 1. With the Modbus card installed, select the ‘…\Configure\Network\Modbus’ menu.

or

The ‘…\Configure\Network\Modbus’ menu is not available if the Modbus card is not

installed. In this case, the Release menu is called up directly via ‘Modbus TCP’.

2. Select the ‘Modbus TCP Access’ menu item and confirm by selecting <ENTER>.

3. Select the ‘Modbus TCP Access’ menu item and set the parameter to ‘Permit’.

82 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D

 4. Confirm the information field by selecting <BACK>.

• Communication via the Modbus® TCP/IP protocol has now been released.

The Modbus® protocol is an unsecured protocol (in the meaning of IT security or

cybersecurity), as such the intended application should be assessed before
implementation to make sure that the protocol is suited.

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 83

Inspection and Maintenance

Safety Information
CAUTION!

Only persons familiar with the maintenance of comparable analyzer systems and
certified as being capable of such work should work on the system.

Safety Labels CAUTION!

Affixed to the Analyzer
Observe the safety labels affixed to the analyzer system or to the individual
System
components:

Consult Documentation!

Hot Surface! (Temperature > 60 °C)

Corrosive Material!

Risk of Electric Shock!

Harmful Substances CAUTION!

When working with corrosive reagents note the hazard information and safety
precautions contained in the applicable material safety data sheets.

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

Harmful Gases CAUTION!

Some of the gases measured with the analyzer system are harmful to health.

Therefore, the sample gas must not escape from the gas path during normal
operation and maintenance works.

A seal integrity check of the analyzer system has to be performed at regular

intervals.

The diluted exhaust gas must be drained out of the installation room of the analyzer
cabinet.

For detailed information on the maintenance of the device, consult the associated
operating instructions (OI)!

84 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D

Analyzer System Shut-Down

Analyzer System Shut-Down

CAUTION!

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

CAUTION!

When working with corrosive reagents note the hazard information and safety
precautions contained in the applicable material safety data sheets.

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

Shutting Down the Step Action

Analyzer System 1 Flush the sampling probe, filter and sample gas line, e. g. by drawing
outside air from the sampling probe.
2 Purge the gas paths of the analyzer system for 30 minutes.
3 Turn off the analyzer system with main switch -Q10.

Disposing of Reagents Empty the (optional) reagent supply bottle and dispose of reagents according to
applicable regulations.

Emptying the Conden- Empty the condensate collecting bottle and dispose of condensates according to
sate Collecting Bottle applicable regulations.

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

Transportation Step Action

Restraints Activation Sample Gas Feed Unit SCC-F: Diaphragm Pumps Transportation Restraints:
1 Using a Ph2 crosshead screwdriver, screw two M6x25 screws through the
holes in the base plate into the diaphragm pumps base plate and tighten
them.
Sample Gas Cooler SCC-C: Compressor Transportation Restraints:
2 Using an offset Ph2 crosshead screwdriver, turn the two screws clockwise
through the holes in the base plate to the point at which the compressor
housing is in contact with the base plate (noticeable resistance).

Ambient Temperature During storage and transport: +2 to +60 °C

After draining and drying parts in contact with condensate: –25 to +60 °C

CI/ACX-EN Rev. D ACX Analyzer System Commissioning Instruction 85

Packing the Analyzer Cabinet or System Components

Packing Step Action

It is strongly recommended that the analyzer cabinet / mounting
plate / electrical distribution cabinet are
• transported by a specialist firm and
• transported in a horizontal position
1 Vacuum-pack the analyzer cabinet / mounting plate / electrical distribu-
tion cabinet in foil.
2 Put desiccating agent in the transport crate. The amount of desiccating
agent should be sufficient for the package volume and the expected
shipping duration (at least 3 months).
3 Place the analyzer cabinet / mounting plate / electrical distribution cabinet
on vibration dampers in the transport crate and fix with wedges.
4 Mark the transport crate according to the regulations (in particular,
“Fragile Goods”).

Ambient Temperature During storage and transport: +2 to +60 °C

After draining and drying parts in contact with condensate: –25 to +60 °C

86 ACX Analyzer System Commissioning Instruction CI/ACX-EN Rev. D

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Stierstädter Str. 5
60488 Frankfurt am Main
Germany
Tel: +49 69 7930-4666
Email: cga@de.abb.com

abb.com/analytical

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We reserve the right to make technical changes or modify the contents of this document
CI/ACX-EN Rev. D 02.2020

without prior notice. With regard to purchase orders, the agreed particulars shall prevail.
ABB does not accept any responsibility whatsoever for potential errors or possible lack of
information in this document.

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.

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