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CEMS START UP

ADVANCE OPTIMA AO2000 SERIES (LIMAS-11 UV, MAGNOS-206 &


URAS26):
1) Installation Check
Check that the gas analyzer has been correctly installed before the Starting it
up.
Test
Is the gas analyzer securely fastened (see operator manual 42-24-10-10-EN
page #62 for detail)?
Are all gas lines including that of the pressure sensor correctly connected
(see operator manual 42-24-10-10-EN page #63 for details)?
Have all the signal, control and interface lines, the power supply lines and, if
applicable, the system bus been correctly laid and connected (See operator
manual 42-24-10-10-EN page 90)?
Are all devices needed for gas conditioning, calibration and waste Gas
disposal correctly connected and ready for use?
2) Gas Path and Housing Initial Purge
Purge before Commissioning
The gas paths and if necessary, the system housing should be purged prior to
starting the gas analyzer.
Firstly this ensures that the gas paths and system housing are free from
Contaminants e.g. corrosive gases, and accumulations of dust on startup.
Secondly this prevents any explosive gas/air mixture present in the gas paths
or system housing being ignited when the power supply is connected.
Purge gas
Nitrogen or instrument air should be used as a purge gas.
Purge Gas Flow Rate during Initial Purge:
Please refer page #108.
3) Power Supply Activation
NOTE:
The gas analyzer may not be calibrated until the warm-up phase has
been concluded.
Power Supply Activation
Turn on the power supply of the gas analyzer with the external breaker
switch.

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If necessary, turn on the separate 24-VDC power supply of the


analyzer module.
The following events will occur after the power supply is turned on.
A. The three "Power", "Maint" and "Error" LEDs light up.
B. The different booting phases are displayed on the screen. Also
the software version is displayed.
C. After a brief time the screen switches to measurement mode.
D. The soft key on the screen. This indicates the possibility of a
temperature or flow problem during the warm-up phase. By
pressing the soft key the user can recall the status message
summary and view status message.
4) Warm up Phase:
The duration of the warm-up phase depends on which analyzer module is
installed in the gas analyzer.
Analyzer Module
LIMAS-11
Magnos-206
URAS-26

Duration of warm up phase


Approx 2.5 hours.
Approx 1 Hour
Approx 0.5/2 hours
without/with thermostat

Remarks

Notes
The warm-up phase can take longer if the gas analyzer was not brought to
room.
During the warm-up phase measurement values can be outside the ranges
specified in the data sheet.
Warm-Up Phase Duration
The warm-up phase is deemed to be over when the measured value drift
indication is acceptable.
This depends on the size of the measurement range.
5) Operation
Ready to Perform Measurements
At the end of the warm-up phase the gas analyzer is ready to carry out
measurements.
Verify the calibration
The gas analyzer is calibrated ex works. However, transport stresses and the
pressure and temperature conditions at the installation site may influence the
calibration. Thus it is recommended to verify the gas analyzer calibration at
the installation location.

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Turn on the sample gas supply


The sample gas supply should be turned on only after calibration.
Adjusting Sample Gas Flow Rate
Please refer approved sample conditioning systems drawings for calibration
pressure, flow rates and sample pressure and flow rates.
Operating Specification:
Please refer the operator manual (42-24-10-10-EN page# 336) operating
specifications for LIMAS-11, MAGNOS-206 & URAS-26.

Menu Tree

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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 gas analyzer.
Password Level:
User Group
Every User
Maintenance team
Specialist team
Function block specialist

