MSA Technical Manual

Thermo Electron Corporation
11 West Thebarton Road

Thebarton SA 5031 AUSTRALIA
Operating as:
Thermo Gamma-Metrics Pty Ltd ABN 35 087 556 527 and
Thermo Ramsey Pty Ltd ABN 60 063 572 949
Phone: +61 8 8150 5300
Fax: +61 8 8234 5882
sales@thermogammametrics.com.au
On-Line Sampling and Analysis System

for

P.O. No:

Equipment Type: X-Ray Multi-Stream Analyser (MSA)

Equipment Nos:

Technical Manual

On-Line Sampling and Analysis Systems using the X-Ray Multi-Stream Analyser
(MSA) and associated documentation, are products of Thermo Electron Corporation
and shall in no way be reproduced or copied without prior written consent
of Thermo Electron Corporation.

Thermo Electron Corporation reserves the right to make changes to the product
and this document without notice.

On-Line Sampling and Analysis Systems using an
X-Ray Multi-Stream Analyser (MSA)
Applicable to Mark 4.2 MSA August 2003
A.C.N. 087 556 527

Operating as:
Thermo Gamma-Metrics Pty Ltd A.C.N. 087 556 527 and
Thermo Ramsey Pty Ltd A.C.N. 60 063 572 949

11 West Thebarton Road Thebarton 5031 Adelaide AUSTRALIA
(PO Box 292 Torrensville Plaza 5031 Australia)
Telephone: +61 8 8150 5300 Facsimile: +61 8 8234 5882
Website: www.thermogammametrics.com.au

5788 Pacific Centre Blvd San Diego CA 92121 USA
Telephone: +1 (858) 458 1700 Facsimile: +1 (858) 452 9250

Thermo Gamma-Metrics S.A.
Ricardo Matte Prez 0322 6641019 Providencia Santiago Chile
Telephone: +56 (2) 269 5005 Facsimile: +56 (2) 269 4978

On-Line Sampling and Analysis System (MSA) Technical Manual 3.1 i

Contents

Page
1 WARNI NGS AND CAUTI ONS .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. 1-1
1. 1 LI QUI D NI TROGEN (LN2) HANDLI NG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1. 2 RADI ATI ON SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.2.1 Maximum Allowable Radiation Levels/Doses.............................................................. 1-3
1.2.2 Radiation Levels Around the Analyser .......................................................................... 1-3
1.2.3 General Rules for Reducing Radiation Exposure ........................................................ 1-6
2 OVERVI EW .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. 2-1
2. 1 I NTRODUCTI ON. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2. 2 GLOSSARY OF TERMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2. 3 TYPI CAL COMPONENTS AND CONFI GURATI ON. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2. 4 OPERATI NG PRI NCI PLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.4.1 Analyser ............................................................................................................................. 2-7
2.4.2 Slurry Sampling.................................................................................................................. 2-9
2. 5 STATUTORY LI CENSI NG REQUI REMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2. 6 SAFETY AND ENVI RONMENTAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.6.1 Probe Protection Devices ............................................................................................. 2-11
2.6.2 Safety Guards ................................................................................................................. 2-11
2.6.3 Radiation Protection...................................................................................................... 2-11
2.6.4 Environmental Protection ............................................................................................. 2-12
2. 7 TRAI NI NG REQUI REMENTS FOR PLANT PERSONNEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2. 8 RECEI VI NG AND STORAGE OF EQUI PMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.8.1 Receipt and Inspection................................................................................................. 2-14
2.8.2 Storage Prior to Installation........................................................................................... 2-14
2.8.3 Filling the MEP Detector with LN2 on Delivery ............................................................ 2-15
2.8.4 Unpacking & Filling MEP Detector with LN2................................................................ 2-16
2.8.5 Routine Filling.................................................................................................................. 2-17
2. 9 CLEANI NG AND STORAGE FOR EXTENDED PLANT SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . 2-18
3 SPECI FI CATI ONS .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. 3-1
3. 1 SPECI FI CATI ON OF MATERI ALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1.1 Wetted Parts ..................................................................................................................... 3-1
3.1.2 Electronic Enclosures ....................................................................................................... 3-1
3.1.3 Paint Specification........................................................................................................... 3-2
3. 2 MECHANI CAL SPECI FI CATI ONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3. 3 METALLURGI CAL SAMPLER SPECI FI CATI ONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.3.1 AM643-300/400 Metallurgical Sampler ......................................................................... 3-6
Contents

On-Line Sampling and Analysis System (MSA) Technical Manual 3.1 ii

3. 4 ANALYSER ACCURACY DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
At t achment 1St i rr er Dat a Sheet s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
At t achment 2Per f ormance Speci f i cat i on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
4 INSTALLATI ON .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . .. . . .. . .. . 4-1
4. 1 RESOURCES & SERVI CES TO BE PROVI DED BY THE CUSTOMER . . . . . . . . . . . . . . . . . . . . . . . 4-2
4. 2 SPECI AL TOOLS REQUI RED FOR I NSTALLATI ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4. 3 CUSTOMER SCOPE OF WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4. 4 DI MENSI ONS AND MOUNTI NG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.4.1 Mounting the MSA........................................................................................................... 4-7
4. 5 I NSTALLI NG THE PROBE CARRI AGE AND MEP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.5.1 Procedure ....................................................................................................................... 4-14
4. 6 I NSTALLI NG THE MSA UMBI LI CAL CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4. 7 I NSTALLI NG SLURRY SAMPLERS AND PI PE WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4.7.1 Primary Samplers............................................................................................................ 4-20
4.7.2 Slurry Pipe Connections to the Analysis Tank............................................................. 4-21
4.7.3 Guidelines for Slurry Sampling Pipe Work ................................................................... 4-21
4. 8 PNEUMATI CS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
4.8.1 Air Requirement ............................................................................................................. 4-25
4.8.2 Air Connection............................................................................................................... 4-26
4. 9 WATER REQUI REMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
4.9.1 Water Requirement ....................................................................................................... 4-28
4.9.2 Water Connection......................................................................................................... 4-28
4. 10 ANALYSER (I N-PLANT) POWER REQUI REMENT AND CONNECTI ON . . . . . . . . . . . . . . . . 4-29
4.10.1 3-Phase Power Requirement........................................................................................ 4-29
4.10.2 3-Phase Power Supply Termination ............................................................................. 4-30
4. 11 CENTRAL (COMPUTER) EQUI PMENT REQUI REMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
4.11.1 Single-Phase Power Requirement and Connection................................................. 4-32
4. 12 I NSTRUMENTATI ON (DATA) CABLI NG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
4.12.1 General Specification for the Data Cable................................................................ 4-35
4.12.2 Recommended Cable Specification for Data Network ......................................... 4-36
4.12.3 Terminating the Data Cable........................................................................................ 4-36
4.12.4 High EMI (Noise) Environments..................................................................................... 4-41
4.12.5 Proximity to Power and High Voltage Cables ........................................................... 4-41
4.12.6 Use of Fibre Optic Cable .............................................................................................. 4-41
At t achment 1 Equi pment Dat a Sheet s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
At t achment 2I nst al l at i on Drawi ngs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
5 COMMI SSI ONI NG. .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . 5-1
5. 1 RESOURCES TO BE PROVI DED BY THE CUSTOMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5. 2 SPECI AL TOOLS & EQUI PMENT REQUI REMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5. 3 MECHANI CAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5. 4 SETTI NG UP THE COMPUTER AND DATA CABLE TERMI NATI ONS . . . . . . . . . . . . . . . . . . . . . . 5-6
5. 5 POWERI NG UP THE I N-PLANT EQUI PMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.5.1 Powering Up the MSA...................................................................................................... 5-9
5.5.2 Powering Up the Signal Analyser................................................................................. 5-11
5.5.3 Applying HV Bias to the MEP........................................................................................ 5-14
5. 6 TESTI NG AND ADJUSTI NG THE PNEUMATI C HOI ST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5.6.1 Testing.............................................................................................................................. 5-16
5.6.2 Hoist Adjustments ........................................................................................................... 5-18
5. 7 I NSTALLI NG THE MEP DETECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Contents

