HM 1400 TRX Total Mercury Analyser - Webshop, Gas Analysis ...

Translation of original operating instructionsDocument:man_hm1400trx_en.docxHM 1400 TRX Total Mercury AnalyserVersion: 04.03.2011 previous Version:Last update: 06.04.2011Print date: 06.04.2011Rev. 17,16.02.2011Order No.: 702 241VerewaUmwelt- und Prozessmesstechnik GmbH Telefon: +49 (40) 55 42 18 – 0Kollaustraße 105 Fax : +49 (40) 58 41 5422453 Hamburg E-Mail: verewa@durag.deInternet: www.verewa.deThis documentation• (approx. 108 pages) has been compiled with the greatest care.• is not intended for the US American market. Documentation in accordance with ANSI Z535standard can be requested. Reference addresses can be found on page 88.• or parts of it may not be duplicated, transmitted or translated into other languages,independent of which way and through which means this happens, electronically ormechanically, without the explicit permission of DURAG GmbH.• refers to the complete equipment in principle, even if individual program modules or devices(device parts) have not been purchased• refers to the current status of the equipment design at the time of updating thisdocumentation (see above).• can be changed without notice with regard to content.© Verewa Umwelt- und Prozessmesstechnik GmbH 2011All rights reserved.

Table of contentsTable of contents0 Foreword .................................................................................................................... 71 General ..................................................................................................................... 111.1 Information on the operating instructions .................................................................. 111.2 Explanation of symbols ............................................................................................. 121.3 Limitation of liability ................................................................................................... 131.4 Warranty information ................................................................................................. 131.5 Customer service ...................................................................................................... 131.6 Copyright .................................................................................................................. 132 Safety ....................................................................................................................... 172.1 Meaning of the warnings and instructions used ......................................................... 172.2 Responsibility of the operating company ................................................................... 182.3 Personal protective equipment .................................................................................. 192.4 General safety instructions ........................................................................................ 202.5 Hazards due to electrical equipment ......................................................................... 212.6 Hazard from hot, aggressive, explosive gases or high measuring gas pressure ....... 212.7 Hazard from chemicals ............................................................................................. 222.8 Hazard from hot components .................................................................................... 222.9 Designated use ......................................................................................................... 232.10 Personnel ................................................................................................................. 232.10.1 Personnel, qualification ............................................................................................. 232.10.2 Unauthorised personnel ............................................................................................ 242.11 Avoidance of consequential damage in the event of a system fault ........................... 242.12 Behaviour in case of hazards and accidents ............................................................. 252.13 Description and location of safety equipment and emergency stop mechanisms ...... 253 HM 1400 TRX Introduction ........................................................................................ 293.1 General ..................................................................................................................... 293.2 Scope of supply of the standard measuring device ................................................... 293.3 Options ..................................................................................................................... 294 Theoretical foundations ............................................................................................. 334.1 Operating principle and mode of operation of the subassemblies ............................. 334.2 The thermocatalytic reduction ................................................................................... 334.3 The UV photometer ................................................................................................... 344.4 Cleaning the photometer ........................................................................................... 354.5 Volume control and system pressure measurement .................................................. 364.6 The thermocatalytic reactor ....................................................................................... 374.7 Gas drying ................................................................................................................ 374.8 Other electronics, control and measuring value calculation ....................................... 385 Installation................................................................................................................. 435.1 Device check ............................................................................................................ 435.2 Device site ................................................................................................................ 435.3 Place of installation of the sampling probe ................................................................ 435.4 Connections .............................................................................................................. 435.4.1 Sampling probe and sampling line ............................................................................ 435.4.2 Power supply (preferably 230 V - 3/N/PE) ................................................................. 445.4.3 Measuring and operating data recording ................................................................... 445.4.4 Exhaust gas .............................................................................................................. 44HM 1400 TRX 3

Table of contents5.4.5 Condensate .............................................................................................................. 446 Operation .................................................................................................................. 476.1 Commissioning with default parameters .................................................................... 476.2 Standby phase .......................................................................................................... 476.3 Measuring mode ....................................................................................................... 487 Operation .................................................................................................................. 517.1 The terminal: ............................................................................................................. 517.2 The Main menu ......................................................................................................... 537.3 Zero offset (manual).................................................................................................. 617.4 Zero offset (automatic) .............................................................................................. 627.5 Calibration (option).................................................................................................... 637.6 Commissioning (manually):....................................................................................... 648 Measuring device check (option)............................................................................... 698.1 Calibration check procedure ..................................................................................... 698.2 Factors influencing the calibration point .................................................................... 698.3 Calculation principle for calibration ............................................................................ 708.4 Checking procedure .................................................................................................. 719 Appendix: Technical data .......................................................................................... 7510 Appendix:Device parameters in delivery status ......................................................... 7611 Appendix:Maintenance ............................................................................................. 7811.1 Appendix: Overview .................................................................................................. 7811.2 Appendix: Service schedule ...................................................................................... 7812 Appendix: Error messages and their elimination ....................................................... 8112.1 Appendix: Monitored parameters and error messages in plain text ........................... 8112.2 Appendix: Error causes and their elimination ............................................................ 8213 Order numbers for replacement and wearing parts ................................................... 8614 Appendix Extracts from safety data sheets ............................................................... 8914.1 Extract from safety data sheet for potassium hydroxide biscuit ................................. 9014.2 Extract from safety data sheet for iodised activated carbon ...................................... 9214.3 Extract from safety data sheet foractivated carbon .................................................... 9314.4 Extract from safety data sheet for mercury ................................................................ 9414.5 Extract from safety data sheet for hydrochloric acid .................................................. 9714.6 Extract from safety data sheet for mercurous (II) chloride ......................................... 9914.7 Extract from safety data sheet for Tin (II) chloride 2xH2O ....................................... 10115 Index ....................................................................................................................... 10416 DURAG GROUP company addresses .................................................................... 107Index of illustrationsFigure 4.1: Schematic diagram HM 1400 TRX .................................................................... 33Figure 4.2: Operating principle of the thermocatalytic reduction .......................................... 34Figure 4.3: Schematic drawing of the gas flow through the Hg photometer ......................... 35Figure 4.4: Volume control and system pressure measurement .......................................... 36Figure 4.5: The thermocatalytic reactor ............................................................................... 37Figure 4.6: Function level of cooler and gas conditioning .................................................... 384 HM 1400 TRX

Table of contentsFigure 7.1 Terminal ............................................................................................................ 51Figure 7.2 The Main menu I ............................................................................................... 53Figure 7.3 The Main menu II .............................................................................................. 55Figure 7.4 The Main menu III ............................................................................................. 56Figure 7.5 The Main menu IV ............................................................................................. 59Figure 7.6 The zero offset determination started manually ................................................. 61Figure 7.7 The zero offset determination automatic ........................................................... 62Figure 7.8 Calibration ......................................................................................................... 63Figure 7.9 Operating statuses ............................................................................................ 64Figure 8.1: Functional principle of wet chemical Hg 0 generator for device calibration .......... 72Index of formula and tablesFormula 1. Calibration point CP = f(C, FR, VF, F) .............................................................. 70Formula 2: Correction value F = f(T, p) ............................................................................... 70Table 2.1: Specific safety symbols ...................................................................................... 18Table 6.1 Commissioning................................................................................................... 47Table 6.2 Standby phase ................................................................................................... 47Table 7.1 Key functions ..................................................................................................... 52Table 8.1 Formulas (Abbreviations) ................................................................................... 70Table 9.1: Technical data .................................................................................................... 75Table 10.1: Device parameters in delivery status ................................................................ 77Table 11.1: Calibration intervals, maintenance effort........................................................... 78Table 13.1: Spare part list ................................................................................................... 88Table 14.1: Dangerous substances in the various device components ............................... 89HM 1400 TRX 5

0. Foreword0 ForewordThe purpose of this manual is to help you to become acquainted with yourVerewa product.In this publication you will find information and technical data on planning,installation / commissioning, operation and maintenance of theHM 1400 TRX.This information is completed by the functional diagram for both thecomplete system and the equipment components, as well as a spare partslist.Our aim is to make a decisive contribution to your success with our productsand services. We hope that the information provided here will enable us todo so.Should you have any further questions on products or applications from theDURAG GROUP, please use our Support & Service!You will find the relevant addresses and telephone numbers on page 107(DURAG GROUP company addresses).Further information is also available from www.verewa.dePlease read through the following information carefully! It is important foryour safety and for preventing damage to the HM 1400 TRX and to theenvironment.HM 1400 TRX 7

HM 1400 TRXTotal Mercury Analyser011 General1.1 Information on the operating instructions1.2 Explanation of symbols1.3 Limitation of liability1.4 Warranty information1.5 Customer service1.6 Copyright

1. General1 GeneralWe hope that our products and services will make a significant contribution toyour success. We will be delighted if the information provided achieves this.Should you require information that is insufficiently covered in this document,please request further information from the respective agent of VerewaUmwelt- und Prozessmesstechnik GmbH. Our Support & Service department isalso available to answer any questions on Verewa products and services. Youwill find the addresses and telephone numbers on page 107).Information on the company and its products can also be found on theInternet at www.verewa.de1.1 Information on the operating instructionsThese operating instructions provide important information on how to use theTotal Mercury Analyser HM 1400 TRX. Compliance with all specified safetyinstructions and guidelines for behaviour is a prerequisite for safe working.In addition, the applicable local accident prevention regulations and generalhealth and safety rules must be adhered to for the Total Mercury Analyserand its application.Before starting any work, read the operating instructions!In particular, read chapter Safety and the relevant safety instructions in full.The operating instructions form part of the product and must be stored in theimmediate vicinity of the Total Mercury Analyser HM 1400 TRX where they canbe accessed by personnel at all times.For logistical reasons a version on CD and separate order or delivery is alsoprovided.This documentation(approx. 110 pages) has been compiled with the greatest care.is not intended for the US American market. Documentation in accordancewith ANSI Z535 standard can be requested. Reference addresses can befound on page 90.or parts of it may not be duplicated, transmitted or translated into otherlanguages, independent of which way and through which means thishappens, electronically or mechanically, without the explicit permission ofDURAG GmbH.refers to the complete equipment in principle, even if individual programmodules or devices (device parts) have not been purchasedrefers to the current status of the equipment design at the time of updatingthis documentation (see above).can be changed without notice with regard to content.© Verewa Umwelt- und Prozessmesstechnik GmbH 2011All rights reserved.HM 1400 TRX 11

1. General1.2 Explanation of symbolsWarning noticesDANGER!In order to make the text in this manual clear, text elements such as safetyinstructions, warnings, tips, keyboard symbols, menu addresses etc. aredisplayed differently.Warning notices are represented by symbols in these operating instructions.The notices are introduced by signal words, which express the extent of thehazard.Comply with these notices and act with care to prevent accidents, injury anddamage.... refers to an immediate hazardous situation, which will result in death orserious injury if not prevented.Tips and recommendationsAn instruction or tip is shown as follows:... highlights useful tips and recommendations, as well as information aimedat ensuring efficient and fault-free operation.Other symbols usedF1If a button is pressed on the measuring unit, it is shown like this:Function key F1 (Home) is used to select the standard operating screen(display of current concentration).Step by step instructions are indicated by the symbol shown. Make sure thatall steps are carried out in the specified sequence. This includes the stepsthat involve your safety (e.g. wear protective goggles)• A (→) indicates that the following term is explained in the glossary.×A in a list indicates that something must not be done or that somethingis not suitable• Unless otherwise specified: all dimensions are in mm• This manual is also available as a pdf file on CD/DVD.12 HM 1400 TRX

1. General1.3 Limitation of liabilityAll information and instructions in this manual have been compiled on thebasis of the applicable standards and regulations, current technology andmany years of knowledge and experience.The manufacturer accepts no liability for damages arising from:• Failure to adhere to the operating instructions• Incorrect use• Employment of untrained personnel• Unauthorised modifications• Technical changes• Use of unapproved spare parts• Use of defective and/or improperly repaired devicesFurthermore, the obligations agreed in the contract of sale, the generalconditions of business ("Conditions of supply for goods and services in theelectrical industry" (ZVEI)) and the manufacturer's Conditions of Supply,together with the statutory regulations in force at the date of signing thecontract are all applicable.1.4 Warranty informationThe terms of the warranty can be found as a separate document in theGeneral Terms and Conditions of Business.Modifications and changes to the Total Mercury Analyser are not permitted.Any work on the device voids the warranty.Fault-free and safe operation of the device depends on appropriatetransportation, correct storage, installation and assembly as well as carefuloperation.1.5 Customer serviceOur Service department is available to provide technical information.Details of relevant offices or partners is available on the Internet at any time,see manufacturer's address on page 2, or DURAG GROUP companyaddresses, see page 107.1.6 CopyrightThis manual must be treated confidentially. It is intended exclusively forpersonnel employed to use the Total Mercury Analyser. Passing on thismanual to third parties without the written consent of the manufacturer is notpermitted.The operating instructions, or sections thereof, may not be reproduced,disseminated or translated into other languages without the written consentof the manufacturer, regardless of the form in which this this is done and themedia - electronic or mechanical - involved.HM 1400 TRX 13

1. General© Verewa Umwelt- und Prozessmesstechnik GmbH 2011. Alle Rechtevorbehalten.The specifications, texts, drawings, pictures and other information containedin this document are protected by copyright and subject to industrial propertyrights. Any improper use is punishable by law.14 HM 1400 TRX

HM 1400 TRXTotal Mercury Analyser022 Safety2.1 Meaning of the warnings and instructions used2.2 Responsibility of the operating company2.3 Personal protective equipment2.4 General safety instructions2.5 Hazards due to electrical equipment2.6 Hazard from hot, aggressive, explosive gases or high measuring gas pressure2.7 Hazard from chemicals2.8 Hazard from hot components2.9 Designated use2.10 Personnel2.11 Avoidance of consequential damage in the event of a system fault2.12 Behaviour in case of hazards and accidents2.13 Description and location of safety equipment and emergency stop mechanisms

2. Safety2 SafetyBefore starting any work, read the operating instructions (the manual)!Observe the following warning notices and safety instructions provided in thismanual. They are there to help avoid hazards that could endanger life orcause injury to personnel, and for avoidance of damage to property. They arealso intended to ensure safe and fault-free operation.2.1 Meaning of the warnings and instructions usedApart from the warning notices and safety instructions, the following generalinstructions and associated pictograms are used to draw particularly importantinformation to your attention:Warning noticesDANGER!... refers to an immediate hazardous situation, which will result in death orserious injury if not prevented.WARNING!... refers to a possible hazardous situation, which may result in death orserious injury if not prevented.CAUTION!... refers to a possible hazardous situation, which may result in slight or minorinjury if not prevented.ATTENTION!... refers to a possible hazardous situation, which may result in damage toequipment and the environment if not prevented.Specific safety instructionsIn order to specify the potential risk the general warning sign can also bereplaced by a special warning sign. To draw attention to specific hazards,warning notices and signal words are used in conjunction with the followingsymbols:HM 1400 TRX 17