Access to password
levels
0
0, 1
0, 1, 2
0, 1, 2, 3

Password
None
471100
081500
325465

6) Calibration:
Gas Analyzer Calibration
Gas Analyzer Manual Calibration
NOTE
A manual zero point calibration must always be carried out before a
manual end-point calibration.
Gas Analyzer Manual Calibration
1. Select the Manual Calibration menu: MENU > Calibrate Manual
>Calibration.
2. For Single Calibration: Select Component and Measurement Range.
Zero calibration:
3. Select Zero Gas.
4. Turn on the zero gas supply.
5. If necessary, change the test gas concentration1 shown, ENTER.
6. When the sample value indication stabilizes, initiate zero calibration with
ENTER.
7. Accept the calibration result with ENTER
or REPEAT2 calibration (back to step 5)
or reject calibration with Back (back to step 6)
or reject calibration with Meas (back to measurement value
readout).
Span Calibration:
8. Select Span Gas.
9. Turn on the span gas.
10. If necessary, change the test gas concentration3 shown, ENTER.
11. When the sample value indication stabilizes, initiate span calibration with
ENTER.
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12. Accept the calibration result with ENTER


or REPEAT4 calibration (back to step 10)
or reject calibration with Back (back to step 11)
or reject calibration with Meas (back to measurement value
readout).
13. For single calibration, repeat steps 2-12 for other components and
measurement ranges.

Shut down CEMS Analyzers


1) Gas Analyzer Shutdown
In the case of a temporary shutdown:
1 Turn off the sample gas supply and reference gas supply, if applicable.
2 Purge the gas lines and gas feed paths in the analyzer module with dry
fresh air or nitrogen for at least 5 minutes.
Limas11 HW: Purge sample gas feed path gas lines and gas feed
paths in the analyzer module with at least with clean and dust-free
air for at least 1 hour.
3 Switch off the gas analyzer power supply.
In the case of a long-term shutdown, carry out the following in
addition:
4 Remove the gas lines from the gas analyzer ports. Tightly seal the gas
ports.
5 Disconnect the electrical leads from the gas analyzer.

Cooler & Feeding Unit Startup (SCC-C & SCC-F):


SCC-F: Start Up:
CAUTION!
Before activating the power supply check once again that the operating
voltage setting (see rating plate) matches the line voltage.
The sample gas flow should only be started after the lead time period.
1) Power Supply Activation
Activate the power supply using the externally installed breaker or the
switched outlet.
The diaphragm pumps and the dosing pump (and where applicable the
hose pumps in the sample gas cooler) start running.
Lead Time

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The lead time for the sample gas feed unit is approx. 10 minutes.
However, the lead time of the connected sample gas cooler is of
greater importance. In the case of the SCC-C sample gas cooler the
lead time is approx. 15 minutes.
Status Signals
The flow alarms are present during the lead time. The condensate alarms
may also be present.
Readiness
At the end of the lead time period the sample gas feed unit is ready for
operation.
2) Switch On Sample Gas:
The sample gas must not be switched on until the sample gas coolers lead
time has finished, i.e. until the sample gas outlet temperature lies within
the limit values set in the factory.
Set Sample Gas Flow
Set the sample gas flow using the appropriate needle valve.
CAUTION!
The needle valves must never be closed completely.

SCC-F: Shut Down:


CAUTION!
Before the sample gas feed unit is shut down it must be purged to
prevent the accumulation of condensate and deposits.
1) Step Action
Disconnect the power supply.
Shut off the sample gas supply to the sample gas feed unit.
Remove the gas pipes from the connections on the sample gas feed
unit.
Thoroughly purge the sample gas feed unit gas paths with an inert gas.
Fully tighten the gas connections.
Remove the electrical cables from the sample gas feed unit
connections.
Note:
Make sure the sample gas feed unit is free of residual moisture that
can freeze if low temperatures are encountered during shipping
and storage.
Ambient temperature for storage and transportation: 25 to +60 C.
Please refer SCC-F operator manual for more details.

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SCC-C: Start Up:


Warning:
The sample gas cooler must stand in operating position for about 24 hours
prior to commissioning.
Before activating the power supply check once again that the operating
voltage setting (see rating plate) matches the line voltage.
The sample gas flow should only be started after the lead time period.
1) Power Supply Activation
Activate the power supply using the externally installed breaker or the
switched outlet.
The peristaltic pumps start to run (counter clockwise).
Lead Time
The lead time is approx 15 minutes. This allows the sample gas outlet
temperature of +3 deg c, which is set in the factory, to be reached.
Status Signal:
During the lead time the monitor will output the temperature alarm
signal.
Readiness:
At the end of the lead time period the sample gas cooler is ready for
operation.
Sample gas supply:
The sample gas must not be switched on until the sample gas outlet
temperature lies within the limit values set in the factory, i.e when it has
fallen below +6dec C.