On-Line Sampling and Analysis System (MSA) Technical Manual 3.1 iii

5. 8 CALI BRATI NG THE LN2 SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
5.8.1 Functional Description of the LN2 Sensor Circuit ....................................................... 5-31
5.8.2 Procedure for Calibrating the LN2 Sensor................................................................... 5-32
5. 9 CHECKI NG AND TESTI NG THE MEP ELECTRONI CS SET UP . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
5.9.1 Connecting & Calibrating the MCA........................................................................... 5-33
5.9.2 Checking the Probe X-Ray Spectrum......................................................................... 5-37
5.9.3 Checking and Adjusting the SCAs .............................................................................. 5-40
5.9.4 Measuring the Probe Resolution.................................................................................. 5-43
5.9.5 Checking the Standard Count-Rates at the Computer .......................................... 5-44
5.9.6 Re-Checking Settings in the Slurry ............................................................................... 5-45
5. 10 STABI LI TY TESTI NG (STANDARDI SI NG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
5. 11 TESTI NG THE METALLURGI CAL SAMPLERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
5.11.1 Calibration-Mode .......................................................................................................... 5-50
5.11.2 Shift Sample .................................................................................................................... 5-51
5.11.3 User Adjustments ............................................................................................................ 5-51
5.11.4 Tests to be Performed.................................................................................................... 5-52
At t achment 1Consumabl es & Tool s Li st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55
At t achment 2Test Dat a Sheet s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57
At t achment 3MCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59
6 CALI BRATI ON. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. 6-1
6. 1 OVERVI EW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6. 2 EQUI PMENT & RESOURCE REQUI REMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6. 3 TAKI NG CALI BRATI ON SAMPLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.3.1 Taking Samples................................................................................................................. 6-5
6.3.2 Rules for Calibration Sampling....................................................................................... 6-6
6. 4 ASSAYI NG THE CALI BRATI ON SAMPLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6. 5 DEFI NI TI ON OF TERMS USED I N CALI BRATI NG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.5.1 Measurement Time.......................................................................................................... 6-8
6.5.2 Standard Count-rates...................................................................................................... 6-9
6.5.3 Calibration Data ............................................................................................................ 6-10
6.5.4 Assay Data...................................................................................................................... 6-11
6.5.5 RMS Error .......................................................................................................................... 6-11
6.5.6 Correlation Coefficient ................................................................................................. 6-11
6.5.7 Relative Error ................................................................................................................... 6-12
6. 6 RUNNI NG A REGRESSI ON. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
6.6.1 Deleting Samples in the Regression ............................................................................ 6-13
6.6.2 General Rules for Choosing the Best Equation.......................................................... 6-14
6. 7 CHECKI NG THE CALI BRATI ON ACCURACY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
6. 8 COMPARI NG CHECK SAMPLES WI TH ON-LI NE ASSAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
7 OPERATI ON. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. 7-1
7. 1 SAFETY & ENVI RONMENTAL PROTECTI ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.1.1 Safety Mode ..................................................................................................................... 7-2
7.1.2 Radiation Shielding.......................................................................................................... 7-3
7.1.3 Environmental Protection ............................................................................................... 7-4
7.1.4 Starting and Stopping ..................................................................................................... 7-4
7.1.5 Sampler Control ............................................................................................................... 7-6
7.1.6 Power Failures ................................................................................................................... 7-6
7. 2 MULTI -STREAM ANALYSER (MSA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.2.1 Basic Operation................................................................................................................ 7-7
7.2.2 Operation of the MEP.................................................................................................... 7-11
Contents

On-Line Sampling and Analysis System (MSA) Technical Manual 3.1 iv

7.2.3 Liquid Nitrogen Requirement of the MEP................................................................... 7-13
7.2.4 MSA Controlling Electronics.......................................................................................... 7-14
7.2.5 Using the Operator Interface Panel ............................................................................ 7-16
7.2.6 OI Panel Menu Options................................................................................................. 7-18
7.2.7 Signal Processing Electronics (Signal Analyser) ......................................................... 7-26
7. 3 SAMPLI NG SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
7.3.1 Sampling System Function............................................................................................ 7-27
7.3.2 Slurry Effects .................................................................................................................... 7-27
7.3.3 Metallurgical Sampler ................................................................................................... 7-28
7. 4 WI NI SA COMPUTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
7. 5 MSA SOFTWARE PROGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
7.5.1 Error Messages................................................................................................................ 7-33
7. 6 DATA COMMUNI CATI ON & I NTERFACI NG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
7.6.1 Data Communication Between Analyser and Computer ...................................... 7-35
7.6.2 Data Transfer to Plant Process Control Systems ........................................................ 7-36
7. 7 SI GNAL ANALYSER CI RCUI TS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38
7.7.1 Chassis Layout ................................................................................................................ 7-38
7.7.2 Signal Flow ...................................................................................................................... 7-40
7.7.3 Auxiliary Cards................................................................................................................ 7-41
7. 8 SI GNAL ANALYSER CARD FUNCTI ONALI TY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43
7.8.1 AM001/91 Linear Amplifier............................................................................................ 7-43
7.8.2 AM002/91 Pulse Validation........................................................................................... 7-43
7.8.3 AM994/01 MCA Access Module ................................................................................. 7-44
7.8.4 AM990 Single-Channel Analyser (SCA) ...................................................................... 7-44
7.8.5 AM092/10 Network Interface Card............................................................................. 7-45
7.8.6 AM093/11 COMMS Adaptor ........................................................................................ 7-46
7.8.7 Functionality of Signal Analyser Support Cards......................................................... 7-46
7.8.8 AM062/02 Bias Supply ................................................................................................... 7-47
7.8.9 AM963/20 Bias Controller.............................................................................................. 7-47
7.8.10 AM091/03 Live-Time Clock ........................................................................................... 7-50
7.8.11 Power Supply Cards ...................................................................................................... 7-50
7. 9 CLEANI NG AND REPLACI NG THE PROBE WI NDOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
7.9.1 Cleaning the Probe Window........................................................................................ 7-52
7.9.2 Replacing the Probe Window...................................................................................... 7-53
7.9.3 Replacing the Primary Window................................................................................... 7-55
7. 10 BACKI NG UP DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57
8 MAI NTENANCE . . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . 8-1
8. 1 PREVENTI VE MAI NTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.1.1 Daily Maintenance.......................................................................................................... 8-2
8.1.2 Weekly Maintenance...................................................................................................... 8-2
8.1.3 Monthly Maintenance .................................................................................................... 8-4
8.1.4 3-Monthly Maintenance................................................................................................. 8-5
8.1.5 6-Monthly Maintenance................................................................................................. 8-7
8.1.6 12-Monthly Maintenance or Plant Shutdown.............................................................. 8-8
8. 2 LUBRI CATI ON SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
8. 3 CLEANI NG THE PROBE AFTER SLURRY PENETRATI ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
8. 4 DI SMANTLI NG AND REASSEMBLI NG THE PROBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
8.4.1 Dismantling the Probe................................................................................................... 8-14
8.4.2 Reassembling the Probe............................................................................................... 8-15
8. 5 DRYI NG OUT THE PROBE PREAMPLI FI ER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
8. 6 STORAGE OF EQUI PMENT FOR EXTENDED PLANT SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . 8-19
8. 7 REPLACI NG THE SAMPLE HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
At t achment 1Recommended St art Up Spar es . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Contents

On-Line Sampling and Analysis System (MSA) Technical Manual 3.1 v

At t achment 2One Year Operat i onal Spar es . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
9 TROUBLE SHOOTI NG . .. . .. . . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. 9-1
9. 1 SOME BASI C SYSTEM MECHANI CAL CHECKS BEFORE PROCEEDI NG. . . . . . . . . . . . . . . . 9-2
9. 2 I SA ASSAYS DI FFERI NG FROM SHI FT/CHECK SAMPLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
9. 3 DI AGNOSTI C LEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
9. 4 LOCATI NG A FAULT WI TH THE ANALYSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
9.4.1 Checking the Signal Analyser Data Communication.............................................. 9-13
9.4.2 Window Rupture Alarm................................................................................................. 9-13
9.4.3 Window Rupture Circuit Self Test ................................................................................. 9-15
9.4.4 LN2 Monitor...................................................................................................................... 9-17
9.4.5 LN2 Circuit Self Test ......................................................................................................... 9-17
9.4.6 Checking the Signal Analyser Settings........................................................................ 9-18
9.4.7 Checking the MEP Detector ........................................................................................ 9-21
9. 5 LOCATI NG A FAULT WI TH METALLURGI CAL SAMPLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
10 SERVI CE &WARRANTY . . . .. . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . 10-1
10. 1 CUSTOMER SERVI CE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
10. 2 SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
10. 3 EQUI PMENT WARRANTY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
10. 4 REPAI RS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4

On-Line Sampling and Analysis System (MSA) Technical Manual 3.1 ii

This page is intentionally left blank

On-Line Sampling and Analysis System (MSA) Technical Manual 3.1 iii

List of Figures

Figure 1-1 Typical Radiation Levels Around an Analysis Tank with a MEP in Operation.....................1-4
Figure 1-2 Maximum Radiation Levels around the probe (MEP) when not in operation and shielded for
maintenance purposes. ...............................................................................................1-5
Figure 1-3 Maximum Radiation Levels around the Radiation Gauge (MEP)when unshielded and raised
on the hoist out of the Analysis Tank. ............................................................................1-5
Figure 1-4 MEP Source Holder Showing fitting of 43403 Shield ........................................................1-7
Figure 2-1 Multi-Stream Analyser .....................................................................................................2-5
Figure 2-2 Typical Configuration of an On-Line Analyser System with an MSA .................................2-6
Figure 4-1 Typical 6-Stream MSA Layout .........................................................................................4-8
Figure 4-2 Typical MSA showing Location of Electronic Control Enclosures .....................................4-9
Figure 4-3 Typical Installation Diagram for a 6-Stream MSA ..........................................................4-10
Figure 4-4 Dimensions and Weight of the MEP..............................................................................4-12
Figure 4-5 MSA Probe Carriage Assembly.....................................................................................4-13
Figure 4-6 Wiring Motor Cable Umbilical Grade.........................................................................4-16
Figure 4-7 Piping and Instrumentation Diagram for a Typical 6-stream MSA. ................................4-27
Figure 4-8 Example Electrical Enclosure and Connections.........................................................4-31
Figure 4-9 Signal Analyser Chassis Layout Central Equipment Requirements ................................4-37
Figure 4-10 AIN Data Cable Termination ......................................................................................4-40
Figure 5-1 AM955 Converter (Data Interface) Unit...........................................................................5-7
Figure 5-2 Signal Analyser Chassis Layout .....................................................................................5-12
Figure 5-3 Example MSA Controller Chassis Layout.....................................................................5-13
Figure 5-4 Piping & Connection diagram for a typical 6-stream MSA...........................................5-17
Figure 5-5 MEP and Detector Exploded View.............................................................................5-23
Figure 5-6 MEP Detector Components and Cable Connections ..................................................5-25
Figure 5-7 Completed MEP/Detector Assembly ............................................................................5-27
Figure 5-8 Fitting the MEP Source Holder and Shield.....................................................................5-28
Figure 5-9 Exploded View of the MEP Window Assembly...............................................................5-30
Figure 5-10 Typical Energy X-Ray Spectrum from a MEP...............................................................5-34
Contents