2. SafetyGeneral warning symbolElectric powerHazardous to theenvironmentChemical burnHot surfaceToxicElectrostaticdevices (ESD)sensitiveTable 2.1: Specific safety symbolsOther symbols usedApart from the warning and safety instructions, the following generalinstructions and associated pictograms are used to draw particularly importantinformation to your attention:Here you will find interesting information or tips on the product and its use.Step by step instructions are indicated by the symbol shown. Make sure thatall steps are carried out in the specified sequence. This includes the stepsthat involve your safety. (e.g. wear protective goggles)Contains information on environmental protectionBefore starting any work, read the operating instructions!2.2 Responsibility of the operating companyThe Total Mercury Analyser is intended for use in commercial operations. Theoperating company of the Total Mercury Analyser is therefore subject to thestatutory health and safety obligations, along with the applicable directives,legislation and standards.In addition to the health and safety instructions contained in these operatinginstructions, the safety regulations, accident prevention regulations and18 HM 1400 TRX

2. Safetyenvironmental protection regulations for the application in which the TotalMercury Analyser is used must be complied with. These specifically include:• The operating company must obtain information about the applicablehealth and safety regulations and perform a risk assessment todetermine any additional hazards that arise due to the special workingconditions at the place of use of the Total Mercury Analyser. He mustconvert these into operating instructions for the operation of the TotalMercury Analyser.• Throughout the period of use of the Total Mercury Analyser, theoperating company must check whether the operating instructions thathe has written satisfy the latest issue of the regulations, and mustupdate them as required.• The operating company must clearly regulate and specify who hasresponsibility for installation, operation, maintenance and cleaning.• The operating company must ensure that all employees who deal withthe Total Mercury Analyser have read and understood the operatinginstructions. In addition, at regular intervals he must train the personneland inform them about the hazards.• Furthermore the operating company is responsible for ensuring that theTotal Mercury Analyser is in a technically fault-free condition at all times,i.e. that the maintenance work has been performed (see section 11).• The operating company must provide the necessary protectiveequipment for the personnel.2.3 Personal protective equipmentDuring work, it may be necessary to wear personal protective equipment tominimise health hazards.Detailed specifications must be set out by the operator depending on thepotential plant-specific hazards.• The protective equipment necessary for the relevant work must be wornat all times.• Do not wear any rings, chains or other jewellery.• Observe any signs relating to personal protective equipment in theworking area.Protective work clothingis tight fitting work clothing with low tear strength, with narrow sleeves and noprotruding parts. It is primarily intended to protect against burns.Protective gogglesto protect the eyes against flying parts and splashed liquids.HM 1400 TRX 19

2. SafetySafety shoesto protect against heavy falling parts and prevent slipping on a slippery floorsurface.Face protectionto protect the eyes and the face against flames, sparks or embers and hotparticles or waste gases.Protective glovesto protect the hands against friction, abrasion, cuts or deeper wounds andcontact with hot surfaces.2.4 General safety instructionsThe Verewa Total Mercury Analyser HM 1400 TRX is designed and built usingstate of the art technology and complies with the recognised safetyregulations. Despite this, hazards can arise.Therefore operate the product only when it is in perfect condition, and observewith the operating instructions. Any change to normal performance should betaken as a serious indication of impaired functionality. In this regard, payattention to:• emission of smoke or unusual smells,• excessive temperatures of system components,• changes in power consumption without obvious cause,• tripping of monitoring devices,• Abnormal significant fluctuations or shifts in the measuring results.The following warning notices and safety instructions apply to the TotalMercury Analyser:• When preparing and performing work:Observe the legal requirements applicable for the system and thecorresponding technical regulations.• Work in accordance with:... the local, plant-specific conditions,... hazards caused by operational processes... specifications.• The operating instructions form part of the product and must be stored inthe immediate vicinity of the Total Mercury Analyser HM 1400 TRX wherethey can be accessed by personnel at all Ensure compliance with theinstructions set out for avoidance of hazards and damage.• Suitable protective devices and personal protective equipment must beavailable in sufficient quantities and used by the personnel inaccordance with the respective potential hazards.• The device may only be operated in perfect condition and in compliancewith the safety instructions!20 HM 1400 TRX

2. Safety• The device as an entity and also its individual components may be usedonly when in their original configuration.2.5 Hazards due to electrical equipmentThe personnel assigned to carry out installation, commissioning andmaintenance must be totally familiar with all potential hazards and repairmeasures as set out in this manual.WARNINGDanger from electrical equipmentDanger from electric shocksBefore removing the housing or accidental-contact protection, the equipmentmust be disconnected from the power supply.If it cannot be disconnected, protective equipment must be worn to ensure theprevention of electric shocks.• The devices may only be connected to the supply voltage shown on thetype plate.• The devices may only be operated on a power supply with an earthingcontact. The protective action must not be cancelled by an extensionwithout a protective earth conductor. Any interruption in the protectiveearth conductor inside or outside the device is dangerous and is notpermitted.• Cables should be laid so that risk of accident due to tripping or gettingcaught on the lines is excluded.ATTENTION!Damage to electronic components due toelectrostatic discharge (ESD)Electronic components are becoming increasingly small and complex. Theirsusceptibility to damage from electrostatic discharge is increasingaccordingly. To protect these components, measures to prevent electrostaticdischarge must be taken before starting any work on the opened device (ESDprotection).As a precaution against electrostatic discharge from the human body, serviceemployees should be equipped with a personal earthing system.2.6 Hazard from hot, aggressive, explosive gases or highmeasuring gas pressureWARNINGRisk of explosion due to explosive atmosphere!An explosive atmosphere can endanger the health and safety of personnel.Use of the total mercury analyser HM 1400 TRX in potentially explosive areasand measurement in and of explosive gas mixtures is not permitted.• The Total Mercury Analyser is connected to the exhaust gas channel bythe sampling probe and the measuring gas line. In the case of systemswith a low danger potential (ambient pressure, low temperatures, nohealth hazard), mounting/removal can occur during system operation. Theapplicable provisions and safety regulations for the system must becomplied with and any necessary and appropriate protective measures taken.HM 1400 TRX 21

2. Safety2.7 Hazard from chemicalsChemicals in principle give rise to particular dangers. Therefore, they mustalways be handled with the necessary care by appropriately trained personnel.WARNINGDanger of chemical burns and skin irritations!Caustic chemicals such as potassium hydroxide are used in theHM 1400 TRX to analyse the mercury concentration.The maintenance work comprises the replacement of these substances.Please comply with the information on the safety data sheets provided withthese chemicals.During analysis of the mercury concentration, the mercury contained in themeasuring gas is bound in the iodised activated carbon filter (betweenmeasuring and reference cuvette of the photometer) and therefore remains inthis filter.WARNINGRisk of poisoningAvoid heating the iodised activated carbon laden with mercury above 150 °C,in order to prevent evaporation and release of mercury.In the case of (elemental) mercury there is a risk of inhalatory absorptionthrough breathing in.Please also comply with the information provided in the mercury safety datasheet during these maintenance tasks.Used selective filter content (iodised activated carbon contaminated withmercury) replaced after 6 months within the scope of device maintenance, andcrystalline KOH (potassium hydroxide) from the pre-filter, must be handled,transported and disposed of under the measuring device operator'sresponsibility in accordance with the Ordinance on Hazardous Substances andthe safety data sheet. It should be noted that, in the case of iodised activatedcarbon laden with mercury, separate data sheets are available for iodisedactivated carbon and mercury. The same applies for disposal of thesesubstances.• Extracts from the relevant safety data sheets can be found in theAppendix to this manual! Persons handling these substances should befamiliar with the contents of these extracts. However, in all cases thecurrent editions of the safety data sheets obtained from the chemicalmanufacturer and enclosed with the delivery of the device, whichDURAG will gladly provide on request (the DURAG GROUP companyaddresses and telephone numbers can be found on page 107), aredefinitive.• All necessary and appropriate protective measures, as specified in thedata sheets, must be taken and implemented. Please observe the firstaidmeasures specified therein.2.8 Hazard from hot componentsSome of the components used in the HM 1400 TRX as well as the samplingprobe, sampling line, flange and flange connection may be or become hot.22 HM 1400 TRX

2. SafetyWARNINGRisk of burnsNever touch parts that could be hot without temperature-resistant safetygloves.Do not put any heat-sensitive material close to or in direct contact with hotcomponents.2.9 Designated use2.10 PersonnelThe Verewa HM 1400 TRX described in this manual is an innovativemeasuring device and is used for continuous mercury determination in fluegases (in accordance with the 17th BImSchV) of incineration plants, forexample in coal-fired power stations, cement plants and smelting plants, in thewood and chemical industry, waste incineration and dust filter plants. Themeasuring device can optionally be converted for process control purposes.The parameters specified in the Technical data from page 73, especially theambient conditions, must be complied with and observed.The HM 1400 TRX has been developed, manufactured, inspected anddocumented in compliance with the pertinent safety standards. If the handlingand safety instructions described for project planning, assembly, properoperation and maintenance are complied with, no dangers normally arise fromthe device in respect of damage to property or the health of people.Faultless and safe operation of this device also requires appropriate transport,correct storage, installation and assembly as well as careful operation andmaintenance by qualified personnel.2.10.1 Personnel, qualificationWARNING!Risk of injury due to inadequate qualifications!Improper use can lead to severe injury and damage.Any activities should only be performed by appropriately trained specialistpersonnel.The operator's personnel who are responsible for safety must ensure that workon DURAG equipment or systems is only carried out by qualified skilledpersonnel, whose competence has been checked by responsible experts.In the event of unqualified operations on the device or failure to comply withthe warnings provided in this manual or affixed to the device, physical injuriesand/or damage to property can occur.Qualified personnel for the purposes of the safety-related instructions in thismanual or for the product itself are individuals who can identify potentialdangers in good time and prevent them.The following knowledge is essential:• Precise knowledge of operation-related dangers (e.g. due to toxic, hot orpressurised gases, gas/liquid mixtures etc. as well as handling of thecaustic substances used by the HM 1400 TRX for measurement andcontaminated by these measurements).HM 1400 TRX 23

2. Safety• Knowledge of system conditions, pertinent standards, regulations andaccident prevention regulations.• Adequate knowledge of the HM 1400 TRX system, acquired throughappropriate training.On the basis of this training, qualified personnel are authorised by the personresponsible for the safety of people and system to carry out work on Verewaequipment or systems,• either as project planning personnel, are familiar with the safetyconcepts of automation technology,• as operating personnel, are instructed in handling automationtechnology equipment and are familiar with the contents of this manualrelating to operation,• as repair and/or service personnel, have training that qualifies them torepair such automation technology equipment or have authorisation tocommission, earth and identify circuits and devices/systems inaccordance with the safety-related standards. Personnel tasked withreplacing chemicals must possess knowledge relating to their handling,the associated dangers and the necessary protective measures.Such personnel are accredited as persons who can be expected to performtheir work reliably. Persons whose responsiveness is compromised bysubstances such as drugs, alcohol or medications will not be accredited. Whenselecting personnel, the local regulations regarding age and professionalqualifications should be complied with.To acquire specialist knowledge of the device, Verewa offers appropriatecourses.Information on these is available on the Internet on the Verewa homepage orby telephone. (For the manufacturer's address, see page 2).2.10.2 Unauthorised personnelWARNING!Hazard to unauthorised personnel!Unauthorised personnel who do not meet the requirements set out here are notfamiliar with the hazards in the working area. Incorrect behaviour can lead tosevere injury and damage.Therefore:• Ensure that unauthorised personnel do not enter the working area.• In case of doubt, approach personnel and instruct them to leave theworking area.• Stop all work if any unauthorised personnel are in the working area.2.11 Avoidance of consequential damage in the event of asystem faultIn order to prevent and limit faults that can directly or indirectly result inphysical injuries or damage to property, the operator must ensure that:• responsible maintenance personnel are available at short notice at anytime.• maintenance personnel have been trained to identify and rectify faults inthe HM 1400 TRX and the associated systems.24 HM 1400 TRX

2. Safety• defective system components can be switched off immediately.• switching off the device will not lead to unpredictable consequentialfaults and damage.2.12 Behaviour in case of hazards and accidentsPreventive measures• Always be prepared for accidents or fire. Note emergency numbers.• Store first aid equipment (first aid kit, blankets etc.) and fireextinguishers within easy reach.• Familiarise personnel with accident reporting, first aid and emergencyequipment.• Keep access routes for emergency vehicles clear.In case of emergency: Correct actions• Initiate first aid measures.• Rescue personnel from the hazard zone.• Notify the person responsible at the place of use.• Notify a doctor and/or the fire brigade.• Clear access routes for emergency vehicles.Emergency reporting - Doing it correctly!Dial the emergency number.Speak slowly, loudly and clearly and give clear information• Where did it happen? - Exact location information is required:• What happened? - Is it a fire, an explosion or an operational accident.Are any people trapped or buried?• How many people are injured?• What injuries do they have? - Is the patient responsive? Are there anybreathing or circulation problems? Is anyone bleeding heavily?• Wait for any queries.2.13 Description and location of safety equipment andemergency stop mechanismsThe operator must incorporate safety measures into the safety concept for theoverall system. This includes the description and location of safety equipmentand emergency stop mechanisms.HM 1400 TRX 25

HM 1400 TRXTotal Mercury Analyser033 HM 1400 TRX Introduction3.1 General3.2 Scope of supply of the standard measuring device3.3 Options

3. HM 1400 TRX Introduction3 HM 1400 TRX Introduction3.1 GeneralThe continuously operating total mercury analyser HM 1400 TRX wasdeveloped in the DURAG Group Hamburg in accordance with the GermanStandard Methods (DEV). The main field of application of the HM 1400 TRXtotal mercury measuring device is the monitoring of mercury concentrations influe gases of incineration plants in accordance with 17th BImSchV. Themeasuring device can optionally be converted for process control purposes.The control is undertaken by a modern PLC, and the ionic mercury is reducedvia a thermocatalytic stage. In addition, the sample gas is hot-filtered.The layout of the device description enables easy familiarisation with theoperation of the measuring device.In the event of queries, please do not hesitate to contact our salesrepresentatives or the staff in head office at any time. Detailed information onthe device technology and contacts is available at www.durag.de.3.2 Scope of supply of the standard measuring deviceThe scope of supply is defined after full technical clarification and agreed inwriting when the order is placed. This clarification refers particularly to thesampling system (sampling probe, type and length of measuring gas line, withor without back-purging) and the installation conditions (with or withoutmeasuring device cooling system, optional equipment).The basic configuration of the measuring device is defined with the suitabilitytest. Fundamental changes to this basic configuration are only permissible if asuitability approval for the measuring task is not required.The total mercury measuring device is installed in a 19" cabinet, so that allcomponents can be accessed from the front.3.3 OptionsIf you have ordered options for the standard device, the following parts mayalso be delivered:• Automatic test gas module HM AKM 10/20• Semi-automatic test gas module HM 1400 TR-81HM 1400 TRX 29