SCC-C Shutdown:
Disconnect the sample gas cooler power supply.
Shut off the sample gas supply to the sample gas cooler.
Loosen the sample gas and condensate lines from the sample gas
cooler ports.
Note: The condensate that accumulates is often acidic. Neutralize
the condensate if necessary and comply with regulations on
disposal.
Thoroughly purge the gas cooler paths with an inert gas.
Fully tighten the gas connections.
Remove the electrical lines from the connectors.
Note:
Please refer SCC-C operator manual for more details.

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Multiwave analyzer
PIR3502 NDIR Analyzer:
Start up
Y Purge
The Y Purge provides a constant, clean, dry air flow through the
enclosures. Y Purge allows the analyzer to operate in a Division I area.
Loss of Y Purge air pressure causes an alarm display on the LCD, but
there is no interruption of analyzer power.
Optical Purge
On the bottom of the Source Enclosure (see Figure 2-1), at the Optical
Purge connection, there is a 1/4-18 NPT-F fitting for connecting an ISA
Grade Air, Nitrogen, or other inert gas supply line (purge supply is
application-specific). Set the supply regulator so the outlet gauge displays
15-30 psig. Set the Optical Purge regulator on the floor inside the Source
Enclosure so the Optical Purge gauge on the front panel displays 8 psig.
Start purge flow and leak check all connections along the purge flow path.
Start Up
After all supplies have been connected, all connections have been tested
and verified, and purge flow continues, turn On the power switch on the
power supply line to the analyzer. If the analyzer has X Purge, the X Purge
must complete its timed cycle before the analyzer will receive power.
Allow at least 30 minutes for the analyzer to heat to operating temperature.
During this time, clear alarms and warnings as they display. When the
sample cell and casting reach their specified temperatures, those alarms
discontinue automatically.
Verify 4 to 20 mA output connections and devices. Now the Analyzer can
be calibrated.

MANUAL CALIBRATION PROCEDURE


The Analyzer is calibrated at the factory, using zero and span samples
specified by the application.
During installation it is vital that the customer calibrate the Analyzer with
local zero and span samples, using the zero and span information in the
Data Package for comparison. Below Steps provides a quick reference
procedure for manual calibration.

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1) Program zero and span sample concentrations in the factory set-up


tables.
2) Go to CALIBRATE/BENCHMARK mode.
3) Zero analyzer.
4) Span analyzer.
Note:
Always calibrate zero first, then calibrate span.
Verify Zero and Span Calibration Concentration Settings
Before calibrating the analyzer, verify the zero and span settings in the
analyzer with the Data Package. If the local zero and span calibration
supplies do not match the analyzer or the Data Package, the Set-up
Tables must be modified to match the local calibration samples.
Select SET-UP TABLES on the front panel of the Detector Enclosure.
Press MODIFY SET-UP (F2), then COMPONENT (F1), then
CALIBRATION (F2), then ZERO (F2).
To change the zero concentration number press the appropriate soft keys.
Soft key F2 moves the cursor to the left, soft key F3 moves the cursor to
the right; the up arrow increases the number above the cursor, and the
down arrow decreases the number above the cursor.
After the correct concentration has been set, press ACCEPT (F1) and
NEXT COMP. (soft key under F1), or ACCEPT (F1) and then EXIT (F4) if
no other component concentrations need to be changed.
For Span changes, follow the same procedure except select SPAN (F3)
instead of ZERO (F2).
Manual Zero (Single Component Applications)
Verify zero and span calibration concentration settings (see "Verify Zero
and Span Calibration Concentration Settings").
Select DISPLAY CONCENTRATION on the front panel of the Detector
Enclosure.
Actuate the Zero Selection Valve on the sample handling system to pass
the zero sample through the sample cell. Zero calibration is always
performed before span calibration.
Allow time for the analyzer to stabilize as indicated by the sample
concentration reading on the front panel display.
When the analyzer is stabilized, use the MODE SELECTION key to move
to CALIBRATE/ BENCHMARK.
Select MANUAL CALIBRATION (F4) and then ZERO (F1).
When the SAMPLE CONCENTRATION reading remains constant, press
ACCEPT (F3) and then EXIT (F4).
Return the Zero Selection Valve to its original position.
Note