On-Line Sampling and Analysis System (MSA) Technical Manual 3.1 iv

Figure 6-1 Example Regression Plot ............................................................................................. 6-14
Figure 6-2 Example plots of the difference between on-line and laboratory assays .................... 6-21
Figure 7-1 An Example of How to Calculate a MSA Zone and Sampler Mask .............................. 7-25
Figure 7-2 Metallurgical Sampler Assembly-Front Elevation.......................................................... 7-30
Figure 7-3 Metallurgical Sampler Assembly-Side Elevation........................................................... 7-31
Figure 7-4 Signal Analyser Chassis Layout .................................................................................... 7-39
Figure 7-5 Signal Flow Through the Signal Analyser....................................................................... 7-41
Figure 7-6 Showing jumper link on AM093/11............................................................................... 7-46
Figure 7-7 Exploded View of the MEP Window Assembly.............................................................. 7-56
Figure 8-1 Exploded View of the Components of an MEP............................................................ 8-13
Figure 8-2 Fitting the MEP Source Holder and Shield.................................................................... 8-14
Figure 8-3 The Sample Hose....................................................................................................... 8-21
Figure 8-4 The sample hose correctly attached to cutter ........................................................... 8-21
Figure 9-1 An Example of how to Calculate a MSA Zone and Sampler mask ................................ 9-5
Figure 9-2 Signal Analyser Chassis Layout ...................................................................................... 9-8
Figure 9-3 Components of the Window Assembly ....................................................................... 9-14
Figure 9-4 Showing jumper link on AM093/11............................................................................... 9-16

Contents

On-Line Sampling and Analysis System (MSA) Technical Manual 3.1 v

List of Tables

Table 3-1 Safety Yellow Paint Specification .....................................................................................3-2
Table 3-2 Equipment Standard Paint Specification.........................................................................3-3
Table 3-3 Mechanical Specifications..............................................................................................3-5
Table 3-4 Metallurgical Sampler Specification................................................................................3-6
Table 3-5 Typical Analysis Accuracies .............................................................................................3-8
Table 4-1 Recommended Cables for Interconnecting Devices ...................................................4-36
Table 5-1 Common Elemental Fluorescent X-Ray Energies ..........................................................5-38
Table 7-1 Variable Speed Drive Factory Settings ...........................................................................7-15
Table 7-2 Signal Analyser Card Function.......................................................................................7-40
Table 9-1 MSA Operator Interface Panel Error Messages ................................................................9-4
Table 9-2 Diagnostic LED Colours ...................................................................................................9-7
Table 9-3 Signal Analyser LEDs - Functionality..................................................................................9-9
Table 9-4 Window Rupture Circuit Status LEDs ...............................................................................9-15
Table 9-5 Fault Diagnosis for Metallurgical Samplers.....................................................................9-24

On-Line Sampling and Analysis System (MSA) Technical Manual 3.1 1-1

1
Warnings and Cautions

Pl ease read t hi s sect i on whi ch descri bes t he any pot ent i al
hazards associ at ed wi t h t he anal yser equi pment . You wi l l
see t hese symbol s t hroughout t hi s manual .

Read thi s secti on BEFORE attempti ng to operate
the i n-stream anal yser equi pment.

Warni ngs and caut i ons, i ncl udi ng for l i qui d ni t rogen are
i dent i fi ed t hroughout t he manual by t hi s symbol i n t he l eft
margi n:

Radi at i on hazard warni ngs and caut i ons are i dent i fi ed by
t hi s t refoi l symbol i n t he l eft margi n:

Contents


1.1 Liquid Nitrogen (LN
2
) Handling
The anal yser uses a sensi t i ve hi gh resol ut i on Sol i d St at e
devi ce, Li qui d Ni t rogen (LN
2
) i s requi red t o cool t he uni t .
The anal yser wi l l not operat e wi t hout LN
2
and can be
permanent l y damaged wi t hout i t .

Prot ect i ve Cl ot hi ng:
LN
2
i s ext remel y col d (-196C, -320F) and wi l l cause
seri ous burns i f al l owed t o come i nt o cont act wi t h ski n or
eyes. ALWAYS use l ong l eat her gl oves, a ful l -face mask
and ful l cover cl ot hi ng (l ong t rousers and l ong shi rt
sl eeves) when handl i ng LN
2
.

St ori ng t he LN
2
Cont ai ner:
Even t hough LN
2
i s an i nert chemi cal , t he st orage
cont ai ner shoul d not be kept i n a confi ned space where
personnel may be worki ng because t he cont ai ner vent s
ni t rogen gas t hat may depl et e t he oxygen l evel i n t he ai r i n
an encl osed area. To t ransfer LN
2
t o t he MEP i t i s best t o
use a 10 l i t re t ransfer dewar t hat i s fi l l ed fi rst from t he
mai n st orage cont ai ner t hen carri ed t o t he MEP requi ri ng
fi l l i ng.

Transport i ng LN
2
:
NEVER t ransport LN
2
i n t he passenger compart ment of a
mot or vehi cl e. Ensure LN
2
t ransfer dewar(s) are properl y
rest rai ned.

Bul k LN
2
Storage
LN
2
may be avai l abl e from a l ocal suppl i er i n t ransport
cont ai ners of around 160 l i t res cal l ed FLE whi ch may be
rent ed on an exchange basi s.

Warni ng:
1. Al ways use LN
2
of at l east 99. 5% puri t y. Lesser puri t y
i ncreases t he l evel of pot ent i al l y expl osi ve l i qui d
oxygen l evel s i nsi de t he MEP Dewar.
2. Never use any cool ant except LN
2
.

The anal yser probe must al ways be kept vert i cal whenever
i t has l i qui d ni t rogen i n i t . Thi s ensures LN wi l l not spi l l ,
and al so t hat LN i s i n good cont act wi t h t he col d fi nger
t hat keeps t he det ect or at LN t emperat ure.

Warnings and Cautions Radiation Safety


1.2 Radiation Safety
For st abi l i t y and l ong t erm rel i abi l i t y, t he anal yser uses a
very smal l but t on radi oi sot ope (di sc of 8 t o 15mm
di amet er) as a source of X-rays, i nst ead of an X-ray t ube.
The part of t he anal yser (t he probe) t hat cont ai ns t he
radi oi sot ope i s cl assifi ed as an i ndust ri al Radi at i on Gauge
by t he Int ernat i onal Commi ssi on for Radi at i on Prot ect i on
(ICRP).

A t refoi l radi at i on warni ng si gn must be at t ached t o each
anal yser i n t he pl ant . The l ocal radi at i on regul at ory
aut hori t y can provi de det ai l s of requi rement s.

1.2.1 Maximum Allowable Radiation Levels/Doses
The ICRP has set t wo l i mi t s for radi at i on exposure; one
for t he general publ i c and one for personnel who work
dai l y wi t h radi at i on and whose exposure i s moni t ored.
These l evel s have been adopt ed by many count ri es
i ncl udi ng Aust ral i a vi a t he Nat i onal Heal t h and Medi cal
Research Counci l (NHMRC). These l evel s are:

1. 1, 000Sv per year maxi mum al l owabl e radi at i on dose
for t he General Publ i c.

2. 20, 000Sv per year maxi mum al l owabl e radi at i on dose
for Radi at i on Workers (i . e. i n an i ndust ri al
envi ronment ).

The al l owed radi at i on exposure may be recei ved i n several
short hi gh l evel burst s or as a l ow even rat e t hroughout t he
year, eg. 1, 000Sv per year i s equi val ent t o 0. 5Sv per
hour for 40 hours per week for 50 weeks per year.

1.2.2 Radiation Levels Around the Analyser
Because t he probe i s used i n an i ndust ri al envi ronment and
cl assi fi ed as a Radi at i on Gauge, t he maxi mum al l owed
l evel s of radi at i on around t he anal yser when t he probe i s
i n normal operat i on i n t he pl ant (i . e. around t he Anal ysi s
Tank) i s 500Sv per hour at any poi nt 50mm from t he
ext ernal surface and 10Sv per hour at any poi nt 1000mm
from t he ext ernal surface.

Act ual t ypi cal radi at i on l evel s around a probe i n operat i on
i n an Anal ysi s Tank are shown i n Figure 1-1.

Radiation Safety Warnings and Cautions


Fi gur e 1- 1 Typi cal Radi at i on Level s Ar ound an Anal ysi s Tank
wi t h a MEP i n Oper at i on
When t he probe i s mount ed i n t he operat i ng posi t i on (i . e.
l owered i nt o t he Anal ysi s Tank), t he radi at i on l evel s
around t he anal yser are negl i gi bl e because t he source X-
rays onl y penet rat e about 5mm i nt o t he sl urry or sol ut i on.
The act i ve wi ndow di amet er i s onl y about 20mm.

When t he radi oi sot ope i s mount ed i n t he radi at i on gauge,
t he radi at i on l evel s on t he surface of t he gauge (probe) are
l ow enough for safe handl i ng i n al l operat i ons. Typi cal
radi at i on l evel s around t he probe are shown i n fi gures 1-2
and 1-3.

The probe emi t s radi at i on onl y i n t he forward di rect i on
from t he gauge head. However, i t i s al ways advi sabl e t hat
radi at i on l evel s are kept t o a mi ni mum so i t i s
recommended t hat sui t abl e shi el ds be pl aced on t he probes
whenever t hey are removed for ext ended peri ods of t i me.

Shi el di ng t he radi at i on from t he probe can be done by
means of ei t her:
1. At t achi ng t he st andard bi scui t (suppl i ed) by cl i ppi ng
i t around t he wi ndow of t he probe head, or
2. Fi xi ng t he Insert i on Guard t o t he face of t he probe
det ect or usi ng t wo M3 x 12 count ersunk screws
suppl i ed wi t h t he guard, refer t o Figure 1-4.

Cauti on:
Avoi d l ooki ng di rect l y at t he source at l ess t han 1 met re.
Al ways use a t el escopi c mi rror when i nspect i ng t he
radi oi sot ope source cl osel y.