HM 1400 TRXTotal Mercury Analyser044 Theoretical foundations4.1 Operating principle and mode of operation of the subassemblies4.2 The thermocatalytic reduction4.3 The UV photometer4.4 Cleaning the photometer4.5 Volume control and system pressure measurement4.6 The thermocatalytic reactor4.7 Gas drying4.8 Other electronics, control and measuring value calculation

4. Theoretical foundations4 Theoretical foundations4.1 Operating principle and mode of operation of thesubassembliesFunctional principleProbe Sampling Line ThermocatalyticReactorChiller3-way ball valvePre-FilterSample Gas Pumpdhm1400tr_01_001UV-Photometer∆PPFlow MeterAbsolute Pressure MeterFigure 4.1: Schematic diagram HM 1400 TRXiodizedA-Coal FilterDuring total mercury analysis, in addition to the elemental metallic mercury allionic mercury compounds occurring in the flue gas are also measured. So thatthe detector can photometrically detect the mercury, all mercury flowing intothe measuring device must be converted into elemental, i.e. atomic mercury.This function is performed by the catalyst at a preset operating temperature.The measuring gas is dried with a compressor or Peltier cooler before thephotometric determination of the mercury concentration; the system pressureand the measuring gas temperature are recorded at each measuring point.The determined concentration is output as current signal 4...20 mA inaccordance with the set measuring range in µg/Nm³ (dry). The internal PLCperforms the measuring value calculation and monitoring of the devicefunctions. Dusts contained in the flue gas are collected on a heated sinteredmetal filter at approx. 180°C.4.2 The thermocatalytic reductionThe matrix of black dots (see Figure 4.2: Operating principle of thethermocatalytic reduction) symbolises the reactor material.Various chemical substances that are contained in the flue gas flow into thereactor. The gas components are displayed in colour as follows: colours red(elemental mercury Hg 0 ), orange (ionic mercury Hg n+ ), green (sulphur dioxideSO 2 ), blue (hydrochloric acid HCL and chlorine Cl 2 ) and turquoise (nitrogenoxides NO x ). This small selection of chemical substances serves only to clarifythe mode of operation of the reactor and could be supplemented by manyHM 1400 TRX 33

4. Theoretical foundationsother compounds. This representation is only intended to show how thereactor material deals with the various incoming compounds.The sampling gas brings all components occurring in the flue gas into contactwith the reactor material. The reactor material itself consists of a carbonsubstrate, whose surface is impregnated with carbonates and hydroxides. Ifthe temperature is set correctly the ionic mercury compounds are reduced toelemental mercury, while incoming elemental mercury passes through thereactor chemically unchanged. The acid components that are also contained inthe flue gas (e.g. SO 2 , HCl, Cl 2 , NO 2 ), on the other hand, are chemically fixedon the surface of the solid reactor material without influencing the reducingeffect of the reactor material. The reason for this behaviour is simple, as theacid components form the relevant salts with the hydroxides and carbonates -if the temperature is set correctly, the reactor material releases just as muchcarbon monoxide as is necessary to reduce ionic mercury to elementalmercury. As carbon monoxide is present as gas at the reaction temperature,the salt formation cannot affect this reaction. The reactor temperature is set insituduring commissioning. The temperature is regulated directly by the PLC.The optimal temperature range is between 270 °C and 300 °C.to detectorfrom stackdhg1400tr_03_001Colour legend: Reactor material NO xHg 0 HCl, Cl 2Hg N+ SO 2Figure 4.2: Operating principle of the thermocatalytic reductionThe gas/liquid mixture is then physically dried and analysed in the photometer.4.3 The UV photometerThe photometer is schematically represented in the following illustration. Thelamp distributes its light onto the measuring and reference cuvettes through aslit diaphragm. The photodiodes are matched and measure any weakening ofthe light intensity in both cuvettes in relation to each other. The weakening ofthe light comes about because the mercury atoms absorb photons of suitableenergy (light from wavelength 253.7 nm), and consequently individualelectrons in a higher energy state are lifted. After a very short dwell time < 10 -634 HM 1400 TRX

4. Theoretical foundationss these electrons fall back to the original basic state "in a step-by-step fashion"via several intermediate energy stages. The light released during this processis emitted undirected into space. The measured weakening in intensity is thenproportional to the mercury concentration, based on the Lambert-Beer law.slitdiaphragmreference cuvettelampiodinecharcoalfilterdhg1400tr_04_001measuring cuvettephotodiodesFigure 4.3: Schematic drawing of the gas flow through the Hg photometerThe arrows symbolise the gas flow through the photometer. The measuringgas enters the measuring cuvette, is then conveyed through a selective filterfor mercury, where it is adsorbed and then flows through the referencecuvette. The advantage of this cuvette circuit is that the entire gas matrix flowsthrough both the measuring cuvette and the reference cuvette, and themercury is filtered out largely selectively before the reference cuvette. Thisdifferential measurement principle means that, in comparison with the singlebeamphotometer, which only has one cuvette, the measurement is at least 10times less susceptible to spectrometric interfering components. For example,in the case of a single-beam photometer, from 50 mg/m³ SO 2, SO 2 is alsomeasured instead of Hg. A higher value, which does not actually exist, isultimately simulated for the mercury concentration. In extreme cases, arandom measuring value can be displayed for Hg due to SO 2 , although nomercury is actually present.In the cuvette circuit of the two-beam device, this cross-sensitivity only takeseffect from 500 mg/m³ SO 2 . From 500 mg/m³ SO 2 scrubbers are available,which eliminate the SO 2 . Reliable measurement is thus also guaranteed withSO 2 concentrations from 1.5 to 2 g/Nm³.The measuring signal from the photometer and the measuring signals from thepressure and temperature measurement after gas drying are sent to theinternal PLC. The mercury concentration is now calculated and the measuringresult is output in µg/Nm 3 (dry).4.4 Cleaning the photometerThe photometer is set to a measuring range of 0...500µg/m³ → 0...10 V outputvoltage. According to the basic setting, the display range is programmed to0...45 µg/Nm³ → 4... 20 mA output signal of the HM 1400 TRX. The remainingapprox. 455µg/m³ (measuring range reserve of the photometer) are madeavailable for the zero offset. On the side of the photometer there is apotentiometer, on which the zero offset can be adjusted. It must be ensuredthat a positive value is shown on the display of the HM 1400 TRX (basicsetting approx. 20...30 µg/Nm³). If the photometer is absolutely clean, then aHM 1400 TRX 35

4. Theoretical foundationsdisplay value of 0 µg/Nm³ will appear on the display when the potentiometer isin the central position. A shift of this symmetry towards positive values will notadversely affect the linearity of the measuring range. If the optics are so soiledby impurities that a display value of 300 µg/Nm³ or higher results at the lefthandstop of the potentiometer, then the photometer optics must be cleaned.Contact the Service department to clean the photometer.Information is available from the Verewa Service department.Information on the offices or partners responsible can be found on the Internetat all times, see manufacturer address on Page 2, or DURAG GROUPcompany addresses see page 107.4.5 Volume control and system pressure measurementThe measuring device is equipped with a measuring gas pump (type:membrane pump). This vacuum pump sucks up the measuring gas at thesampling point and pumps it through the complete measuring device. Themeasuring gas only flows through the volume control and the pump itself afterit has been measured in the photometer.The Figure 4.4: Volume control and system pressure measurement shows thegas flow measurement (differential pressure transducer, differential pressurenozzle), the gas volume presetting and the measuring components forstandardisation (absolute pressure transducer, gas temperaturemeasurement), which are arranged on an installation panel on the back of themeasuring device. These components are maintenance-free, from theannual replacement of the pump's wearing parts.The control valve enables correction of the sampling gas flow. As guide value,a volume flow of 90 to 100 l/h should be set. The measuring device operatesas a concentration measuring device and is therefore independent of the flow.However, an inadequate flow will cause an unnecessary extension of the T 90time, while an excessive flow will result in an inadequate system pressure,which will then be incorporated into the standardisation calculation as acorrespondingly high mathematical proportion. The volume flow is measuredwith a differential pressure nozzle operated on the pressure side.System pressuremeasurement500...1200mbarVolume settingDifferential pressuremeasurement venturi flowcontroller 0 ...15 mbarMeasuring gas pump,V max.: 400l/hFigure 4.4: Volume control and system pressure measurement36 HM 1400 TRX

4. Theoretical foundations4.6 The thermocatalytic reactorThe operating principle of the reduction is described under "Thethermocatalytic reduction" from page 33. The thermocatalytic reactorcomprises the internal reduction vessel with the reactor material, thesurrounding heating element with external thermal insulation and the reactorbox for housing the specified components. The reactor is electrically heatedwith 4 high-performance 125 watt heating cartridges and regulated to itsoperating temperature. The reactor filling has a lifetime of approx. 6 monthsand can then be replaced in-situ. Alternatively, we recommend simplyreplacing the reduction vessel with a new pre-packed (filled) vessel, which willconsiderably reduce the time required. For redundant replacement, it is onlynecessary to loosen and re-establish the hose connections of the samplinggas input and output, as well as the electrical connections of the heatingcartridges - naturally with the device switched off and cooled down. We alsorecommend sending the replaced reduction vessel back to the devicemanufacturer for refilling. Directly before the reactor input a heated 3-way ballvalve is connected and fixed to the reactor box. This ball valve switches thegas path over between measuring mode and zero offset control andadjustment or reference point control and adjustment.Sampling gas supplyGas path switching(3-way ball valve in reactor,drive externally visible)Electrical terminal stripfor heating cartridgesSampling gas dischargeline to gas dryingFigure 4.5: The thermocatalytic reactor4.7 Gas dryingAfter the reactor output, the measuring gas is conveyed unheated to the gasdrying stage. The drying stage comprises a maintenance-free Peltier cooler,the glass vessel for gas pre-drying, the condensate collector and a condensatedetector.HM 1400 TRX 37

4. Theoretical foundationsThe cooler setpoint temperature is fixed on the cooler. The PLC monitors thecontrol hysteresis within pre-programmable temperature limits. The measuringgas then passes through the condensate collector, which has the function of agas/liquid separator.The condensate produced is conveyed into a condensate tank with levelmonitoring using a hose pump. A liquid monitor with emergency shutdown forthe gas pump is installed between the cooler and the photometer.Figure 4.6: Function level of cooler and gas conditioning4.8 Other electronics, control and measuring value calculationThe control, measuring value calculation and status monitoring of themeasuring device are undertaken by the internal PLC. Use of the measuringdevice is described in Chapter Operation (page 47). All possible functions andthe function descriptions are clearly shown. Apart from the "Condensate inmonitor" error message, which instantly switches the measuring device toStandby status, the other limit value infringements cause a system shut-downafter 2 minutes. Limit value infringements mean that the measuredtemperatures, system pressure and volume flow pass outside theirprogrammed permissible ranges. Another exception is the "Condensatecontainer full" error message, which only switches the measuring device toStandby status after 12 hours. Actual, nominal and limit values as well asstatus messages can be queried on the interactive display. The event memorycan also be activated via the display. For service purposes, it is helpful to be38 HM 1400 TRX

4. Theoretical foundationsable to query all error messages with date and time in the form of a messagelist for previous operating phases.Measuring values from the Hg photometer are read into the PLC as voltagesignals. These measuring values correspond to mercury concentrations inµg/m³. With the measured system pressure and the gas temperature,correction to standard conditions is enabled by the ideal gas equation, i.e. thecalculation of the mercury concentration in a gas with a residual moisture

HM 1400 TRXTotal Mercury Analyser055 Installation5.1 Device check5.2 Device site5.3 Place of installation of the sampling probe5.4 Connections

5. Installation5 Installation5.1 Device check5.2 Device siteAfter unpacking the device and all accessories, please check that the deliveryis complete using the delivery note (also see Scope of supply of the standardmeasuring device and Options on page 29).Please inform the forwarding agent and the DURAG Group of all damage intransit immediately.The site of the measuring device must be prepared according to the relevantproject. The measuring device HM 1400 TRX should be located in an areawhere it is protected from dust and splash water as far as possible.5.3 Place of installation of the sampling probeThe installation position of the sampling probe must be defined beforehand (inaccordance with the conditions of the surveillance authority if necessary);flange connection and flange must be installed in accordance withDIN 2573 / 2576.WARNINGRisk of burningFlange and flange connection may be hot, depending on the measuring gas.Never touch parts that could be hot without temperature-resistant safetygloves. Do not put any heat-sensitive material close to or in direct contactwith hot components.The sampling probe must be pushed through the flange opening into theexhaust gas channel and screwed down on the flange side. Make sure that theSwagelock fittings on the system are securely attached and there are leaks.When installing the heated sampling system, you must ensure that no thermalbridges occur; connection points and transitions must be thermally insulated ifnecessary, upon completion of all installation work.5.4 Connections5.4.1 Sampling probe and sampling lineThe sampling probe must be connected gas-tight to the measuring gas input ofthe sampling line. Please ensure that no mechanical stress results during theinstallation process on either the probe or the line side, and that thepermissible bending radii are observed when laying the sampling line. Themeasuring gas output of the sampling line is generally connected to thethermocatalytic reactor and the regulation functions tested in the factory.The temperatures of sampling probe and sampling line are measured andregulated in the HM 1400 TRX.HM 1400 TRX 43