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Zero Calibration readings must be accepted or the analyzer will


revert to the previous setting and analysis results may be
inaccurate.
It is good practice always to record zero and span readings before
calibration, then record the calibration readings, the date performed,
and any changes that may result. Zero calibration should be
performed more often than span. How often zero is performed
depends on the application. Always compare zero calibration
readings with the last recorded zero calibration. If there is a
significant difference please refer operator manual for
troubleshooting.
Manual Span (Single Component Applications)
Note:
Zero calibration is always performed before span calibration.
Verify zero and span calibration concentration settings (see "Verify Zero
and Span Calibration Concentration Settings").
Actuate the Span Selection Valve on the sample handling system to pass
the span gas through the sample cell.
Select SPAN (F2).
When the SAMPLE CONCENTRATION reading remains constant, press
ACCEPT (F3) and then EXIT (F4).
Return DISPLAY CONCENTRATION to the front panel of the Detector
enclosure.
Return the Span Selection Valve to its original position.
Open the Sample Valve to allow sample flow.
Note:
Span Calibration readings must be accepted, or the analyzer will
revert to the previous setting and analysis results may be
inaccurate.
Hot Start up:
First purge the optical path with 99.999% pure laboratory grade nitrogen, the
pressure should be set to 8 PSI as per data sheet.
Make sure that you have removed the black caps on the 1/16 - inch vents
near the sample cell.
In this condition leave the analyzer for purging at least 24 hours over night,
else on power up you may blow up the source due to moisture.
Check the power supply to the analyzer L-N = 120 VAC, N-G 0 VAC, L - G
120 VAC
Power ON the analyzer. Check all parameter settings and make sure that they
are as per data sheet.
Check the power supply voltages are OK.
Make sure that the casting and sample cell temperature reaches the set point
and is controlled.

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Make sure that the sample system is perfect, no leaks and apply zero gases
after analyzer has warmed up for at least 2 hours.
Check zero, before adjusting note the absorbance and detector voltages.
Make a note of the zero and compare with data sheet.
Do not calibrate.
Apply span gas and again note down the absorbance and detector voltages.
Make a note of the response factor as well.
Calibrate zero and note the zero absorbance value and detector voltages.
Calibrate span and note the new response factor and absorbance value and
filter values.
Line up the process sample and sample pressure and flow as per SCS
drawings and note down the absorbance and detector voltages.
Shutdown
The Analyzer does not have an On/Off button or switch, nor are there start
and stop commands. To stop the analyzer, simply remove power. It is not
necessary to stop purge or sample flows before removing analyzer power.
To shut down the analyzer in an orderly fashion:
Turn off the sample flow at the Sample Inlet Valve.
Depending on the analyzer configuration and the reason for stopping the
analysis, it may or may not be necessary to stop the optical or enclosure
purge flows; verify analyzer configuration with the analyzer identification
tag on the side of the Detector Enclosure, or with the Data Package.
See Section 4 for information on the X Purge Override operation, if
applicable.
Purge the sample cell with zero sample, or a non-hazardous sample if
necessary; turn off the zero flow at the Zero Inlet Valve.
Drain the sample cell.
Shut Off the power to the analyzer at the power supply circuit breaker.
Depending on the reason for stopping the analysis, shut off the other
supplies as appropriate.
Note:
Please refer PIR3502 MW operator manual for more details.

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