<0.1

<0.1

<0.1

<0.1

<0.1

<0.1

<0.1

100

cm

5

50

100

50

5
<2

Sv/h

100
50

5

cm

Source Type: C m - 244 or Pu - 238

Maximum Source Activity of 100 mCi

Fi gur e 1- 2 Maxi mum Radi at i on Level s ar ound t he pr obe ( MEP)
when not i n oper at i on and shi el ded f or mai nt enance pur poses.

<0.
<0.
1. <0. <0.
22 <2
10

cm
5

5
10 5
5
800 Sv/h
10 5 5

cm

1.

Fi gur e 1- 3 Maxi mum Radi at i on Level s ar ound t he Radi at i on
Gauge ( MEP) when unshi el ded and r ai sed on t he hoi st out of
t he Anal ysi s Tank.
Source Type: Cm-244 or Pu-238
Maximum Source Activity of 100mCi


Note:
1. The X-rays from t he radi oi sot ope sources used i n
Thermo El ect ron i nst rument s DO NOT make t he sl urry
or sol ut i on radi oact i ve. Exci t at i on of t he at oms i n t he
sampl e i s an ext remel y short process, l ast i ng for l ess
t han 1 t housandt h of a mi crosecond!
2. The radi at i on source remai ns act i ve even i f t he anal yser
power i s off.
3. Ask your RSO (Radi at i on Safet y Offi cer) or cont act t he
Company i f you have any concerns.

1.2.3 General Rules for Reducing Radiation Exposure

Mi ni mi se t he t i me spent near a source of radi at i on;

Maxi mi se t he di st ance from t he source of radi at i on;

Use shi el di ng bet ween t he source of radi at i on and
yoursel f.

Note:
Some appl i cat i ons may requi re t he probe t o use t wo
sources.



Multi-Element Probe
Beryllium
Window
Shield
43403
M3x12
Csk Screw
57565 (2)
Source
(3 possible
positions)
Window Contact
Fingers

Fi gur e 1-4 MEP Sour ce Hol der Showi ng f i t t i ng of 43403 Shi el d



On-Line Sampling and Analysis System (MSA) Technical Manual 3.1 Attachment 1

Section 1 Warnings and Cautions
Attachment 1
LN
2
Material Safety Data Sheet


Material Safety Data Sheet

Liquid Nitrogen

This product evaporates to form a simple asphyxiant and is not classified as hazardous according to
hazardous substances classification criteria of Worksafe Australia.

IDENTIFICATION
Product name: Liquid nitrogen
Other name:
Product code: 701, 702, 703, 704, 705, 706, 707, 711, 713
UN number: 1977
Dangerous Goods: 2.2
HAZCHEM code: 2RE
Poisons schedule: None allocated
Use: Low temperature heat transfer fluid, purge gas, inert atmospheres, semiconductor applications.
Application method: Vaporised liquid distributed through pressure and flow controlled distribution
systems.

Physical Description/Properties:
Appearance: colourless and odourless liquid.
Boiling point (deg. C at 101.32 kPa): -195.8
Vapour pressure (kPa at 25 deg. C): No liquid phase.
Relative density (0 deg. C, 101.3 kPa, Air = 1): 0.967
Flashpoint (deg C): Non-flammable
Lower flammability limit (%): Non-flammable.
Upper flammability limit (%): Non-flammable.
Solubility in water (101.32 kPa, 20 deg. C): 0.0149 cm3 gas/cm3

Other properties:
Storage pressure is regulated to process requirements, refer to operating instructions.
Cryogenic liquid, critical temperature deg. C: -146.9
Critical pressure kPa: 3,400
Material compatibility: Inert, non-corrosive. Low temperature will change mechanical
properties of some materials.


HEALTH HAZARD INFORMATION

Health Effects: Liquid will cause rapid freezing on contact and will rapidly evaporate to form a simple
asphyxiant.

Acute: Low temperatures created during evaporation may cause hypothermia. Skin may freeze to
surfaces cooled by liquid and be torn on removal.
Swallowed: Unlikely route of exposure due to rapid evaporation of liquid.
Eye: Liquid can cause tissue freezing or frostbite.
Skin: Liquid can cause tissue freezing or frostbite, cold gas may cause hypothermia.
Inhaled: Low temperature gas when inhaled may induce an asthma attack in susceptible individuals. May
replace oxygen in the inhaled air and cause asphyxiation.
As the amount of oxygen inhaled is reduced from 21 to 14 volume % the pulse rate will accelerate and
the rate and volume of breathing will increase. The ability to maintain attention and think clearly is
diminished, muscular co-ordination is somewhat disturbed. As oxygen decreases from 14 to 10%
judgement becomes faulty, severe injuries may cause no pain. Muscular effort leads to rapid fatigue.
Further reduction to 6% may cause nausea and vomiting. Ability to move may be lost.
Permanent brain damage may result even after resuscitation from exposure to this low level of oxygen.
Below 6% breathing is in gasps and convulsions may occur.
Inhalation of a mixture containing only nitrogen will result in unconsciousness from the first
breath and death will follow in a few minutes. (adapted from Henderson and Haggard)

Chronic: No known effects, not carcinogenic or mutagenic and no specific
reproductive effects.

First Aid: Rescue personnel are advised to monitor oxygen concentration when entering confined spaces
and poorly ventilated areas. Self contained breathing apparatus is recommended.
Swallowed: Not applicable.
Eye: Immediately flush with tepid water in large quantities, or with sterile saline
solution. Hold eyelids apart and irrigate with gentle flow for 15 minutes bathing entire eyeball. Seek
medical attention.
Skin: Cold Burns: Irrigate with tap or tepid water for 15 to 30 minutes. Apply sterile dressing and treat as
thermal burn. Immerse large areas or limbs in tap or tepid water for 15 to 30 minutes. Do not apply any
form of direct heat. Seek medical attention.
Hypothermia: Move to warm place. Wrap in blanket, avoid direct heat. Seek medical attention. Summon
ambulance recommend Hospital admission for observation.
Inhaled: Remove from exposure. Check there is no obstruction to the airway if breathing is weak or has
ceased and give artificial respiration, preferably using an oxygen resuscitator. Keep warm and rested.
Seek medical attention. Further treatment should be symptomatic and supportive.
First Aid Facilities: OxyViva , water and sterile dressings. Self-contained breathing apparatus for
rescue personnel.

Advice to Doctor: Treatment for asphyxia and cold burns.
Overview Glossary of Terms


PRECAUTIONS FOR USE

Exposure Standards: No Worksafe exposure standard. Liquid will evaporate at ambient conditions to
form Asphyxiant in high concentrations.

Engineering Controls: Refer to Australian Standard AS1894 for more detailed installation and
operating recommendations. Obtain specialist advice before installing and operating cryogenic liquid
equipment. Low temperature insulation is required for liquid storage and transfer. Equipment design and
materials must allow for contraction at low temperature. Pressure relief valves must be used between
points where liquid and cold gas can be trapped as high pressures will develop as liquid evaporates and
gas warms. Uninsulated surfaces must be protected against skin contact. Connect all pressure relief
devices to a safe location having good natural ventilation. Check for leaks prior to use. Ensure liquid
supply valve is shut and equipment is depressurised and warmed to ambient temperature before
commencing maintenance and repairs.

Personal Protection: Avoid contact with escaping liquid and gas. Only experienced and properly trained
people should use this product. Wear safety glasses, safety shoes, use leather or low temperature
compatible protective gloves when operating valves. Follow equipment operating instructions.

Flammability: Non-flammable product.

SAFE HANDLING INFORMATION

Storage and Transport: Commonwealth, State and Territory Dangerous Goods legislation contain
requirements which affect cryogenic liquid storage and transport.
Store: Refer to vessel operating instructions. Do not store near sources of ignition, oxidising agents,
poisons, combustible material and flammable liquids. Portable liquid containers should be stored:
upright, prevented from falling, in a secure area; below 45 deg C, in a dry, well ventilated enclosure
constructed of non-combustible material with firm level floor (preferably concrete), away from areas of
heavy traffic and emergency exits. Transport: Transport on open top vehicles in accordance with
Australian Code for the Transport of Dangerous Goods. Shipping name: Nitrogen, refrigerated liquid
Transport E.P.G. card: 2C3.

Spills and disposal: Release of liquid to atmosphere will generate vapour fog clouds which can travel
considerable distances and affect visibility. These clouds should be treated as asphyxiating atmospheres
as the evaporated liquid will have displaced air.
Refer to vessel operating instructions. In an emergency allow liquid and gas to escape to atmosphere.
Monitor oxygen concentration in confined spaces. Contact nearest BOC Gases centre for guidance. Leak
checking may be done by pressure drop test or soapy water at joints and outlets. Shut liquid and gas
supply valves to stop leak if possible and safe to do so. Notify the nearest BOC Gases centre. Residual
product will be disposed of under BOC Gases supervision.

Fire/Explosion Hazard: Temperatures in a fire may cause liquid vessels and related equipment to
rupture and internal pressure relief devices to be activated. Storage vessels may contain fine particle
insulation materials or foam products which may be hazardous or release hazardous decomposition
products in a fire. Call fire brigade.
Cool vessels exposed to fire by applying water from a protected location. Do not approach vessels
suspected of being hot. Evacuate the area if unable to keep vessels cool.




2
Overview

The On- Li ne Sampl i ng and Anal ysi s System manual
cont ai ns t echni cal i nformat i on and procedures for
operat i ng and mai nt ai ni ng an on-l i ne anal ysi s syst em
i ncorporat i ng a Mul t i -St ream Anal yser (MSA).

The manual i s organi sed i nt o sect i ons for easy
accessi bi l i t y by t he personnel carryi ng out t he work. The
sect i ons are desi gned t o be st and-al one manual s for t he
purposes of i nst al l i ng, operat i ng and mai nt ai ni ng t he
equi pment .