5. Installation5.4.2 Power supply (preferably 230 V - 3/N/PE)WARNINGDanger from electrical equipmentDanger from electric shocksBefore removing the housing or accidental-contact protection, the equipmentmust be disconnected from the power supply.If it cannot be disconnected, protective equipment must be worn to ensure theprevention of electric shocks.A fixed energy supply connection must be established to the measuringdevice. The mains cable is connected to a residual current protective device for230 V / 50 Hz, 25 A / 30 mA in the device cabinet. The customer fuse protectionfor the energy connection must be designed accordingly.5.4.3 Measuring and operating data recordingThe interface lines for measuring values, control signals and operating anderror status messages agreed in the project must be provided by thecustomer. The terminal assignment can be found in the circuit diagrams.Attention! Before connecting the signal line for the measuring signal, the wirejumper at terminal X3 between contacts 16 and 17 (also 18 and 19 if thesecond measuring signal output is used) must be removed. The signal line isthen attached to the same terminal points.5.4.4 Exhaust gasWhen the gas sample has passed through the device and been analysed, itexits the device's gas duct. Depending on the project, this exhaust gas canalso be conveyed to its destination via a hose connection in the device roof.Once again, a bulkhead fitting with hose connection for DN 4/6 on both sidesserves for connection to a simple plastic hose, which in turn is led directly tothe destination or to a central exhaust gas system.5.4.5 CondensateThe condensate resulting from the gas drying phase is now pumped out of themeasuring device by a hose pump. The approx. 1.50 m long transparentcondensate hose end (DN 4/6) is led out through the side wall of themeasuring device. It is now possible to connect the hose end directly to thecondensate receptacle or to a central condensate collecting system. If thecondensate receptacle with level monitoring is used, you must ensure that thecables for the signal connection between level sensor and measuring deviceare installed according to the terminal plan.Generally the condensate receptacle is housed in the device cabinet.WARNINGCondensate fluid: Risk of skin irritationCondensate can give rise to specific dangers. These are dependent on thepollutants contained in the measuring gas. The receptacle must thereforealways be handled by appropriately trained personnel with the necessary careand with any required protective equipment.44 HM 1400 TRX

HM 1400 TRXTotal Mercury Analyser066 Operation6.1 Commissioning with default parameters6.2 Standby phase6.3 Measuring mode

6. Operation6 Operation6.1 Commissioning with default parametersOperating states:StartStandbyOperationZero controlCalibrationPurge (option)All installation steps must be completed before commissioning.System start:Main switch S0 "on":Table 6.1 CommissioningSwitch on the deviceThe heating systems for sampling probe andmeasuring gas line are switched on. All electricalsystem parts are supplied with current. The controlcomputer runs through the start initialisation, andthe menu for measuring mode and additionalinformation on the current operating state appear onthe display6.2 Standby phaseIn the standby phase, the control computer queries essential status signals inthe following sequence, and then sets them when the operating conditions arefulfilled:1. Condensate monitor: no condensate in the monitor2. Condensate receptacle: condensate container empty3. 3-way ball valve: temperature in programmed tolerance range4. Thermocatalytic reactor: temperature in programmed tolerance range5. Sampling probe: temperature in programmed tolerance range6. Sampling line: temperature in programmed tolerance range7. Measuring gas cooler: temperature in programmed tolerance range8. Sample gas temperature: temperature in programmed tolerance rangeIf one or more status conditions in accordance with 1. ... 8. have not been fulfilled,the measuring device will remain in standby status.Table 6.2 Standby phaseWhen the operating conditions have been fulfilled and the status signals set,the vacuum pump is activated and measuring mode begins.HM 1400 TRX 47

6. Operation6.3 Measuring modeFunctionally relevant parameters are cyclically monitored in measuring mode(see Appendix:Device parameters in delivery status and Appendix: Errormessages and their elimination).If one of these parameters moves outside its preset limit values, an errormessage is generated in the event memory with the date and time of the eventstart and is indicated by a flashing LED on the help key "?". The measuringdevice switches into standby mode after 120 seconds. If condensate is foundin the monitor this event has a higher priority, and the measuring device is putinto standby mode immediately. If the level sensor of the condensatereceptacle indicates "Condensate container full", switch-off (standby) onlyoccurs after 2 hours. Only after eliminating the error cause can the measuringdevice be switched into measuring mode. This is either done manually orautomatically, depending on the setting.48 HM 1400 TRX

HM 1400 TRXTotal Mercury Analyser077 Operation7.1 The terminal:7.2 The Main menu7.3 Zero offset (manual)7.4 Zero offset (automatic)7.5 Calibration (option)7.6 Commissioning (manually):

7. Operation7 Operation7.1 The terminal:The HM 1400 TRX is operated via the operating terminal on the front panel ofthe device.Figure 7.1 TerminalKey functions:Editing keys+-Control keysThe Plus key is used to enter positive values. When thekey is pressed, the selected value increases by 1. If the keyis held down, the function is repeated. The repetition speedis automatically increased.The Minus key is used to enter negative values. When thekey is pressed, the selected value decreases by 1. If thekey is held down, the function is repeated. The repetitionspeed is automatically increased.The Cursor left key directly selects adjacent masks ormessages, exits the operating mode or positions the cursorone character to the left within a variable.The Cursor down key directly selects adjacent masks ormessages, changes to the message list during operation orpositions the cursor on the next editable variabledownwards.HM 1400 TRX 51

7. OperationKey functions:Special keys?The Help key outputs the current help text or errormessages. Flashing of the Help key LED indicates pendingmessages.The Data release key changes from menu to Editor. If thiskey is pressed in Editor mode, this mode is exited again.The Data acceptance key (Enter) concludes the datainput.Function keysF1F2F3F4Function key F1 (Home) is used to select the standardoperating screen (display of current concentration).Function key F2 performs the function shown in thecurrent display.Function key F3 (Event list) allows you to select a list oferror status messages.Function key F4 performs the function shown in thecurrent display.Table 7.1 Key functions52 HM 1400 TRX

7. Operation7.2 The Main menuFigure 7.2 The Main menu IHM 1400 TRX 53

7. Operation• Menu item "PASSWORD"You only need to enter a password if you wish to make changes to thefollowing parameters. (Password for changes – except for calibrationprocess – = 1111, password for calibration process = 2222).• Menu item “Sample Volume”The current volume flow is displayed in l (operating conditions). The limitvalues are editable and generate a corresponding error message if theupper or lower range limit is exceeded. In calibration mode, themeasured volume flow is included in the concentration calculation.• Menu item "Systempressure"The current system pressure of the measuring system is displayed. Thelimit values are editable and generate a corresponding error message ifthe upper or lower range limits are exceeded. The system pressure isrequired to calculate the concentration under standard conditions.• Menu item "Reactor ACT"The current temperature of the thermocatalytic reactor is displayed. Thetarget value can be changed. The limit values are also editable andgenerate a corresponding error message if the upper or lower rangelimits are exceeded.54 HM 1400 TRX

7. OperationFigure 7.3 The Main menu II• Menu items "Probe", "Probetube" and "S.Line"The temperature measurement and temperature control on the samplingprobe, probe tube and probe cable are optionally supported by thesystem-internal PLC. The target value can be changed. The limit valuesare editable and generate a corresponding error message if the upper orlower range limits are exceeded.The options can be activated or deactivated with key F2.HM 1400 TRX 55

7. OperationFigure 7.4 The Main menu III56 HM 1400 TRX

7. Operation• Menu item "3-W-V" (Three-way-valve)The current temperature of the 3-way ball valve is displayed. The targetvalue can be changed. The limit values are editable and generate acorresponding error message if the upper or lower range limits areexceeded.• Menu item "Chiller"The current temperature of the cooling circuit for the gas sample isdisplayed. The limit values are editable and generate a correspondingerror message if the upper or lower range limits are exceeded.• Menu item "Gas"The current gas temperature is displayed. The gas temperature isrequired to calculate the concentration under standard conditions. Thelimit values are editable and generate a corresponding error message ifthe upper or lower range limits are exceeded.• Menu item "Backflusher"The time interval for probe purging is identical to the interval for theautomatic zero offset measurement, and is only displayed here for thesake of completeness and for orientation purposes. The countdowndisplays the remaining time until the next zero offset measurement.By pressing key the countdown for automatic zero offset measurementcan be reset to its start position.• Menu item "Zero offset"Pressing key takes you to the manual zero control process afterentering a valid password (see Zero offset (manual).Key takes you to the input mask for the parameters of theautomatic zero offset measurement. (see Zero offset (automatic)).• Menu item "Stop last measuring value at zero offset"Here you can set whether the last measuring value is to be stopped atthe current output during automatic (internal) zero control. This isdeactivated by pressing thekey, and activated by pressing thekey.• Menu item "Cleaning up Goldtrap" (option)Here you can start baking out of the gold trap.HM 1400 TRX 57

7. Operation• Menu item "Systemstart"Automatic start is deactivated and activated by pressing theandkeys. When the HM 1400 TRX is restarted (main switch S0 from0 to l), after start initialisation and completion of the standby phase(Commissioning with default parameters) the measuring device beginsmeasuring mode when key F4 is pressed, without additional operation ifautomatic start is activated. Manual stopping is then not possible.58 HM 1400 TRX

7. OperationFigure 7.5 The Main menu IVHM 1400 TRX 59

7. Operation• Menu item "Measuring range"The measuring range can be freely selected within the limits 0-500µg/Nm³ (separately for both current outputs). A message is output if theupper end value for the measuring range of the first output is exceeded.Current from 4 to 20 mA is available (in parallel for both outputs) at thecorresponding terminals (customer interface X3).The second output is optional.• Menu item "Calibration"The calibration parameters can be directly changed after entering a validpassword.A calibration process is triggered by pressing theCalibration)key. (see• Menu item "Threshold value"The threshold value is freely definable and generates a message ifexceeded.• Menu item "Record Parameter"(Optional for service purposes)• Menu item "Integration time"The output of the concentration measuring value can be freed fromundesirable peaks through average value formation over a variable timeperiod.Attention! The average value formation is also active during calibration.• Menu item "Service request”This displays in how many weeks the next instruction to request aservice visit for device maintenance will occur.• Zero gas concentration” menu item”If the measuring signal (!) exceeds the specified concentration value [µg]the device is switched to zero gas via the bypass. When the specifiedTime [seconds] has elapsed, the device reverts to measuring gas.Entering 0 (zero) seconds for the time deactivates this function.60 HM 1400 TRX

7. Operation7.3 Zero offset (manual)Figure 7.6 The zero offset determination started manuallyThe zero offset determination can be started manually.Attention! If the device is currently in measuring mode, triggering a zero offsetmeasurement will result in an interruption of measuring mode.After triggering the zero offset measurement by pressing the key, acurrent measuring value ("zero" measuring value) will appear in the display inμg/Nm³. To ensure that the "zero" measuring value is not falsified by anyresidual quantities of mercury in the suction intake, you must wait a fewminutes for the value to stabilise before accepting it.After pressing the key, the zero offset measuring value in μg/Nm³ isstored as offset. The display changes back to the standard operating screenafter approx. 2 seconds.HM 1400 TRX 61

7. Operation7.4 Zero offset (automatic)Figure 7.7 The zero offset determination automaticAfter selecting zero offset (automatic) by pressing the key, allparameters required to control zero offset (automatic) appear in the display.• Interval describes the time period between two zero offsetmeasurements.• Duration describes how long you must wait for the measuring value tostabilise.• Average value (yes) performs an average value formation over the last2 minutes of a zero offset measurement.The time of the next zero offset measurement can be influenced by triggeringa purge process. As purging is in principle carried out during each zero offsetdetermination, zero offset and purge interval start at the same time.62 HM 1400 TRX

7. Operation7.5 Calibration (option)Figure 7.8 CalibrationAttention! If the device is currently in measuring mode, triggering calibrationwill result in an interruption of measuring mode.After triggering the calibration process by pressing the key and enteringa valid password (if necessary), you will be prompted to enter the followingparameters.Concentration of the stock solutionDosing capacity of the dosing pumpPressing the key again displays the parameters required to calculate thespan (volume flow, gas temperature and system pressure).HM 1400 TRX 63

7. OperationIf the key is pressed again, the calculated and measured mercuryconcentration will appear in the display.If the measuring value is stable after approx.15 minutes, the span calculationcan be triggered and saved by pressing thekey again.7.6 Commissioning (manually):• Switch on measuring device by pressing the main switch.• After the start initialisation (time period depending on previous operatingsituation) presskey, in order to access the main menu.• Measuring mode is started by pressing the key (start).Stand By ModePreparation modeheating upOperation modeFigure 7.9 Operating statusesThe date and time appear in the standard operating screen in addition to themercury concentration (required for time assignment of error messages in theevent memory message list).64 HM 1400 TRX

7. OperationThe device is put into operating status with the key. The device remainsin standby status until the operating conditions are fulfilled and the statussignals are set. It is possible to cancel the start process and return to standbymode by pressing the key, unless automatic start is parameterised. Afterfulfilment of all start conditions necessary for operation, the HM 1400 TRXswitches to measuring mode automatically.All operating parameters can be read after pressing the key and alsoedited after entering a valid password (default password: 1111 for all changes- except for triggering the calibration process, password for calibrationprocess: 2222.HM 1400 TRX 65

HM 1400 TRXTotal Mercury Analyser088 Measuring device check (option)8.1 Calibration check procedure8.2 Factors influencing the calibration point8.3 Calculation principle for calibration8.4 Checking procedure

8. Measuring device check (option)8 Measuring device check (option)8.1 Calibration check procedureIn the course of various studies and experience of practical use, the"adjustment by stochiometric reduction" method has established itself. Thismethod leads to stable adjustment points on the one hand, but on the otherhand is only reproducible if fresh SnCl 2 solution is applied immediately beforethe adjustment run. This behaviour is due to the oxidation and light sensitivityof the aqeous Sn² + solution.In practice, an Sn²+ concentration of 10 g/l has proved to be sufficient for anadjustment time of 90 minutes.With this configuration, adjustment points of up to 2 mg/Nm³ Hg can beachieved with linear dependency for volumetric flow rates of 80 - 120 l/h.8.2 Factors influencing the calibration pointThe calibration point is essentially dependent on the following parameters:• Dosing capacity of the hose pump (Hg²+ solution)• Volume flow of the measuring gas• Concentration of the Hg²+ dosing solution• System pressure• Temperature of the measuring gasThe dosing capacity of the hose pump can be simply determined through"volumetric measurement" or weighing a volume of fluid pumped in the timeunit. This process is generally only necessary once. However, fluctuations canoccur in the flow rate after prolonged operating times due to material fatigue inthe hose systems.The volume flow of the measuring gas can affect the quality of thecalibration point in the range > 100 l/h. This effect is particularly evident in thecase of calibration above 300 µg/Nm³. For this reason, volume flows ≥ 100 l/hare generally desirable. Volume flows above 150 l/h cause erratic lowering ofthe system pressure and over-intensive purging of the Sn² + receiver, whichimpedes uniform gas discharge (Hg) (frothing of the calibration solution).The concentration of the Hg² + dosing solution has a direct influence on thecalibration point, in accordance with the formula specified below.The system pressure and the temperature of the measuring gas areessential parameters for converting the concentration from µg/m³ to µg/Nm³.The temperature is determined with a PT100 at the measuring cuvette of thephotometer (gas inlet) and displayed in calibration mode. The system pressureis a direct measurement for the volume flow and tightness of the system. Thetightness should basically be inspected before each calibration by checkingthe gas quantity at the gas inlet of the measuring device in comparison withthe gas quantity at the gas outlet with a gas meter. The system pressure istherefore an instrumental parameter dependent on volume flow, barometricpressure and transport cross-sections, which is displayed in calibration mode.HM 1400 TRX 69