Thi s sect i on provi des an i nt roduct i on t o t he On- Li ne
Sampl i ng and Anal ysi s System i ncorporat i ng a Mul t i -
St ream Anal yser (MSA). It descri bes what t he equi pment
l ooks l i ke, i t s pri nci pl e of operat i on, a gl ossary of t erms,
st at ut ory requi rement s, t rai ni ng requi rement s and
recei vi ng and st orage of t he equi pment on-si t e pri or t o
i nst al l at i on.

The Inst al l at i on sect i on covers act i vi t i es associ at ed wi t h
i nst al l i ng t he equi pment such as si t e preparat i on, ut i l i t i es
requi red, t rade personnel requi rement s, mechani cal and
el ect ri cal i nst al l at i on, st art -up and t est i ng.

The Commi ssi oni ng sect i on covers t he i ni t i al poweri ng up
and t est i ng of t he equi pment pri or t o cal i brat i ng.

The Cal i brat i on sect i on covers t he on-l i ne cal i brat i on
procedures for t he equi pment .
Introduction Overview


The Operat i on sect i on covers t he day-t o-day use of t he
equi pment , i ncl udi ng st art -up, shut down, and rout i ne
operat i onal and mai nt enance checks.

The Mai nt enance sect i on covers mechani cal , pneumat i c
and el ect ri cal servi ce act i vi t i es. Di sassembl y procedures
are provi ded for repai r and mai nt enance. Thi s sect i on i s t o
be used i n conj unct i on wi t h t he Part s Li st Manual whi ch
provi des part i dent i fi cat ion drawi ngs. Recommended
Spare Part s are l i st ed i n t he Mai nt enance sect i on.

The Troubl e Shoot i ng sect i on provi des i nformat i on t o ai d
di agnosi ng t he cause of a mal funct i on wi t h t he equi pment .

A separat e st and-al one manual i s provi ded for t he
cont rol l i ng Sof t ware t hat i s suppl i ed wi t h t he equi pment .
That manual i s al so provi ded el ect roni cal l y i n PDF format
on t he soft ware CD suppl i ed wi t h t he equi pment .

2.1 Introduction
The Mul t i -St ream Anal yser (MSA) i ncorporat es an XRF
on-l i ne (or i n-st ream) anal ysi s i nst rument t hat provi des
real -t i me, cont i nuous on-l i ne anal yses of key met al s and
pul p densi t y for cont rol of mi neral processi ng pl ant s. The
MSA enabl es a si ngl e Mul t i -El ement Probe (MEP) t o be
used t o measure up t o 12 process st reams on a t i me-shari ng
basi s. The i nformat i on i s present ed i n graphi cal and
numeri cal form t o meet t he needs of pl ant operat ors,
met al l urgi st s and managers.

The MEP i s a robust sol i d-st at e devi ce and has been i n use
i n mi neral processi ng pl ant s worl dwi de for many years.
The MEP forms t he basi s of anal ysi s i n t he fami l y of wet
sampl e on-l i ne anal ysers. For exampl e, dedi cat ed si ngl e
st ream anal yser (MEP or AnSt at ), Si ngl e and Mul t i -St ream
Sol ut i on Anal yser (SSSA and MSSA) and t he Mul t i -St ream
Anal yser (MSA), t hat i s det ai l ed i n t hi s manual .

Rat her t han mul t i pl ex t he sl urry t hrough a si ngl e fl ow cel l
measurement zone, t he MSA works by movi ng a probe
bet ween adj acent sl urry st reams, bought t oget her i n a
si ngl e l ocat i on. Refer sect i on 2. 3 for di scussi on of
confi gurat i on opt i ons.
Overview Glossary of Terms


2.2 Glossary of Terms
ADAM Anal ogue Dat a Acqui si t i on Modul e (4-20 mA i nput / out put
devi ce)
AIN Hi st ori cal l y t hi s acronym comes from Amdel Inst rument
Net work. Thermo El ect ron now owns and mai nt ai ns t he AIN
prot ocol . It descri bes a si mpl e fi el dbus wi t h si ngl e mast er and
up t o 31 sl ave devi ces usi ng a t wo wi re RS-485 bus.
AnStat Anal ysi s and Sampl i ng St at i on (a mul t i -st age sl urry sampl i ng
t ank desi gned i n accordance wi t h t he l aws of sampl i ng t heory.
The l ast st age of t he t ank houses t he MEP)
ISA In-St ream Anal ysi s (name gi ven t o t he on-l i ne anal ysi s syst em
because i t i s based mai nl y on i mmersi on probe t echnol ogy)
LN
2
Li qui d Ni t rogen (ext remel y col d i nert l i qui d for cool i ng t he
MEP) Int erchangeabl e wi t h LN.
LTR Li ve-Ti me-Rat i o (t he percent age of t i me t he MEP el ect roni cs
act ual l y processes i nformat i on)
MCA Mul t i -Channel Anal yser (used for set t i ng up SCAs for MEP
El ect roni cs)
MEP Mul t i -El ement Probe (hi gh sensi t i vi t y XRF anal ysi s probe
capabl e of measuri ng up t o ei ght el ement s and sl urry densi t y
si mul t aneousl y)
MSA Mul t i -St ream Anal yser (on-l i ne anal ysi s equi pment whi ch uses
j ust one MEP for measuri ng mul t i pl e sl urry st reams on a t i me-
shari ng basi s (mul t i pl exed)).
OI Operat or Int erface. Local di spl ay and keyboard for
cont rol l i ng t he RLC
OLE Obj ect Li nki ng and Embeddi ng
OPC OLE for Process Cont rol . Communi cat i on Prot ocol . Refer
Soft ware Manual .
RARP Regressi on Anal ysi s Program (The Thermo El ect ron soft ware
package for performi ng cal i brat i ons)
RLC Remot e Logi c Cont rol l er (si mi l ar t o a PLC but has propri et ary
funct i onal i t y for anal ysers)

RSO Radi at i on Safet y Offi cer
s. d. St andard Devi at i on i n count i ng st at i st i cs
SCA Si ngl e-Channel Anal yser (provi ded i n t he el ect roni cs (Si gnal
Anal yser) associ at ed wi t h t he MEP for set t i ng mul t i pl e si ngl e
measurement wi ndows (channel s))
Wi nISA The mai n soft ware package t hat runs on t he cent ral comput er,
used for capt uri ng and di spl ayi ng assay dat a and confi guri ng
t he syst em.
XRF X-Ray Fl uorescence
Typical Components and Configuration Overview


2.3 Typical Components and Configuration
A Typi cal 6-st ream Mul t i -St ream Anal yser (MSA) i s
shown i n Fi gure 1-2. A t ypi cal confi gurat i on of t he
anal ysi s syst em i s shown i n Fi gure 2-2.

Typi cal In-pl ant Equi pment i ncl udes:

MSA Frame t o whi ch t he probe carri age, Anal ysi s
Tanks, Si gnal Anal yser, MSA Cont rol l ers and ot her
associ at ed equi pment are at t ached t o form a compl et el y
sel f-cont ai ned on-l i ne anal ysi s uni t provi di ng
i nt ermi t t ent st ream measurement wi t h assay up-dat e
t i mes of nomi nal l y 8 mi nut es for a si x st ream MSA
uni t . To ai d i n mai nt enance of t he probe a Servi ce Bay
i s somet i mes fi t t ed at one end of t he MSA uni t .
MEP (Mul t i -El ement Probe) t he anal ysi s probe,
mount ed on a pneumat i cal l y operat ed hoi st on t he MSA
Frame, and i mmersed i nt o t he sl urry i n an Anal ysi s
Tank for sl urry measurement . A spray ri ng washes t he
probe as i t rai ses, t hus prevent i ng cont ami nat i on
bet ween st reams.
Anal ysi s Tank i s a speci al l y desi gned t ank (Anal ysi s
Zone) used t o de-aerat e and homogenousl y mi x t he
sl urry as i t passes t he probe; t hus present i ng a
represent at i ve sl urry sampl e t o t he measurement probe.
Each MSA frame may cont ai n up t o 6 smal l (300mm
wi de) anal ysi s t anks. Each anal ysi s t ank i ncl udes a
St i rrer for mi xi ng and a Wat er Spray for frot h
suppressi on. The wat er spray can be t urned off vi a an
i sol at i on needl e val ve at t he mai n wat er i nl et of t he
MSA uni t . A fl anged out l et i s provi ded i n t he anal ysi s
sect i on for mai nt enance purposes. If i ncl uded, a
Met al l urgi cal Sampl er wi l l be fi t t ed t o t he out l et
sect i on of each anal ysi s t ank i n t he MSA frame. The
mai n advant ages of usi ng i ndi vi dual anal ysi s t anks for
each st ream rat her t han re-di rect i ng fl ows from
di fferent st reams i nt o t he same anal ysi s t ank are:
1. Anal ysi s t anks can handl e a very l arge dynami c
range of fl ow rat es.
2. No need for sl urry de-mul t i pl exi ng.
3. No cross-cont ami nat i on bet ween st reams.
4. No empt yi ng, fi l l i ng nor washi ng t i mes. Probe i s
washed duri ng movement bet ween st reams.
5. Met al l urgi cal Sampl ers can operat e i ndependent l y
of t he ISA syst em, t hus al l owi ng shi ft composi t e
sampl es t o be t aken.
Overview Typical Components and Configuration


6. The out l et s can easi l y be re-di rect ed back i nt o t he
process. A possi bi l i t y i s t o re-di rect a number of
process st reams t o a common sump.
Met al l urgi cal Sampl er i s l ocat ed at t he out l et t o t he
Anal ysi s Tank. Each Met al l urgi cal Sampl er has a
separat e t i mer, whi ch has bot h manual and t wo t ypes of
aut omat i c modes (shi ft and cal i brat i on mode) of
operat i on sel ect abl e vi a t he Operat or Int erface (OI)
panel . Hence, t hey are i deal l y sui t ed for bot h
cal i brat i on purposes and t he col l ect i on of shi ft
composi t e sampl es.
MSA Cont rol l ers. El ect roni c encl osures i ncorporat i ng a
Si gnal Anal yser for processi ng t he probe si gnal s and
t ransmi t t i ng t he dat a vi a a RS-485 (AIN) t o a cent ral
cont rol l i ng PC, t he Operat or Int erface (OI) panel and
RLC for cont rol l i ng and moni t ori ng probe movement
and i nt erl ocks.
Pri mary Sampl ers (or st ream spl i t t ers); are provi ded as
part of t he syst em or opt i onal l y provi ded by t he
Cust omer. Such sampl ers are requi red t o l i mi t t he
sl urry st ream fl ow rat es t o t he MSA t o l ess t han
20m
3
/ hr (nomi nal l y 5 10m
3
/ hr) for t he smal l (300mm
wi de) t anks and t o l ess t han 35m
3
/ hr for t he medi um
(400mm wi de) t anks (nomi nal l y 5-20m
3
/ hr).

Fi gur e 2- 1 Mul t i -St r eam Anal yser
Central Equi pment i ncl udes:
Cont rol l i ng PC whi ch i s usual l y i nst al l ed i n t he pl ant
cont rol room and runs t he Thermo El ect ron Wi nISA
soft ware package on a Wi ndows NT or 2000 pl at form. The
cent ral cont rol l i ng PC can be i nt erfaced t o t he Cust omers
process cont rol syst em usi ng t he Modbus prot ocol , ei t her
RS232 Seri al or net worked vi a TCP/ IP (Et hernet ) or usi ng
OPC (Obj ect Li nki ng and Embeddi ng for Process Cont rol ).
The soft ware l ogs dat a from t he MSA and di spl ays t he on-
l i ne assays, cal cul at ed from t he MEP si gnal s i n t he pl ant .
Typical Components and Configuration Overview


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Fi gur e 2- 2 Typi cal Conf i gur at i on of an On- Li ne Anal yser Syst em
wi t h an MSA
Overview Typical Components and Configuration


2.4 Operating Principle
2.4.1 Analyser
The Mul t i -St ream Anal yser (MSA) enabl es a si ngl e hi gh
performance anal ysi s probe (MEP) t o be appl i ed t o up t o
fi ft een mi neral processi ng st reams on a t i me-shari ng basi s.
The MEP i s suspended on a pneumat i c hoi st so t hat i t can
be l owered i nt o any one of a number of smal l speci al l y-
desi gned anal ysi s t anks mount ed on a st urdy frame. The
purpose of t he MSA mechani sm i s t o t ransport t he probe
bet ween t he anal ysi s t anks (one anal ysi s t ank per st ream)
i n mi ni mum t i me. The MSA uni t i s modul ar i n desi gn so
t hat furt her anal ysi s t anks can be added. Typi cal l y one
MSA modul e (frame) wi l l cont ai n up t o si x (6) 300mm
wi de (smal l ) anal ysi s t anks (l ess for 400 mm wi de, medi um
si ze t anks) and so l arge MSA uni t s such as a 12-st ream
uni t wi l l consi st of t wo modul ar uni t s (frames) bol t ed
t oget her. Met al l urgi cal Sampl ers, i f fi t t ed, are l ocat ed at
t he out l et t o each of t he anal ysi s t anks (see phot o l eft ).
These sampl ers have bot h manual and aut omat i c (shi ft and
cal i brat i on) modes of operat i on.

The vert i cal movement i s produced by a pneumat i c ram
(hoi st ) whi ch l i ft s t he anal ysi s probe out of t he sl urry and
cl ear of t he anal ysi s t anks (see phot o l eft ). Hori zont al
movement i s by t hree-phase mot or and vari abl e frequency
AC dri ve (i nvert er). The mot or i s fi t t ed wi t h a speed
reduct i on gearbox and dri ves by a fri ct i on wheel on a
t rack. Accurat e hori zont al posi t i oni ng i s achi eved by
feedback from proxi mi t y sensors t hat det ect t he probe
carri age. One sensor per anal ysi s t ank i s provi ded and
t hey are cl amped al ong a rai l at t he cent re l i ne of each
anal ysi s t ank (see phot o l eft ).

The probe can al so be rai sed from t he sl urry and "homed"
t o a mai nt enance (servi ce) zone by pushi ng a Park Probe
but t on.

The Remot e Logi c Cont rol l er (RLC) cont ai ned wi t hi n t he
MSA Cont rol l er encl osures mount ed on t he MSA frame
cont rol s al l of t he funct i ons requi red by t he MSA uni t (eg.
probe movement , st ream measurement t i me, frequency and
sequence, met al l urgi cal sampl i ng, probe wat er sprays and
st i rrer operat i on) wi t h user i nt eract i on obt ai nabl e vi a t he
Operat or Int erface (OI) panel l ocat ed on t he cont rol l er' s
out si de panel .
Statutory Licensing Requirements Overview


Hi gh l evel access t hrough t he OI t o change t he hardware
confi gurat i on requi res a password t o be ent ered. Refer t o
t he sect i on on t he RLC menu i t ems for operat i onal det ai l s.
Low l evel access al l ows for vi ewi ng of st at us of t he MSA.

The cont rol l i ng comput er, l ocat ed i n t he cont rol room, al so
provi des cont rol l i ng soft ware cont rol over t he st ream
measurement t i me (i n i nt egral seconds), frequency and
sequence. The MSA uni t makes no rest ri ct i ons on t he
order t hat st reams are sel ect ed al t hough i t wi l l cert ai nl y
t ake l ess t i me movi ng bet ween adj oi ni ng anal ysi s t anks
t han wi del y separat ed ones. In normal operat i on t he
comput er i ssues commands t o t he MSA, vi a t he RLC, t o
move t o a part i cul ar st ream where i t wi l l st ay unt i l
i nst ruct ed t o move t o anot her. Provi di ng t he MSA i s not
i n manual operat i ng mode, i t wi l l respond t o t he command
i mmedi at el y.

The Mul t i -El ement Probe (MEP) i s t he anal yser part of t he
MSA and i s an energy di spersi ve X-ray fl uorescent
(EDXRF) devi ce wi t h hi gh sensi t i vi t y and sel ect i vi t y and
i s capabl e of measuri ng up t o ei ght el ement s and densi t y
si mul t aneousl y. The MEP uses a Li qui d Ni t rogen (LN
2
)
cool ed Si (Li ) sol i d-st at e X-ray det ect or whose sensi t i vi t y
enabl es t he measurement of very l ow concent rat i ons of
el ement s, such as t hose encount ered i n t ai l i ngs st reams.

Each el ement i n t he sl urry (or sol ut i on) emi t s fl uorescent
X-rays of an energy and i nt ensi t y whi ch i s charact eri st i c
of t hat el ement and i t s concent rat i on. Fl uorescent and
scat t ered X-rays from t he sl urry i mpi nge on t he det ect or t o
produce smal l el ect ri cal pul ses t hat are shaped and
ampl i fi ed. The peak ampl i t ude of t he pul se i s proport i onal
t o t he energy of t he i nci dent X-ray. The scat t ered X-rays
are used t o provi de measurement s of t he sl urry densi t y.
The number of X-rays i s proport i onal t o t he el ement al
concent rat i on i n sl urry. Energy spect rum resol ut i on i s
t ypi cal l y bet t er t han 200eV, measured on t he FeK peak.

The anal yser i s cal i brat ed for each st ream agai nst a sui t e
of sampl es t aken over a peri od of t i me t o cover a wi de
range of pl ant operat i ng variabl es and condi t i ons i n each
st ream of t he MSA. The out put s from t he anal yser are sent
on t he AIN RS-485 dat a communi cat i on fi el dbus t o t he
cont rol l i ng comput er l ocat ed i n a cl ean, dust -free room i n
t he pl ant (usual l y t he cont rol room). The comput er l ogs t he
i ncomi ng dat a, comput es t he on-l i ne assays usi ng preset
cal i brat i on equat i ons and di spl ays t he assay i nformat i on i n
t abl es and as t rend graphs. Informat i on may al so be
pri nt ed and di st ri but ed t o a pl ant process cont rol syst em.
Overview Statutory Licensing Requirements


2.4.2 Slurry Sampling
The correct present at i on of sampl ed sl urry t o on-l i ne
anal ysers i s fundament al t o t he success of any on-l i ne
anal ysi s syst em. It i s a wel l known fact t hat t he ful l fl ow
sampl i ng and anal ysi s wi t h dedi cat ed measurement i s t he
preferred met hod, however for t he MSA, most st reams wi l l
requi re sampl i ng as fl ow rat es wi l l t oo hi gh for t hi s t ype
of anal yser. Refer sect i on 3. 2 for fl ow rat e capaci t i es.

Sl urry Sampl i ng i s usual l y done usi ng Pri mary Sampl ers
(as shown l eft ), ei t her Pressure (t op) or Gravi t y (bot t om)
t ype.

2.5 Statutory Licensing Requirements
For prot ect i on of workers and t he publ i c, t he use of
radi oi sot ope sources and radi at i on gauges i s regul at ed by a
government aut hori t y, whi ch i n al l t he St at es of Aust ral i a
i s t he Depart ment of Heal t h or i t s equi val ent . Si mi l ar
regul at i ons are i n use i n all count ri es and t hey are al l
based on recommendat i ons of t he Int ernat i onal At omi c
Energy Agency (IAEA).

Note:
The AM282 Mul t i -El ement probe (MEP) i s cl assi fi ed as a
Seal ed Source Radi at i on Gauge.