8. Measuring device check (option)8.4 Checking procedureWARNINGRisk of poisoning and chemical burnsChemicals, in this case mercury, hydrochloric acid and tin(II) chloridedihydrate in principle give rise to particular dangers. Therefore, they mustalways be handled with the necessary care by appropriately trainedpersonnel. Please comply with the information provided on the safety datasheets provided with these chemicals. Persons handling these substancesshould be familiar with the contents of these extracts. Extracts from the"Mercury" safety data sheet can be found in the Appendix to this manual!1. Connect the calibration module to the device2. Dissolve defined concentration of mercury stock solution (example: Hg 2+0.5 mg/l) in HCl 1 mol/l,3. Fill glass vessel with appropriate concentration of mercury stock solution,4. Immerse hose end of dosing pump in the solution,5. Dissolve SnCl 2 (flakes, powder) in HCl 1 mol/l (10 ... 50 g SnCl 2 per l HCl 1mol/l),6. Pour approx. 100 ... 120 ml of the dissolved SnCl 2 into the calibrationreactor and seal with glass insert,7. Connect hoses to measuring setup according to Figure 8.1: Functionalprinciple of wet chemical Hg0 generator for device calibration,8. Switch measuring system to calibration mode and wait until the systempressure and flow have stabilised ( display),9. Now start the calibration (a constant value will appear on the display afterapprox. 10 minutes),10. Only apply this new value if you are sure that the measuring system is leakfreeand other errors can be excluded.Note:Attention!!1. Applying these results will permanently adjust the span of the storedcalibration curve. The numeric value of the span can be queried in themenu. Normally the numeric value is between 0.8 and 1.2.2. Before handling the specified chemicals, the pertinent safety data sheetsmust be complied with.HM 1400 TRX 71

8. Measuring device check (option)Legend:Peristaltic pumpCalibration gasAirChemicalReactions:Sn 2+ – 2e - → Sn 4+Hg 2+ + 2e - → Hg 0 ↑Figure 8.1: Functional principle of wet chemical Hg 0 generator for device calibration72 HM 1400 TRX

HM 1400 TRXTotal Mercury AnalyserAppendix9 Appendix: Technical data10 Appendix:Device parameters in delivery status11 Appendix:Maintenance12 Appendix: Error messages and their elimination13 Order numbers for replacement and wearing parts14 Appendix Extracts from safety data sheets15 Index16 DURAG GROUP company addresses

9. Appendix: Technical data9 Appendix: Technical dataMeasuring range:0 - 45 to 0-400 µg/Nm³ selectableTested measuring range:Detectable limit:0 - 45 µg/Nm³< 0,5 µg/Nm³Reference method: Basic calibration according to VDI 3868 p. 2Maintenance interval according toEN15267-3:> 1 monthAvailability: > 95%Warm-up time:Setting time (90% time):Energy supply:Power consumption:Permissible ambient temperature:Measuring value output:Mercury detector:Partial gas volume flow:Converter120 minutes< 180 seconds230/400 V ( + 10%, - 15%), 50 Hz, 3L, N, PE, max. 10 kVA230 V ( + 10%, - 15%), 50 Hz, L, N, PE, max. 5 kVAMeasuring device: approx. 1200 WSampling probe: approx. 650 WSampling line: approx. 100 W / mSampling tube (heated): for tube lengths0.6m/1.0m/1.5: 600 W / 800 W / 1200 WMounted cooling unit (option): 850 W,rated current: 5.4 A, initial current: 22.0 A+ 5°C to +40°C4 - 20 mAUV absorption two-beam photometer (253.7nm)60 - 120 Nl/hthermocatalytic, running life: typ. 6 monthHousing Sheet steel cabinet, RAL 7035Class of protection:Dimensions:HxWxDWeight:IP551650 x 800 x 500 mm1750 x 800 x 500 mm with base/plinth 100 mm1850 x 800 x 500 mm with base/plinth 200 mm2350 x 800 x 600 with base/plinth andmounted cooling unitapprox. 200 – 240 kgSampling system: Sampling probe with heated 2 µm filter, IP 54sampling line, heated T max 200°C, PTFE, IP54Table 9.1: Technical data75 HM 1400 TRX

10. Appendix:Device parameters in delivery status10 Appendix:Device parameters in delivery status(project-specific, see supplementary sheets for device description!)Parameter setting for HM 1400 TRX /Article no.: / Serial no.:Passwordsee Technical Manual!Volume flow Setting value approx.100 l/h (setting at fine regulation valve)Minimum50 l/hMaximum 200 l/hSystem pressure (abs.) Minimum 550 mbarMaximum 1200 mbarReactor temperature Nominal 285 °CMinimum 250 °CMaximum 350 °CProbe (option) Nominal 180 °CMinimum 160 °CMaximum 200 °CProbe tube (option) Nominal 180 °CMinimum 160 °CMaximum 200 °CSampling line Nominal 180 °CMinimum 160 °CMaximum 200 °C3-W-V temperature Setting value approx.150 °C (tuning value in reactor)Minimum 130 °CMaximum 200 °CCooler temperature Setting value +2 °C (programmed at cooler)Minimum +0.5 °CMaximum +6 °CGas temperature Minimum 10 °CMaximum 60 °CBack-purging Intervals 2 hCountdown current counter statusZero offset (automatic) Actuation of F4 (automatic)Intervalafter 2 hDuration8 minutesAverage value yes / noHold value yes / noSystem startmanual / automaticMeasuring range 1 from 0 µg / Nm 3to 45 µg / Nm 376 HM 1400 TRX

10. Appendix:Device parameters in delivery statusMeasuring range 2 from 0 µg / Nm 3Calibration reactor, automatic(option)to 75 µg / Nm 3Nominal 0Minimum 0Maximum 0Calibration parameter Span 0.8 ... 1.2Offset 20 ... 30 µg / Nm 3manual / automaticThreshold value 200 µg / Nm 3Parameter recording (option)Integration timeNext service request inyes / no10 seconds26 weeksZero gas (option) Conc.Value 0,0 µgDuration0,0 secTable 10.1: Device parameters in delivery statusHM 1400 TRX 77

11. Appendix:Maintenance11 Appendix:Maintenance11.1 Appendix: OverviewThe maintenance has to be carried out for the following fields:1 0-point check • automatic zero check at 1 - 99 hour interval2 Operation cycle • emptying of condensate container ( 20 l ) approx. every 1…2 months• replacement of condensate pump hose3 Measuring value check: • annual check of measuring value displayin calibration mode with optionalcalibration unit4 Functional check: • annual functional check in-situ in situ by arecognised measuring institute5 Calibration: • a calibration is performed in-situ by arecognised measuring instituteyearlyin accordance withEN 14181in accordance withEN 14181in accordance withEN 141816 article protection filter: • filter change on back of photometer approx. every 3 months7 Gas hoses • replacement of Tygon hoses yearly8 Gas pump • replacement of gasket and diaphragm yearly9 Reactor material • replacement of Katalysatormaterials approx. every 6 monthsTable 11.1: Calibration intervals, maintenance effort11.2 Appendix: Service scheduleWARNING!Risk of injury due to inadequate qualifications!Improper use can lead to severe injury and damage.Any activities should only be performed by appropriately trained specialistpersonnel!Caustic chemicals such as potassium hydroxide are used in theHM 1400 TRX to analyse the mercury concentration. The mercury is filteredout in the iodised activated carbon of the photometer, where it remains. Themaintenance tasks involve handling these substances. Chemicals in principlegive rise to particular dangers. Therefore, they must always be handled withthe necessary care by appropriately trained personnel. Please comply withthe information provided on the safety data sheets provided with thesechemicals. Extracts from the relevant safety data sheets can be found in theAppendix to this manual! Persons handling these substances should befamiliar with the contents of these extracts.Maintenance is made up of the following activities, which are carried out byservice personnel (see Page 23):78 HM 1400 TRX

11. Appendix:Maintenance1.• Exchange of the reactor material2.3.Maintenance cycle• Check of the photometer, replacement of anydefective componentstyp. every 6 monthWARNINGDanger of chemical burns and skin irritationsPotassium hydroxide (KOH)Avoid direct contact with the skin. Wear protective equipment.Also comply with the information in the safety data sheet.4. Maintenance cycle• Replacement KOH (potassium hydroxide) * (seepage 80)During analysis of the mercury concentration, themercury contained in the measuring gas is bound inthe iodised activated carbon filter (between measuringand reference cuvette of the photometer) andtherefore remains in this filter.every 12 monthWARNINGRisk of poisoningAvoid heating the iodised activated carbon laden with mercury above 150 °C,in order to prevent evaporation and release of mercury.In the case of (elemental) mercury there is a risk of inhalatory absorptionthrough breathing in.Please also comply with the information provided in the mercury safety datasheet during these maintenance tasks.5.6.• Replacement of the iodised activated carbon *(seepage 80)• Check of condensate pump, replacement of anydefective components7. • Read-out of message list in status memory8. • Reference point control9.Maintenance cycle• Check of measuring signal output 4...20 mA andstatus signalstyp. 6 Monate10. • Test of vacuum pump11. • Leak test of complete measuring device12.• Check of gas-transporting glass components andhose materials13. • Resetting of maintenance interval to 26 weeksTabelle 11.1: Maintenance intervals, maintenance work IHM 1400 TRX 79

11. Appendix:MaintenanceThis maintenance is made up of the following activities, which can be carriedout by the operating personnel (see Page 23):14.• Check and readjustment (if necessary) of thesample gas flow ( 90 - 110 l/h)15. Maintenance cycle • Check of possible error messagesmonthly16• Querying of zero offset and adjustment, if necessary(zero offset must be a positive numeric value)Tabelle 11.2: Maintenance intervals, maintenance work II* The measuring device operator is responsible for disposal of the following, inaccordance with the pertinent regulations:• the used reactor material enriched with exhaust gas ingredients• used selective filter content, replaced after 6 months as part of the devicemaintenance (iodised activated carbon contaminated with Hg)• KOH (potassium hydroxide) from the pre-filterIt is also possible to commission DURAG with disposal. The operator sendsthe material at his cost, declared accordingly, to DURAG's company address(you can find the DURAG GROUP company addresses and telephone numberson page 107); DURAG will then undertake disposal in accordance withregulations. The disposal costs are borne by the respective device operator.80 HM 1400 TRX

12. Appendix: Error messages and their elimination12 Appendix: Error messages and their elimination12.1 Appendix: Monitored parameters and error messages inplain textTemperatures:• „"Reactor temp. too low/ too high"• "Probe temp. too low / too high"• "3-W-V temp. too low / too high"• "Cooler temp. too low / too high"• "Gas temperature too low / too high"• "Probe line temp. too low / too high"• "Probe tube temp. too high"Flow :• "Volume flow too low / too high"Pressure::• "System pressure too low / too high"Limit value::• "Upper / lower threshold value exceeded"Condensate:• "Condensate in monitor"• "Condensate container full"Drift phenomenon:• "Zero offset drift too large"HM 1400 TRX 81

12. Appendix: Error messages and their elimination12.2 Appendix: Error causes and their eliminationError messages in the event memory1. "Reactor temp. too low/ too high"Description: Violation of lower/upper temperature range limit valueCauses: • Setpoint setting incorrectly programmed Elimination: • Check/correct setpoint input• Temperature limit values incorrectly programmed• Pt100 temperature sensor defective• Energy supply for heating cartridges interrupted• Heating cartridge defective• Check/correct limit value input• Measure temperature at reactor (A6) and compare with display actualvalue, replace Pt100 if necessary• Activate automatic cutout F7 (find cause of F7 tripping)• Replace heating cartridge(s)2. "Probe temp. too low / too high"Description: Violation of lower/upper temperature range limit valueCauses: • Setpoint setting incorrectly programmed Elimination: • Check/correct setpoint input• Temperature limit values incorrectly programmed• Pt100 temperature sensor defective• Energy supply for sampling probe interrupted• High-performance heating cartridge in heated filter of sampling probedefective• Check/correct limit value input• Measure temperature at sampling probe filter and compare with displayactual value, replace Pt100 if necessary• Activate automatic cutout F5 (find cause of F5 tripping)• Hochleistungsheizpatrone ersetzen3. "3-W-V temp. too low / too high"Description: Violation of lower/upper temperature range limit valueCauses: • Temperature limit values incorrectly programmed Elimination: • Check/correct limit value input• Insulating material packed incorrectly• Reactor temperature error • See error elimination under 1.• Open cover of reactor box and check arrangement of insulating elements82 HM 1400 TRX

12. Appendix: Error messages and their elimination4. "Cooler temp. too low / too high"Description: Violation of lower/upper temperature range limit valueCauses: • limit values incorrectly programmed Elimination: • Check/correct limit value input• Temperature setting on measuring gas cooler not correct • Correct temperature setting on measuring gas cooler (see DeviceDescription Part 2)• Pt100 temperature sensor in cooling medium of cooler defective • Measure temperature in cooling medium and compare with display actualvalue, replace Pt100 if necessary• Energy supply for measuring gas cooler interrupted • Activate automatic cutout F6 (find cause of F6 tripping)• Controller module on measuring gas cooler defective • Replace controller module on measuring gas cooler5. "Gas temperature too low / too high"Description: Violation of lower/upper temperature range limit valueCauses: • Temperature limit values incorrectly programmed Elimination: • Check/correct limit value input• Gas sample cooling (gas drying) is not operating correctly • See error elimination under 46. "Probe line temp. too low / too high"Description: Violation of lower/upper temperature range limit valueCauses: • Setpoint setting incorrectly programmed Elimination: • Check/correct setpoint input• Temperature limit values incorrectly programmed • Check/correct limit value input• Pt100 temperature sensor (embedded in the line) defective • Measure temperature in PTFE core of measuring gas line and comparewith display actual value, inform manufacturer / supplier• Energy supply for sampling line interrupted • Activate automatic cutout F4 (find cause of F4 tripping)83 HM 1400 TRX