The onus i s on t he Cust omer t o not i fy t hei r l ocal
regul at ory aut hori t y wi t h det ai l s of t he radi at i on gauges
and radi oi sot opes t o be used i n t hei r XRF anal yser syst em
t o ensure compl i ance. The regul at i ons normal l y provi de
for at l east t he fol l owi ng mat t ers:
1. Regi st rat i on of ownershi p of each radi oi sot ope
used wi t h t he cont rol l i ng regul at ory aut hori t y.
2. Responsi bi l i t y of t he owner for mai nt ai ni ng
records of radi oi sot ope det ai l s i ncl udi ng l ocat i on.
3. Responsi bi l i t y of t he owner for safe st orage and
safe usage of t he radi oi sot ope sources.

Sampled
Flow
Main
Flow

Sampled
Flow
Main
Flow
Statutory Licensing Requirements Overview


4. Nomi nat i on of one person as a Radi at i on Safet y
Offi cer (RSO) t o carry out t he nomi nat ed dut i es
i n rel at i on t o safe worki ng pract i ces.
5. Inst ruct i on of personnel i n correct use of
radi oi sot ope sources, and t he i ssue t o t hem of
radi at i on moni t ori ng devi ces when requi red by
t he regul at i ons.
6. Not i fi cat i on t o t he cont rol l i ng aut hori t y of t he
l oss of any radi oi sot ope, or of any i nci dent such
as mechani cal damage or fi re t o t he radi at i on
gauge.
7. Ensure t hat radi at i on warni ng si gns are
promi nent l y l ocat ed and are mai nt ai ned i n a
cl ean, i nt act and l egi bl e st at e.

As part of t he Vendor Dat a Suppl y, t he Company provi des
det ai l s of t he radi at i on gauges and radi oi sot opes and t hi s
i nformat i on i s t o be ret ai ned by t he si t e RSO.

Overview Safety and Environment


2.6 Safety and Environmental
2.6.1 Probe Protection Devices
In t he event t hat any operat i ng condi t i ons are abnormal
(eg. power, ai r suppl y, probe wi ndow rupt ure, et c. ) t he
MEP pneumat i c hoi st wi l l aut omat i cal l y rai se t he probe
cont ai ni ng t he radi oi sot ope from t he t ank so as t o prevent
possi bl e damage t o t he probe det ect or. The probe cannot
be l owered i nt o t he t ank unt i l such t i me as t he probl em i s
rect i fi ed. A Wi ndow Rupt ure i s al so report ed on t he
di spl ay screen of t he comput er.

In t he event t hat t he probe runs dry of LN
2
and warms up,
a t emperat ure devi ce i nsi de t he probe aut omat i cal l y shut s
down t he Hi gh Vol t age bi as t o t he det ect or t o mi ni mi se
i nt ernal damage. Pri or t o runni ng dry, a Low Li qui d
Ni t rogen warni ng wi l l be di spl ayed on t he comput er
screen once t he LN
2
l evel drops t o and bel ow 1 l i t re.

2.6.2 Safety Guards
Safety Guards, wi t h an Interl ocked Door, are provi ded
on t he MSA frame t o prevent i nj ury from t he movi ng
probe. When t he i nt erl ocked door i s opened, t he probe i s
rai sed and i t s movement st opped. The MSA revert s t o
manual mode and cannot be put back i nt o aut omat i c
(operat i onal ) mode unt i l t he door i s cl osed. When t he
i nt erl ocked door i s opened, t he st i rrers can cont i nue
worki ng t o prevent t he anal ysi s t anks from sandi ng up i f
manual l y request ed usi ng t he St i rrer Overri de but t on,
l ocat ed i nsi de t he door.

Two pneumat i c ai r cyl i nders are used i n t he MSA uni t ; one
l arge uni t vert i cal l y mount ed on t he probe carri age hoi st
and a second smal l uni t for t he probe safet y l at ch, al so on
t he probe carri age hoi st . Bot h of t hese ai r cyl i nders
operat e under aut omat i c cont rol ; however t hey are
compl et el y encl osed behi nd t he safet y guards t hus
prevent i ng any i nj ury t o operat ors. Because t he safet y
guard door t hat al l ows access t o t hese uni t s i s i nt erl ocked
al l movement , i ncl udi ng t he el ect ri cal and pneumat i c
operat i on, ceases when t he door i s opened and wi l l onl y
resume when t he door i s ful l y cl osed.

2.6.3 Radiation Protection
The MEP cont ai ni ng t he radi oi sot ope onl y emi t s radi at i on
i n a forward di rect i on from t he probe wi ndow when t he
st andard bi scui t has been removed. Under normal
operat i on wi t h t he probe l owered i nt o t he anal ysi s t ank,
t he t ank i t sel f and t he sl urry act s as a shi el d.
Overview Safety and Environment


When t he probe i s rai sed from t he t anks duri ng movement
bet ween st reams, radi at i on shi el di ng i s provi ded by t he
st rat egi cal l y mount ed surroundi ng met al work.

2.6.4 Environmental Protection
By i t s nat ure most of t he mechani cal part s of t he anal yser
syst em have t o operat e under t he normal l y arduous
envi ronment al condi t i ons t hat prevai l i n a mi neral
processi ng pl ant . The desi gn mi ni mi ses t he number of
movi ng part s t hus exposed and speci fi es l arge safet y
margi ns and wear l i fet i mes on t hose t hat are. El ect ri cal
and el ect roni c cont rol equi pment i s envi ronment al l y
prot ect ed t o AS1939-1990 cl ass IP66 (NEMA4). Mat eri al s
Speci f i cat i ons are gi ven i n chapt er 3.

Envi ronment al operat i ng condi t i ons are:

Si gnal Anal yser and cont rol l i ng el ect roni cs: Ambi ent
Operat i ng Temperat ure: -10 t o +50C.
Sun Exposure: Onl y a probl em i f operat i ng
t emperat ures i nsi de t he Si gnal Anal yser cabi net
i ncrease beyond t hat quot ed above. In t hi s case t he
Cust omer may need t o i nst al l a sun shade over t he
MSA.

Note:
The Company recommends t hat a roof be i nst al l ed over t he
MSA uni t i f i t i s t o be i nst al l ed out doors, or i f si gni fi cant
spi l l age i s expect ed from above.

Cauti on:
Caut i on IP rat i ng may be compromi sed by i mproperl y
seal ed gl ands or gl and hol es.

2.7 Training Requirements for Plant Personnel
Duri ng si t e commi ssi oni ng t he Company engi neer wi l l
provi de i nformal hands-on t rai ni ng i n t he operat i on,
radi at i on safet y and rout i ne mai nt enance of t he anal yser
syst em. Very det ai l ed operat i on and mai nt enance
procedures are provi ded i n t hi s manual .

Overview Training Requirements for Plant Personnel


Radi at i on l evel s around t he MEP are very l ow; however, i t
i s usual l y a requi rement of t he regul at ory heal t h
aut hori t i es t hat si t e personnel are l i censed t o handl e
radi oi sot opes and use radi at i on gauges. One si t e empl oyee
shal l al so be appoi nt ed as t he Radi at i on Safet y Offi cer
(RSO). Thi s i mpl i es t hat at l east one si t e person must be
formal l y t rai ned i n radi at i on safet y and become sui t abl y
l i censed. Your l ocal regul at ory heal t h aut hori t y provi des
t he formal t rai ni ng and l i censi ng, t herefore t hi s cannot be
done by t he Company.

Note:
Any si t e personnel who are requi red t o remove t he probe
wi ndow and radi oi sot ope source hol der may be requi red t o
be l i censed or supervi sed by t he RSO. Check wi t h your
l ocal aut hori t y.

Any ot her operat i onal or mai nt enance st aff who wi l l not be
requi red t o work wi t h t he act ual radi at i on gauge (t he MEP
i t sel f), do not need t o be l i censed; however, t hey must be
demonst rat ed t he radi at i on safet y i ssues rel at ed t o t he
equi pment i f requi red t o work i nsi de t he MSA safet y
guards (e. g. t o mai nt ai n st i rrers). Thi s i s done by t he
Company engi neer duri ng commi ssi oni ng of t he equi pment
or i t can be done by ot her t rai ned and l i censed si t e
personnel .

It i s t he responsi bi l i t y of t he si t e RSO or ot her l i censed
and responsi bl e personnel t o ensure t hat t he probe i s
adequat el y shi el ded whi l st mai nt enance personnel carry
out t hei r work on t he equi pment . The st andard bi scui t
used for st andardi si ng t he probe al so act s as a radi at i on
shi el d for t he probe. [Because t he radi at i on l evel drops t o
essent i al l y background wi t hi n 1m of t he front of t he probe
t hen shi el di ng of t he probe i s somet i mes not necessary].

The Company al so hol ds formal Trai ni ng Courses i n
operat i ng and mai nt ai ni ng i t s anal ysers i n Aust ral i a for i t s
Cust omers. Addi t i onal Trai ni ng Courses can al so be hel d
on-si t e upon request and t hese are usual l y from t wo t o fi ve
days durat i on dependi ng on t he cust omers t rai ni ng
requi rement s and t he number of empl oyees requi ri ng
t rai ni ng. Refer t o our web si t e for furt her det ai l s.

Receiving and Storage of Equipment Overview


2.8 Receiving and Storage of Equipment
2.8.1 Receipt and Inspection
Upon recei pt of cont ai ners and crat es, i nspect for any
obvi ous damage duri ng t ransport . Take det ai l ed not es and
phot ographs of any not i ceabl e damage and not i fy t he
Transport Company and Thermo Electron i mmedi at el y.