12. Appendix: Error messages and their elimination7. "Volume flow too low / too high"Description: Violation of lower/upper volume flow range limit valueCauses: • Volume flow limit values incorrectly programmed Elimination: • Check/correct limit value input• Volume flow setting on measuring device altered • Check actual value on measuring device, correct with regulating valve ifnecessary• Obstruction of sampling probe/sampling line (dust concentration influe gas > 50 mg / m 3 , even if these concentrations only occur over aperiod of approx. 30 minutes)• Check system for leaks• Particle protection filter at measuring gas input of Hg photometersoiled• Replace particle protection filter (round filter) on Hg photometer• Maintenance requirement for vacuum pump (M2) • Replace wearing parts on vacuum pump8. "System pressure too low / too high"Description: Violation of lower/upper system pressure range limit valueCauses: • Differential pressure nozzle obstructed Elimination: • Clean differential pressure nozzle• Volume flow error • See error elimination under 7• Energy supply for absolute pressure transducer (B3) interrupted • Activate automatic cutout F7 (find cause of F7 tripping), test miniaturefuse on power supply module (T1) (red LED must illuminate) and replaceif necessary9. "Threshold value exceeded"Description: Limit value violation, threshold value limit exceededCauses: • System-related increase in Hg concentration (operator) Elimination: • Eliminate system-related causes (operator)• Soiling of gas duct components • Locate component(s) at fault and clean if necessary10. "Condensate in monitor"Description: Moisture indicated by sensor contacts in condensate monitor and status message from level controller (condensate detector) (A4) to PLCCauses: • Energy supply for condensate detector (A4) interrupted Elimination: • Activate automatic cutout F7 (find cause of F7 tripping), test miniature fuseon power supply module (T1) (red LED must illuminate) and replace ifnecessary• Gas sample cooling (gas drying) is not operating correctly • See error elimination under 4• Condensate hose pump not operating or condensate hose oncondensate pump damaged• Activate automatic cutout F6 (find cause of F6 tripping), check functioningof hose pump, replace condensate pump hose if necessary84 HM 1400 TRX

12. Appendix: Error messages and their elimination11. "Condensate container full"Description: Level sensor in condensate receptacle sends status message to PLCCauses: • Condensate receptacle is full Elimination: • Empty condensate receptacle• Level sensor defective • Check level sensor (floating contact should move freely), replace levelsensor if necessary12. "Zero offset drift too large"Description: Zero point offset values between 2 zero checks > 3%Causes: • Extremely soiled sampling system Elimination: • Clean (purge) sampling system• Gas sample cooling (gas drying) not operating correctly,condensation in gas duct and particularly in Hg photometer• See error elimination under 4 and 10(Clean quartz glass windows in Hg photometer,clean measuring and reference cuvettes if necessary)13. "Service request"Description: A maintenance interval has been reachedCauses: • The device has been operating without maintenance of 6 months Elimination: • Request service visit for maintenanceFurther information for operationDescription: Calibration value is not reachedCauses,counter-measures:• The measuring instrument must be checked for leaks from the sampling onwards by gradually closing the gas path. AThe criterion for an assessment as freeof leaks is a system pressure of 500 mbar, including at the fittings for the hoses carrying sample gas. In any case, the wearing parts of the sample gas pump(structure diaphragm, valve plates, sealing rings) should also be checked and replaced. In rare cases, leaks can also occur in the heated sampling system(sampling probe, sampling line), particularly at the connecting points.In the event of an error it is advisable to inform the device manufacturer / supplier.85 HM 1400 TRX

13. Order numbers for replacement and wearing parts13 Order numbers for replacement and wearing partsDesignation Order no. Order no.Included inCKSKHeated sampling system:PTFE core, 4 * 1 mm, per meter wdischlDN4/6 1400-100-001 10Line, heated and temp.-controlled, first meter 1400-100-002Line, heated and temp.-controlled, additional meter 1400-100-003Particle protection filter cartridge for heated probe (option) wdi90S0020 1400-100-005Thermocatalytic probe treatment:Pt 100, high-temperature version wdithermoPT100H 1400-200-004Heat rod for reactor mdiheizpatrone 1400-200-005Solid mixture for 1 filling BHM1400TRFG 1400-200-006 2Reactor vessel (VA body, aluminium jacket, 4 heat rods,Pt100)Reactor vessel (VA body)BHM1400TRRG -wdiglaswolle -BHM1400TRFG+ BHM1400TRHKBHM1400TRRGwithoutBHM1400TRFG1400-200-0071400-200-008Glass wool for one reactor filling (approx. 50 g) wdiglaswolle 1400-200-009Seal for reactor container cover mdg1400010212# 1400-200-010Hose kit for HM-1400TR"newest": 1400-300-0027 m Tygon hose B-44-4X 3.2 x 1.60.5 m Verderprene hose,W=1.6mm,Di=4.8mm1 m PTFE hose DN 4/68 m PVC hose, glass-clear DN 4x1(De=6mm, Di=4mm)1 m hose PA hard (De=6mm, Di=4mm)Pumps:Sample gas pump N 89 KTE / S wdiPM18129-89 1400-400-001 1Wearing kit for sample gas pump (1400-400-001) mdimembr29231 1400-400-002 1mdivenpl43295mdg292312- channel hose pump for calibration, Alitea wdiU4-OEM 1400-400-0031- channel hose pump for condensate, ASF wdiSR25-15UPM 1400-400-00486 HM 1400 TRX

13. Order numbers for replacement and wearing partsDesignation Order no. Order no.Included inCKSKHose for condensate hose pump wdischlauch4,8 1400-400-005Wearing parts kit for 1-channel hose pump (1400-400-004)SETKONSR25 1400-400-006Gas dryingReactor 1 ( 7) or 2 ( 8 ) mdireaktor 1400-500-002 2Condensate vessel ( 9 ) mdiflabscheider 1400-500-003 2Fluid monitor ( 10 ) mdiflwaechter 1400-500-004 2Level controller type ER 230 for (10) wdiER230 1400-500-005UV photometer, detectorDetector, complete wdiHgmonitor744 1400-600-001UV replacement lamp mlaUV0791.124 1400-600-013Iodised activated carbon, per kg (for several years) wdiiodkohle 1400-600-003 1Reference filter container (GL32) without filling wdiGL32 1400-600-004 1Input filter wdistfilthalter 1400-600-005 1Particle protection filter, for 1400-600-005, 100 pc. wdipapierfilter 1400-600-006 1Tygon hose 6.25 x 3.2 mm per m wditygonschlB44 1400-600-007 4Hose connectors, set of 10 wdiverbsetW +wdiverbsetM1400-600-008 1Quartz glass cuvette tube (set of 2) mdikuevrohr 1400-600-014Hose connector block wdiverb907.031 1400-600-015Quartz glass window mdiqufenster 1400-600-016O-ring (cuvette tube/window, set of 12) mor2.132.062 1400-600-017PTFE ring (optical filter) mor907.025 1400-600-018Optical UV filter mdiuv-filter 1400-600-019O-ring (optical filter) mor2.132.064 1400-600-020Calibration module:Calibration reactor wdikalreaktor 1400-800-001Erlenmeyer flask 50 ml wdikolben50ml 1400-800-002Zero gas cartridge wdigasfilter 1400-800-003 1Chemicals:H 2O VE, distilled water, per litre xxx6 1400-900-001HCl, hydrochloric acid p.a. per litre, 37 % xxx5 1400-900-002SnCl 2*2H 2O, tin(II)chloride dihydrate p.a. 1VE=250g xxx004 1400-900-003KOH, potassium hydroxide for 140-600-004, p.a., 1kg wdiKOH 1400-900-004HM 1400 TRX 87

Designation Order no. Order no.Included inCKSKHg stock solution 0.2ppm Hg(NO 3) 2 in 1molar HLC 1400-900-005HCL (hydrochloric acid) 1molar, 250ml 1400-900-006Miscellaneous:Ball valve complete with actuator mdi6C0733.00 +mdi6E1548.141400-1000-001Ball valve without actuator mdi6C0733.00 1400-1000-002Pt - 100 temperature probe wdithermoPT100 1400-1000-005Power supply GE 23/5 wdinetztGE23/5 1400-1000-008Mains switch mscCH10 1400-1000-011Test socket red mklPKl10A/red 1400-1000-012Test socket black mklPKl10A/sc 1400-1000-013Absolute pressure sensor, 500 - 1200mbar wdiAD1000 1400-1000-014Differential pressure transducer 0 - 15 mbar wdi404304/000 1400-1000-015Mains filter 16 A wdinetzfEM816 1400-1000-016PTFE regulating valve for flow rate adjustment wdiventil5A0111 1400-1000-017Consumables kit for one year's operation HM-1400TR/CK xSpare parts kit HM-1400TR/SK x(Completion of "CK" and "SK" depending on equipmentfeatures and options)Table 13.1: Spare part list88 HM 1400 TRX

14. Appendix Extracts from safety data sheets14 Appendix Extracts from safety data sheetsWhich substances are used or collected in the various device components andwhat are the associated dangers?Danger fromAlready contained inanalysis material:Chemicals containedAdded to analysis materialfrom measuring gas:Device componentMeasuringgas-dependent-/-Condensate from measuringgas-dependent pollutantsCondensate(from gas drying beforegas cooler)Potassium hydroxide (KOH)biscuitMeasuring gas-dependentpollutantsPre-filterIodised activated carbonMeasuring gas-dependentmercury *PhotometerHydrogen chloride (HCl)(hydrochloric acid)Not applicable(optional)Reference pointmeasuring deviceMercurous (II) chloride (HgCl 2) Not applicableTin(II)chloride dihydrate (SnCl 2 Not applicable• 2H 2O)Table 14.1: Dangerous substances in the various device components* During analysis of the mercury concentration, the mercury contained in themeasuring gas is bound in the iodised activated carbon filter (betweenmeasuring and reference cuvette of the photometer) and therefore remains inthis filter.WARNINGRisk of poisoningAvoid heating the iodised activated carbon laden with mercury above 150 °C,in order to prevent evaporation and release of mercury.In the case of (elemental) mercury there is a risk of inhalatory absorptionthrough breathing in.Please also comply with the information provided in the mercury safety datasheet during these maintenance tasks.HM 1400 TRX 89

14. Appendix Extracts from safety data sheetsTransport and handling of the abovementioned substances must occur inaccordance with the Ordinance on Hazardous Substances and the safety datasheet. It should be noted that, in the case of iodised activated carbon ladenwith mercury, separate data sheets are available for iodised activated carbonand mercury. The same applies for disposal of these substances.Standard emergency phone number:112 (EU)NOTE!The following information on chemicals comprises of summarised(incomplete!) extracts from various (German) safety data sheets. It isintended to provide an overview of the dangers associated with thesesubstances, and instructions on handling.No guarantee is provided with regard to the completeness, correctness andup-to-dateness of this information. In all cases the complete (national) safetydata sheets provided with the chemicals when delivered, which are published(in national language) by the manufacturers of these chemicals and whichcan generally also be viewed on the Internet, are authoritative.14.1 Extract from safety data sheet for potassium hydroxidebiscuitManufacturer:Total formula:Synonyms:VariousKOHCaustic potashPotential dangers:Harmful if swallowed. Causes serious chemical burns.Chemicals in principle give rise to particular dangers. Therefore, they mustalways be handled with the necessary care by appropriately trained personnel.First-aid measures:Eye contact: Rinse with plenty of water, keeping the eyelid open (min. 10min.), consult eye specialist immediately.Skin contact: Wash off with plenty of water, dab with polyethylene glycol 400.Remove contaminated clothing immediately.Ingestion: Drink plenty of water (several litres if necessary), do not inducevomiting (risk of perforation!). Consult a doctor immediately. Do not attempt toneutralise.Inhalation: Fresh air. Consult doctor.Fire-fighting measures:Suitable extinguishing agents: according to environment.Particular dangers: Non-combustibleSpecial protective gear during fire-fighting: Only remain in danger area withrespiratory equipment independent of ambient air. Avoid skin contact bymaintaining a safety distance or wearing suitable protective clothing.Additional notes: Prevent extinguishing water from entering surface water orground water.Measures in case of accidental release:90 HM 1400 TRX

14. Appendix Extracts from safety data sheetsPersonal precautions: Avoid contact with substance. Avoid dust formation; Donot inhale dust.Environmental protection measures: Do not allow substance to enter sewagesystem.Cleaning/pick-up method: Pick up carefully when dry. Forward for disposal.Final clean.Storage:Tightly closed, dry. At +5 °C to +30 °C.Requirements for storage areas and containers: No aluminium, tin or zinccontainers.Personal protective equipmentRespiratory protection: Necessary in presence of dustHand protection for full or splash contact: Nitrile rubber protective gloves,coating thickness 0.11 mm, breakage time > 480 min.Eye protection: necessary. Safety goggles must always be worn whenhandling chemicals.Body protection: Suitable protective clothing must always be worn whenhandling chemicals.Safety and hygiene measures: Avoiding eating, drinking and smoking in theworkplace, and pay attention to cleanliness. Wash hands and face at the endof work. Change contaminated clothing immediately and wash thoroughlybefore re-using. Preventive Skin protection recommended.Stability and reactivityConditions to avoid: No information availableSubstances to avoid: Acute reactions possible with: metals, light alloys: Thefollowing can result: hydrogen (risk of explosion!);ammonium compounds, alkaline earth metals, halogens, halogen-halogencompounds, halogenated hydrocarbons, non-metal oxide halogenides,halogen oxides, organic nitro compounds, phosphorus, non-metal oxides,hdyrocarbons, anhydrides, strong acids.Dangerous products of decomposition: No data available.Additional notes: Extremely hygroscopic; exothermic dissolution process withwater; incompatible with metals, various plastics, glass, animal/vegetabletissues.Toxicological informationAcute toxicityAdditional toxicological information:After inhalation: corrosion of mucous membrane.After skin contact: chemical burns. After eye contact: chemical burns. Risk ofblinding! After swallowing: chemical burns in mouth, throat, oesophagus andgastrointestinal tract. There is a risk of perforation for oesophagus andstomach.Disposal informationChemicals must be disposed of in compliance with the pertinent nationalregulations.Transport informationRID/ADR: UN 1813 POTASSIUM HYDROXIDE, SOLID, 8, IIIMDG code: UN 1813 POTASSIUM HYDROXIDE, SOLID, 8, IIEmS: F-A S-BThe transport regulations are cited in accordance with the internationalregulations and in the form in which they are applied in Germany. Possibledeviations in other countries are not taken into account.Regulations1. IdentificationHM 1400 TRX 91

14. Appendix Extracts from safety data sheets2. National regulationsEC number 215-181-3Symbols: C CausticR phrases: 22-35Harmful if swallowed. Causes serious chemical burns.S phrases: 26-36/37/39-45In case of contact with the eyes, rinse thoroughly with water and consult adoctor immediately. Wear suitable protective clothing, protective gloves andsafety goggles/face protection. In case of accident or feeling unwell, consult adoctor immediately (produce "Potassium hydroxide" safety data sheet ifpossible)Water hazard class: 1Storage class VCI:8 BBG-Chemie data sheet:M004 Irritant substances/Caustic substancesM051 Hazardous chemical substancesEmployment restrictions:Comply with employment restrictions forjuveniles in accordance with § 22 JArbSchGand restrictions for pregnant and nursingwomen in accordance with §§ 4 and 5MuSchRiV14.2 Extract from safety data sheet for iodised activated carbonPlease note the reference to the extracts from safety data sheets used here on page 90!Manufacturer:Total formula:Synonyms:variousCActivated carbon, iodisedPotential dangers:Not a hazardous product in accordance with directive 67/548/EECChemicals in principle give rise to particular dangers. Therefore, they mustalways be handled with the necessary care by appropriately trained personnel.First-aid measures:Eye contact: Rinse with plenty of water, if pain persists consult an eyespecialist.Skin contact: Wipe off with water.Ingestion (particles, dust): Drink plenty of water. In case of feeling unwell,consult a doctor immediately.Inhalation (particles, dust): Fresh air.Fire-fighting measures:Suitable extinguishing agents: Powder, foam, water.Particular dangers: Combustible. Risk of dust explosion. In the event of firehazardous fumes or vapours may result.Special protective gear during fire-fighting: Only remain in danger area withrespiratory equipment independent of ambient air.Measures in case of accidental release:Personal precautions: Avoid dust formation.Cleaning/pick-up method: Pick up when dry. Forward for disposal. Final clean.Storage:Tightly closed, dry. Storage temperature: no limitation.Personal protective equipment92 HM 1400 TRX

14. Appendix Extracts from safety data sheetsRespiratory protection: Necessary in presence of dustHand protection for full or splash contact: Nitrile rubber protective gloves,coating thickness 0.11 mm, breakage time > 480 min.Eye protection: necessary. Safety goggles must always be worn whenhandling chemicals.Body protection: Suitable protective clothing must always be worn whenhandling chemicals.Safety and hygiene measures: Wash hands at the end of work.Stability and reactivityConditions to avoid: Strong heatingSubstances to avoid: Strong oxidants;Dangerous products of decomposition: No data available.Additional notes: Dust explosion possible.Toxicological informationAcute toxicity does not existAdditional toxicological information: No hazardous properties known; no toxiceffects are expected if handled correctly.Disposal informationChemicals must be disposed of in compliance with the pertinent nationalregulations.Transport informationRegulations1. Identification2. National regulationsNot subject to shipping instructionsEC number ---Symbols: ---R phrases: ---S phrases: ---Water hazard class:nwg (not hazardous to water)Storage class VCI: 10-1314.3 Extract from safety data sheet foractivated carbonPlease note the reference to the extracts from safety data sheets used here on page 90!Manufacturer:Total formula:Synonyms:variousCPure activated carbonPotential dangers:Not a hazardous product in accordance with directive 67/548/EECFirst-aid measures:Eye contact: Rinse with plenty of water, if pain persists consult an eyespecialist.Skin contact: Wash off with water.Ingestion (particles, dust): Drink plenty of water. In case of feeling unwell,consult a doctor immediately.Inhalation (particles, dust): Fresh air.Fire-fighting measures:Suitable extinguishing agents: Powder, foam, water.Particular dangers: Combustible. Risk of dust explosion. In the event of fireHM 1400 TRX 93

14. Appendix Extracts from safety data sheetshazardous fumes or vapours may result.Special protective gear during fire-fighting: Only remain in danger area withrespiratory equipment independent of ambient air.Measures in case of accidental release:Personal precautions: Avoid dust formation.Cleaning/pick-up method: Pick up when dry. Forward for disposal. Final clean.Storage:Tightly closed, dry. Storage temperature: no limitation.Personal protective equipmentRespiratory protection: Necessary in the presence of dustHand protection for full or splash contact: Nitrile rubber protective gloves,coating thickness 0.11 mm, breakage time > 480 min.Eye protection: necessary. Safety goggles must always be worn whenhandling chemicals.Body protection: Suitable protective clothing must always be worn whenhandling chemicals.Safety and hygiene measures: Wash hands at the end of work.Stability and reactivityConditions to avoid: Strong heatingSubstances to avoid: Strong oxidants;Dangerous products of decomposition: No data available.Additional notes: Dust explosion possible.Toxicological informationAcute toxicity does not existAdditional toxicological information:No hazardous properties known; no toxic effects are expected if handledcorrectly.Disposal informationChemicals must be disposed of in compliance with the pertinent nationalregulations.Transport informationRegulations1. Identification2. National regulationsNot subject to shipping instructionsEC number ---Symbols: ---R phrases: ---S phrases: ---Water hazard class:nwg (not hazardous to water)Storage class VCI: 10-1314.4 Extract from safety data sheet for mercuryPlease note the reference to the extracts from safety data sheets used here on page 90!Manufacturer:variousTotal formula:Hg94 HM 1400 TRX

14. Appendix Extracts from safety data sheetsFirst-aid measures:Potential dangers:Toxic if inhaled. Risk of cumulative effects.Very toxic for water organisms, can havelong term harmful effects in water courses.Chemicals in principle give rise to particular dangers. Therefore, they mustalways be handled with the necessary care by appropriately trained personnel.First-aiders: Ensure self-protectionEye contact: Rinse with plenty of water, keeping eyelid open (min. 10 min.),consult eye specialist immediately.Skin contact: Wash off with plenty of water. Remove contaminated clothingimmediately.Ingestion: If conscious drink plenty of water, induce vomiting. Administration ofactivated carbon (20 - 40 g in 10 % suspension). Consult a doctorimmediately.Inhalation: Fresh air. Artificial respiration or mechanical respiration ifnecessary. Consult a doctor immediately.Fire-fighting measures:Suitable extinguishing agents: according to environment.Particular dangers: Non-combustible. Vapours heavier than air. Fire insurrounding areas can cause hazardous fumes. The following can result in theevent of fire: Mercury vapours.Special protective gear during fire-fighting: Only remain in danger area withrespiratory equipment independent of ambient air. Avoid skin contact bymaintaining a safety distance or wearing suitable protective clothing.Additional notes: Prevent extinguishing water from entering surface water orground water.Measures in case of accidental release:Personal precautions: Do not inhale vapours/aerosols. Avoid contact withsubstance. Ensure supply of fresh air in closed roomsEnvironmental protection measures: Do not allow substance to enter sewagesystem.Cleaning/pick-up method: Pick up with suitable device. Forward for disposal.Final clean.Handling:Work under a fume hood. Do not inhale substance. Avoid development ofvapours/aerosols.Storage:Tightly closed, in a well ventilated location. Only accessible for experts. At+15°C to +25°C.Personal protective equipmentRespiratory protection: necessary. Combination filter Hg-P3Hand protection for full or splash contact: Nitrile rubber protective gloves,coating thickness 0.11 mm, breakage time > 480 min.Eye protection: necessary. Safety goggles must always be worn whenhandling chemicals.Body protection: Suitable protective clothing must always be worn whenhandling chemicals.Safety and hygiene measures: Avoiding eating, drinking and smoking in theworkplace, and pay attention to cleanliness. Wash hands and face at the endof work. Change contaminated clothing immediately and wash thoroughlybefore re-using. Preventive Skin protection recommended.Stability and reactivityConditions to avoid: Strong heating.Substances to avoid: Acetylides, ammonia, amines, alkali metals, azides,metals, halogens, acids (conc. sulphuric acid, nitric acid / hydrohalic acids),HM 1400 TRX 95

14. Appendix Extracts from safety data sheetscarbides, halogen oxides.Dangerous products of decomposition: The following can result in the event offire: Mercury vapours.Toxicological informationAcute toxicityAdditional toxicological information: After skin contact: Risk of skin sensitisation.Other information: In the event of intoxication, Hg compounds act as cell andprotoplasmic poisons.Symptoms of poisoning: acute: eye contact results in severe lesions. Afterswallowing and inhalation of dusts, the mucous membranes in thegastrointestinal and respiratory tract are damaged (metallic taste, nausea,vomiting, abdominal pain, bloody diarrhoea, intestinal corrosion, glotticoedema, aspiration pneumonia); reduction in blood pressure, cardiacdisrhythmia, circulatory collapse and kidney failure; chronic: Inflammation ofthe oral cavity with loss of teeth and mercury edge. Main manifestationsappear in the CNS (speech, vision, hearing, sensitivity disorders, amnesia,irritability, hallucinations, delirium, among other things).Disposal informationChemicals must be disposed of in compliance with the pertinent national regulations.Transport informationRID/ADR: UN 2809 MERCURY, 8, IIIIMDG code: UN 2809 MERCURY, 8, IIIEmS: F-A S-BThe transport regulations are cited in accordance with the internationalregulations and in the form in which they are applied in Germany. Possibledeviations in other countries are not taken into account.Regulations1. IdentificationEC number: 231-106-7Symbols:T ToxicN Hazardous to the environmentR phrases: 23-33-50/53Toxic if inhaled. Risk of cumulative effects.Very toxic for water organisms, can have long term harmful effects in water courses.S phrases: 7-45-60-61Keep container tightly closed. In case of accident or feeling unwell, consult adoctor immediately (produce "Mercury" safety data sheet if possible). This substanceand its container are to be disposed of as hazardous waste. Avoid release intothe environment. Refer to special instructions/consult safety data sheet.2. National regulationsWater hazard class: 3Storage class VCI:6.1 BBG-Chemie data sheet:M024 Mercury and its compoundsM050 Handling hazardous substancesHazardous Incident Ordinance no.: 29aEmployment restrictions:Comply with employment restrictions forjuveniles in accordance with § 22 JArbSchGComply with restrictions for pregnant andnursing women in accordance with §§ 4 and5 MuSchRiV96 HM 1400 TRX

14. Appendix Extracts from safety data sheets14.5 Extract from safety data sheet for hydrochloric acidPlease note the reference to the extracts from safety data sheets used here on page 90!Manufacturer:variousTotal formula:HClPotential dangers: Causes chemical burns. Irritates therespiratory organs. Risk of pulmonaryoedemaChemicals in principle give rise to particular dangers. Therefore, they mustalways be handled with the necessary care by appropriately trained personnel.First-aid measures:Eye contact: Rinse with plenty of water, keeping eyelid open (min. 10 min.),consult eye specialist immediately.Skin contact: Wash off with plenty of soap and water. Remove contaminatedclothing immediately.Ingestion: If conscious drink plenty of water, do not induce vomiting. Consult adoctor immediately.Inhalation: Remove casualty to fresh air and keep at rest.Fire-fighting measures:Suitable extinguishing agents: Water mist, foam, carbon dioxide, dry powder.Particular dangers: Particular hazard from the substance, its combustionproducts or resulting gases. In the event of fire, the following can be released:Hydrogen chloride ( HCl )Special protective gear during fire-fighting: Only remain in danger area withrespiratory equipment independent of ambient air.Measures in case of accidental release:Personal precautions: Remove persons to safety. Ensure supply of fresh air inclosed roomsEnvironmental protection measures: Do not allow substance to enter sewagesystem or waterways.Cleaning/pick-up method: Pick up with liquid-binding material (e.g. sand,kieselgur, universal binder). Neutralise with lime. Forward for disposal in wellsealed containers.Handling:Extraction.Only use acid-proof equipment.Storage:Notes on storage with other substances: Do not store together with strongoxidants.Tightly closed, in a well ventilated location. Storage class: 8L Causticsubstances, liquidPersonal protective equipmentGeneral protective measures: Do not inhale vapours.Respiratory protection: necessary (full mask).Hand protection for full or splash contact: Protective rubber glovesEye protection: necessary (see respiratory protection). Safety goggles mustalways be worn when handling chemicals.Body protection: Suitable protective clothing (acid-proof in this case) mustalways be worn when handling chemicals.Safety and hygiene measures: Wash hands before breaks and at the end ofwork. Change contaminated clothing immediately and wash thoroughly beforere-using. The use of protective skin ointment is recommended for preventiveskin protection.Stability and reactivityHM 1400 TRX 97

14. Appendix Extracts from safety data sheetsThermal decomposition: No decomposition if used properly.Dangerous reactions: Reactions with strong oxidants.Reactions with light alloys with formation of hydrogen.Dangerous products of decomposition: Chlorine.Toxicological informationAcute toxicity:Additional toxicological information: Other information: Causes chemical burns.Experience with human exposure: Vapours and mists cause chemical burnsand strongly irritate eyes and respiratory organs.Disposal informationAfter pre-treatment, the product must be forwarded to an approved specialwaste site in compliance with the special waste regulations.Chemicals must be disposed of in compliance with the pertinent nationalregulations.Transport informationTransport by landADR 8 / 05 BProduct description: 1789 Hydrochloric acid,Hazard no. 80 Substance no. 1789RID 8 / 05 BProduct description: 1789 Hydrochloric acid,Hazard no. 80 Substance no. 1789Transport by seaIMDG/UN 8 / 1789 / IIEmS 8-03 MFAG 700Correct technical name: HYDROCHLORIC ACID,Transport by airICAO/IATA-DGR 8 / 1789 / IICorrect technical name: HYDROCHLORIC ACID,Sending by post NOT PERMITTEDThe transport regulations are cited in accordance with the internationalregulations and in the form in which they are applied in Germany. Possibledeviations in other countries are not taken into account.RegulationsLabelling in accordance with Ordinance on Hazardous Substances/EC: subjectto labelling requirementDanger symbols C CausticR phrases34 Causes chemical burns.37 Irritates the respiratory organs.S phrases26 In case of contact with eyes, rinse thoroughly with water immediately andconsult doctor.45 In case of accident or feeling unwell, consult a doctor immediately (producethis label if possible).2. National regulationsWater hazard class: 1The specification of the water hazard class(WHC) refers to the pure substance98 HM 1400 TRX

14. Appendix Extracts from safety data sheetsOther regulations: ZH 1/129 "Data sheet: Irritantsubstances/Caustic substances (M 004)"14.6 Extract from safety data sheet for mercurous (II) chloridePlease note the reference to the extracts from safety data sheets used here on page 90!Manufacturer:variousTotal formula: Hg Cl 2First-aid measures:Potential dangers:Very toxic if swallowed. Causes chemicalburns. Toxic: Risk of serious damage tohealth from prolonged exposure throughcontact with skin or swallowing. Very toxic forwater organisms, can have long term harmfuleffects in water courses.Chemicals in principle give rise to particular dangers. Therefore, they mustalways be handled with the necessary care by appropriately trained personnel.First-aiders: Ensure self-protectionEye contact: Rinse with plenty of water, keeping eyelid open (min. 10 min.),consult eye specialist immediately.Skin contact: Wash off with plenty of water. Dab with polyethylene glycol 400.Remove contaminated clothing immediately.Ingestion: If conscious drink plenty of water, induce vomiting. Consult a doctorimmediately. Clean skin of vomit.Inhalation: Fresh air. Consult doctor.Fire-fighting measures:Suitable extinguishing agents: according to environment.Particular dangers: Non-combustible. Fire in surrounding areas can causehazardous fumes. The following can result in the event of fire: Mercuryvapours, hydrogen chloride.Special protective gear during fire-fighting: Only remain in danger area withrespiratory equipment independent of ambient air. Avoid skin contact bymaintaining a safety distance or wearing suitable protective clothing.Other information: Combat escaping vapours with water. Prevent extinguishingwater from entering surface water or ground water.Measures in case of accidental release:Personal precautions: Avoid dust formation; Do not inhale dust. Avoid contactwith substance. Ensure supply of fresh air in closed roomsEnvironmental protection measures: Do not allow substance to enter sewagesystem.Cleaning/pick-up method: Pick up carefully when dry. Forward for disposal.Final clean. Avoid dust formation.Handling:Work under a fume hood. Do not inhale substance.Storage:Tightly closed, in a well ventilated location. Only accessible for experts. Dry.Storage temperature: without limitations.Personal protective equipmentThe type of protective gear must be selected workplace-specifically,depending on concentration and quantity of hazardous substance. Thechemical resistance of the protective gear should be clarified with the relevantsupplier.HM 1400 TRX 99

14. Appendix Extracts from safety data sheetsRespiratory protection: Necessary in the presence of dust. Combination filterHg-P3Hand protection for full or splash contact: Nitrile rubber protective gloves,coating thickness 0.11 mm, breakage time > 480 min. EC directive89/686/EEC standard EN374.Eye protection: necessary. Safety goggles must always be worn whenhandling chemicals.Body protection: Suitable protective clothing must always be worn whenhandling chemicals.Safety and hygiene measures: Never eat or drink in the workplace. Washhands and face at the end of work. Change contaminated clothingimmediately. Preventive Skin protection recommended. Work under a fumehood. Do not inhale substance.Stability and reactivityConditions to avoid: Strong heating.Substances to avoid: Alkali metals, fluorine.Dangerous products of decomposition: The following can result in the event offire: Mercury vapours, Hydrogen chloride.Toxicological informationAcute toxicityAdditional toxicological information: After skin contact: Risk of skin resorption.Other information:In the event of intoxication, Hg compounds act as cell and protoplasmicpoisons. Symptoms of poisoning: acute: eye contact results in severe lesions.After swallowing and inhalation of dusts, the mucous membranes in thegastrointestinal and respiratory tract are damaged (metallic taste, nausea,vomiting, abdominal pain, bloody diarrhoea, intestinal corrosion, glotticoedema, aspiration pneumonia); reduction in blood pressure, cardiacdisrhythmia, circulatory collapse and kidney failure; chronic: Inflammation ofthe oral cavity with loss of teeth and mercury edge. Main manifestationsappear in the CNS (speech, vision, hearing, sensitivity disorders, amnesia,irritability, hallucinations, delirium, among other things.)Additional information:The substance must be handled with particular caution.Disposal informationChemicals must be disposed of in compliance with the pertinent nationalregulations.Transport informationRegulationsRID/ADR: UN 1624 MERCURIC (II) CHLORIDE, 6.1, IIIMDG code: UN 1624 MERCURIC CHLORIDE, 6.1, II, Marine Pollutant: PPEmS: F-A S-AThe transport regulations are cited in accordance with the internationalregulations and in the form in which they are applied in Germany. Possibledeviations in other countries are not taken into account.1. Identification in accordance with EC guidelinesEC number: 231-299-8Symbols: T+ Very toxicN Hazardous to the environmentR phrases: 28-34-48/24/25-50/53Very toxic if swallowed. Causes chemical burns. Toxic: Risk of seriousdamage to health from prolonged exposure through contact with skin orswallowing. Very toxic for water organisms, can have long term harmful effectsin water courses.Very toxic for water organisms, can have long term harmful effects in water100 HM 1400 TRX

14. Appendix Extracts from safety data sheets2. National regulationscourses.S phrases: 36/37/39-45-60-61Wear suitable protective clothing, protective gloves and safety goggles/faceprotection. In case of accident or feeling unwell, consult a doctor immediately(produce "Mercuric (II) chloride" safety data sheet if possible). This substanceand its container are to be disposed of as hazardous waste. Avoid release intothe environment. Refer to special instructions/consult safety data sheet.Water hazard class:3 (severe hazardous to water) VwVwS App.2Storage class VCI:6.1 BBG-Chemie data sheet:M004 Irritant substances/Caustic substancesM024 Mercury and its compoundsM050 Handling hazardous substancesHazardous Incident Ordinance no.: 19aEmployment restrictions:Comply with employment restrictions forjuveniles in accordance with § 22 JArbSchGComply with restrictions for pregnant andnursing women in accordance with §§ 4 and5 MuSchRiV14.7 Extract from safety data sheet for Tin (II) chloride 2xH2OPlease note the reference to the extracts from safety data sheets used here on page 90!Manufacturer:Total formula:Potential dangers:variousSnCl 2 x 2H 2 OHarmful if swallowed. Causes chemicalburns.Chemicals in principle give rise to particular dangers. Therefore, they mustalways be handled with the necessary care by appropriately trained personnel.First-aid measures:General notes: Symptoms of poisoning may not occur for many hours,therefore casualties should be monitored by a doctor for at least 48 hours afteran accident.Eye contact: Rinse with plenty of water, keeping eyelid open (min. 10 min.),consult eye specialist immediately if complaints persist.Skin contact: Wash off with plenty of water. Remove contaminated clothingimmediately.Ingestion: Consult a doctor immediately.Inhalation: Fresh air. Consult doctor.Fire-fighting measures:Suitable extinguishing agents: according to environment.Particular dangers:Special protective gear during fire-fighting: No special measures necessary.Other information:Measures in case of accidental release:Personal precautions: not necessary.Environmental protection measures: No special measures necessary.Cleaning/pick-up method: Ensure adequate ventilation. Must not be disposedof with domestic waste. Do not allow substance to enter sewage system.HM 1400 TRX 101

14. Appendix Extracts from safety data sheetsHandling:Chemicals must be disposed of in compliance with the pertinent nationalregulations.Safe handling instructions: No special measures necessary.Fire and explosion protection information: No special measures necessary.Storage:Requirements for storage areas and containers: -Information on storage with other substances: No special measuresnecessary.Additional information on storage conditions: Keep container tightly closedStorage class: -Classification according to Ordinance on Industrial Safety and Health(BetrSichV): -Personal protective equipmentThe type of protective gear must be selected workplace-specifically,depending on concentration and quantity of hazardous substance. Thechemical resistance of the protective gear should be clarified with the relevantsupplier.Respiratory protection: not necessaryHand protection: Protective gloves. The glove material must be impermeableand resistant to the productEye protection: necessary. Safety goggles must always be worn whenhandling chemicals.Body protection: Suitable protective clothing must always be worn whenhandling chemicals.Safety and hygiene measures: Keep away from food, drink and animal feed.Wash hands at the end of work and before breaks. Change contaminatedclothing immediately.Stability and reactivityConditions to avoid: No decomposition if stored and handled correctly.Substances to avoid: -Dangerous products of decomposition: Irritant gases/vapoursToxicological informationAcute toxicity:Additional toxicological information:After skin contact: Irritates skin and mucous membranes. Eyes: Stronglyirritant.Other information:No sensitising effect known.Disposal informationMust not be disposed of with domestic waste. Do not allow substance to entersewage system. Chemicals must be disposed of in compliance with thepertinent national regulations.Transport informationRegulationsRID/ADR: UN 3260 CAUSTIC ACID INORGANIC SOLID SUBSTANCE N.A.G.(Tin(II)- chloride dihydrate), 8, IIIIMDG code: UN 3260 CORROSIVE SOLID, ACIDIC, INORGANIC, N.O.S., 8,III,EmS:The transport regulations are cited in accordance with the internationalregulations and in the form in which they are applied in Germany. Possibledeviations in other countries are not taken into account.102 HM 1400 TRX

14. Appendix Extracts from safety data sheets1. Identification in accordance with EC guidelinesEC number:Symbols: C Caustic2. National regulationsR phrases: 22-34Harmful if swallowed. Causes chemical burns.S phrases: 7/8-26-36/37/39-45-60Keep container dry and tightly closed. In case of contact with eyes, rinsethoroughly with water immediately and consult doctor. Wear suitable protectiveclothing, protective gloves and safety goggles/face protection. In case ofaccident or feeling unwell, consult a doctor immediately (produce "Tin (II)chloride dihydrate" safety data sheet if possible).This substance and its container are to be disposed of as hazardous waste.Water hazard class:Storage class VCI:BG-Chemie data sheet:Hazardous Incident Ordinance no.:Employment restrictions:1 (slightly hazardous to water)HM 1400 TRX 103

15. Index15 Index3-W-V 59Accidents 25Backflusher 593ABCCalculation principle for calibration 72Calibration 62, 65Calibration checkprocedure 71Checking procedure 73Commissioning 49Company addresses 109Condensate 44Condensate collector 38Condensate container full 39Control keys 53Customer service 13Cuvette circuit 35DData, technical 77Device parameters in delivery status 78Differential pressure transducer 36EEditing keys 53Emergency phone number 92Error messages 50, 833-W-V temp. too low / too high 84Condensate 83Condensate in monitor 86Cooler temp. too low / too high 85Drift phenomenon 83flow 83Limit value 83Pressure 83Probe line temp. too low / too high 85Probe temp. too low / too high 84Reactor temp. too low/ too high 84Service request 87System pressure too low / too high 86temperatures 83Threshold value exceeded 86Volume flow too low / too high 86Zero offset drift too large 87Error messages: 85, 87Explanation of symbols 12, 17Function keys 54Gas drying 37Gold trap 59FGHHazard 25from chemicals 22from gases 21from hot components 22Hazards due to electrical equipment 21Heating cartridge 37Index 106Integration time 62Iodised activated carbon filter 22, 81, 91Key functions 53Limitation of liability 13IKLMMain menu 55Maintenanceoverview 80service schedule 80Measuring gas pump 36Measuring mode 50Measuring range 62, 77Measuring value calculation 38104 HM 1400 TRX

NNotesenvironmental protection 18general tip or information 18OOperating states 49Operating statuses 66Operating terminal 53Options for the standard device 29PParameter recording 62Password 56, 67, 78Personnel, qualification 23Power consumption 77Power supply 44Probe 57Probetube 57RReactor 56Reactor filling 37Reactor material 33rror messages in the event memory 84SS.Line 57Safety data sheetactivated carbon 95hydrochloric acid 99iodised activated carbon 94mercurous (II) chloride 101mercury 96potassium hydroxide biscuit 92Tin (II) chloride 2xH2O 103Safety data sheets 22Safety instructionsspecific 17Safety instructions, general 20Sample gas 34Sample Volume 56Scope of supply 29, 43Service request 62Spare parts and wearing parts 88Special keys 54Standby phase 49Symbols, other 12, 18System start 60Systempressure 56TThermocatalytic reactor 37Thermocatalytic reduction 33Thermocatalytic stage 29Three-way valve 59Threshold value 62Tips, recommendations 12Type approval 20Use, designated 23UV photometer 34UWWarning instructions, specificelectric power 18ESD 18General warning symbol 18hot surface 18Warning notice 17Warning notices 12Warning notices, generalHigh risk - danger 12, 17Lesser risk - caution 17Medium risk - warning 17Risk of equipment/environmental damage -Notice 17Warnings, meanings. 17Warnings, specificread operating instructions 18Warnings, specific.chemical burn 18hazardous to the environment 18toxic 18Warranty 13ZZero gas concentration 62Zero offset 59(automatic) 64(manual) 63determination 63HM 1400 TRX 105

16. DURAG GROUP company addresses16 DURAG GROUP company addressesDURAG GmbH Kollaustr. 10522453 Hamburg GermanyTel. +49 (0)40 55 42 18 – 0Fax +49 (0)40 58 41 54E-Mail: info@durag.deDVN – DURAGVertrieb/Service NordDVO – DURAGVertrieb/Service OstDVS – DURAGVertrieb/Service SüdDVW – DURAGVertrieb/Service WestE-Mail: DURAG-Nord@durag.de E-Mail: DURAG-Ost@durag.de E-mail: DURAG-Sued@durag.de E-Mail: DURAG-West@durag.deKollaustr. 10522453 HamburgTel. +49 (0)40 55 42 18 – 0Fax +49 (0)40 58 41 54Meißner Ring 409599 FreibergTel. +49 (0)37 31 30 04 – 0Fax +49 (0)37 31 30 04 – 22Weidenweg 1673087 Bad BollTel. +49 (0)71 64 9 12 25 – 0Fax +49 (0)71 64 9 12 25 – 50DURAG UK Office DURAG France Sarl DURAG Italia S.r.lAn der Pönt 53a40885 RatingenTel. +49 (0)21 02 74 00 – 0Fax +49 (0)21 02 74 00 – 28E-Mail: durag.uk@durag.de E-Mail: info@durag-france.fr E-Mail: info@durag.itSuite 17Brookside Business ParkCold Meece,Stone ST15 0RZGreat BritainTel. +44 (0)17 85 76 00 07Fax +44 (0)17 85 76 00 1449 rue Léonard de VinciBP 7016695691 GoussainvilleFranceTel. +33 (0)1 30 18 11 80Fax +33 (0)1 39 33 83 60Via Carlo Panseri, 11828100 NovaraItalyTel. +39 03 21 67 95 69Fax +39 03 21 47 41 65DURAG, Inc.Durag IndiaInstrumentationPrivate LimitedE-Mail: info@durag.comE-Mail: info@duragindia.com1355 Mendota Heights Road,Suite 200Mendota Heights,Minnesota MN 55120USATel. +1 (0)65 14 51 – 17 10Fax +1 (0)65 14 57 – 76 84#143/16, 4th Main Road,Industrial Town,RajajinagarBangalore 560 044IndiaTel.: + 91 (0)80 23 14 56 26Ext 20Fax: + 91 (0)80 23 14 56 27DURAG process &systems technology gmbhDURAG data systemsGmbHHegwein GmbHSmitsvonk Holland B.V.E-Mail: info@durag-process.de E-Mail: info@durag-data.de E-Mail: info@hegwein.de E-Mail: sales@smitsvonk.nlKollaustr. 10522453 HamburgGermanyTel. +49 (0)40 55 42 18 – 0Fax +49 (0)40 58 41 54Kollaustr. 10522453 HamburgGermanyTel. +49 (0)40 55 42 18 – 30 00Fax +49 (0)40 55 42 18 – 30 99Am Boschwerk 770469 StuttgartGermanyTel. +49 (0)7 11 13 57 88 – 0Fax +49 (0) 7 11 13 57 88 – 5P.O.Box 180 · 2700ADZoetermeerLoodstraat 57 · 2718 RVZoetermeerThe NetherlandsTel. +31 (0)79 361 35 33Fax +31 (0)79 361 13 78VEREWA Umwelt- undProzessmesstechnik GmbHE-Mail: verewa@durag.deKollaustr. 10522453 HamburgGermanyTel. +49 (0)40 55 42 18 – 0Fax +49 (0)40 58 41 54HM 1400 TRX 107

GmbH · Kollaustraße 105 · 22453 Hamburg · www.durag.de