An Equi pment Li st and schemat i c di agram of your syst em
component s i s provi ded as an at t achment t o t he
Inst al l at i on sect i on of t hi s manual . The i t ems i n t he
Equi pment Li st shoul d be checked off agai nst t he act ual
suppl y of equi pment and packi ng l i st s t o ensure t hat
cri t i cal i t ems have not been omi t t ed. Not i fy Thermo Electron
i mmedi at el y i f you t hi nk t hat some equi pment may have
been omi t t ed from t he consi gnment .

Note:
El ect roni c equi pment can sust ai n el ect rost at i c damage
wi t hout evi dence of physi cal abuse.

2.8.2 Storage Prior to Installation
Any equi pment t hat i s not requi red for i ni t i al i nst al l at i on,
i . e. equi pment whi ch i s onl y requi red for syst em t est i ng
and cal i brat i on by t he Company engi neer upon arri val on-
si t e, shoul d be l eft packed i n i t s shi ppi ng crat es and st ored
i n a dry safe l ocat i on away from di rect sun, corrosi ve
fl ui ds and vi brat i on. For exampl e, t he MEP det ect or and
i sot ope, comput er equi pment , spare part s, t est equi pment
and consumabl e i t ems.

Warni ng:
Any damage t o or l oss of equi pment whi l st st ored on
Cust omer premi ses may resul t i n del ays i n commi ssi oni ng
t he syst em and addi t i onal cost s t o t he Cust omer.

Cauti on:
If t he equi pment i s t o be st ored on-si t e past 4 weeks aft er
shi pment , t hen t he MEP det ect or must be removed from i t s
packi ng crat e and fi l l ed wi t h LN
2
.

Overview Receiving and Storage of Equipment


2.8.3 Filling the MEP Detector with LN
2
on Delivery
As soon as t he equi pment arri ves on-si t e, t he MEP det ect or
(cont ai ni ng t he radi oi sot ope) must be fi l l ed wi t h l i qui d
ni t rogen (LN
2
) t o prevent possi bl e damage occurri ng due
t o prol onged exposure t o normal ambi ent t emperat ures.
Refer t o t he unpacki ng and fi l li ng i nst ruct i ons i n cl ause
2. 8. 4.

Warni ng:
Al ways use LN
2
i ncreases t he l evel of pot ent i al l y expl osi ve l i qui d oxygen
l evel s i nsi de t he MEP dewar. Use onl y LN
2
, do not
subst i t ut e LN
2
wi t h any ot her cool ant .

Warni ng:
The Company speci fi es on t he i nst ruct i on document
at t ached t o t he det ect or (and/ or crat e) t he dat e by whi ch
t he MEP det ect or must be fi l l ed wi t h LN
2
. Fai l ure t o
compl y wi t h t hi s requi rement may voi d t he warrant y on t he
MEP det ect or.

The det ect or dewar wi l l requi re 10 t o 11 l i t res of LN
2
t o
fi l l i t . Because t he dewar i s warm t hen t he LN
2
wi l l boi l
off more rapi dl y i ni t i al l y and so i t must be t opped up.
Use a t orch or l ong bl ack pl ast i c cabl e-t i e t o check l evel s.
Do not use a hol l ow di pst i ck.

Cauti on:
The t emperat ure of LN
2
i s very l ow; -196C (-320F).
Pl ease fol l ow safet y handl i ng i nst ruct i ons herei n careful l y.

Warni ng:
Check t he l evel of LN
2
regul arl y for t he fi rst 24 hours of
cool -down and t op up as requi red.

Thereaft er and when i nst al l ed i n t he pl ant , i t wi l l onl y
need fi l l i ng t wi ce per week, provi di ng i t i s not al l owed t o
warm up, usual l y Mondays and Thursdays are i deal (refer
t o rout i ne Mai nt enance).
Receiving and Storage of Equipment Overview


Warni ng:
The more t i mes t he MEP det ect or i s al l owed t o run dry of
LN
2
t he ri sk of det ect or fai l ure i ncreases exponent i al l y.
Thermal cycl i ng i s t he most damagi ng form of non-
physi cal probe abuse.

Whi l st t he det ect or i s i n i t s met al st and i t must have t he
foam pl ug i nsert ed t o prevent di rt from ent eri ng t he dewar.

Note:
It i s not necessary t o use t he foam pl ug once t he MEP
det ect or i s i nst al l ed i n i t s shroud i n t he pl ant . Keep t he
foam pl ug i n a safe pl ace for l at er use i f t he det ect or needs
t o be removed from i t s prot ect i ve shroud for mai nt enance.

2.8.4 Unpacking & Filling MEP Detector with LN
2

1. Lay t he box hori zont al l y as di rect ed by marki ngs.
Remove bandi ng and nai l s around t he edge of t he t op
panel and remove i t . Careful l y remove enough packi ng
mat eri al t o expose t he equi pment . There i s onl y a
si ngl e pi ece of equi pment i n t he box.

2. Li ft t he uni t out careful l y and pl ace i t upri ght on t he
base of i t s at t ached met al st and. Do not open, remove
or ot herwi se i nt erfere wi t h t he pl ast i c bag cont ai ni ng
si l i ca gel at t he bot t om unt i l i nst al l at i on t i me.

3. Remove any packi ng t ape securi ng t he cap of t he dewar
and ext ract t he foam pl ug from t he t op. Pour l i qui d
ni t rogen i nt o t he dewar. Do not use any ot her cool ant .
Duri ng t hi s i ni t i al fi l l , because t he uni t i s warm,
consi derabl e boi l off can be expect ed so t ake care not
t o spl ash on ski n or eyes. The dewar has a capaci t y of
11 l i t res but i t may requi re 12 t o 15 l i t res for t he i ni t i al
fi l l . Insert t he foam pl ug when boi l i ng subsi des. Thi s
pl ug i s onl y t emporary unt i l t he uni t i s i nst al l ed. It
need not be ful l y i nsert ed.
Overview Receiving and Storage of Equipment


4. Aft er about one hour, check t hat vi ol ent boi l i ng has
ceased and some LN
2
remai ns. Al so check t hat t he uni t
i s NOT t oo col d and possi bl y becomi ng covered wi t h
condensat i on or i ce i n t he l ower part s. The dewar
shoul d not be col der t han about 5
o
C bel ow ambi ent
t emperat ure. If t he uni t i s very col d i t may have
suffered a vacuum fai l ure i n t ransi t . Take not e of i t s
LN
2
consumpt i on usi ng a di pst i ck. If i t consumes more
t han 5 l i t res i n 5 hours, st op fi l l i ng and al l ow i t t o
ret urn t o room t emperat ure and cont act t he Company for
i nst ruct i ons.

5. If t he uni t i s not sweat i ng (condensi ng wat er) or i ci ng
up one hour aft er i ni t i al fi l l i ng, t op up t he dewar wi t h
more LN
2
. Up t o 2 l i t res may be requi red. From t hi s
poi nt one may begi n t he rout i ne fi l l i ng schedul e (refer
t o cl ause 2. 8. 5). It shoul d be st ored i n such a manner
t hat i t wi l l not be overt urned.

Note:
Refer Sect i on 1 for MSDS for LN
2
.

2.8.5 Routine Filling
Whi l st i n st orage or operat i on t he uni t wi l l consume LN
2

at about 0. 7 t o 1. 2 l i t res each day. It i s i mport ant t o
prevent t ot al evaporat i on; hence t he dewar must be t opped
up (at l east ) every 7 days. Before every rout i ne fi l l , check
t hat some LN
2
remai ns i n t he dewar.

Use a t orch and some cl ean wood dowel i ng or bl ack pl ast i c
cabl e-t i e as a di pst i ck for t hi s purpose, t hen t op up wi t h
LN
2
. It i s not necessary t o recheck aft er an hour. The uni t
shoul d be fi l l ed as frequent l y as necessary t o prevent i t
runni ng dry. Pl ease advi se t he Company i f t he uni t appears
t o be consumi ng more t han t wo l i t res per day.

Cleaning and Storage for Extended Plant Shutdown Overview


2.9 Cleaning and Storage for Extended Plant Shutdown
If t he pl ant i s t o be shut down for a l ong peri od of t i me
t hen i t may be deci ded by t he owners t o remove t he
radi oi sot ope from t he MEP for safe st orage. Thi s i s not a
requi rement by t he Company. Si mi l arl y i t may be deci ded
t o move t he det ect or wi t h shi el ded source t o a st orage
l ocat i on whi ch i s more conveni ent for regul ar LN
2
fi l l i ng.
Agai n, t hi s i s t he owners deci si on.

To remove t he det ect or wi t h i t s (shi el ded) source i n pl ace,
fol l ow t he procedure i n sect i on 8. 4. Thi s provi des for
put t i ng a radi at i on shi el d on t he source hol der. The
det ect or shoul d t hen be put i nt o i t s met al st and t hat i t was
ori gi nal l y suppl i ed wi t h, st ored i n a safe cl ean and dry
pl ace and be kept fi l l ed at l east once per week wi t h LN
2
.
The foam dewar pl ug must be i nsert ed i nt o t he det ect or t o
keep di rt and moi st ure out .

The pl ace of st orage may be on si t e near t o t he l ocat i on of
t he FLE or ot her Li qui d Ni t rogen suppl y, or off si t e wi t h a
t hi rd part y. It may be necessary t o remove t he
radi oi sot ope. Consul t your Radi at i on Safet y Offi ce for
advi ce.

If t he source (wi t h shi el d at t ached) must be removed from
t he det ect or t hen unscrew t he t hree M3 screws t hat fi x t he
source hol der i nt o t he det ect or. Thi s shi el ded source
hol der t hen needs t o be st ored i n a safe pl ace t hat i s
cl assi fi ed as t he si t e radi at i on st ore wi t h cont rol l ed access.
The si t e RSO i s responsi bl e for carryi ng out t hi s t ask and
ensuri ng t hat t he radi oi sot ope i s properl y st ored.

Note:
Repl ace t he upper dewar cover and wi ndow aft er removi ng
t he det ect or t o ensure t he i nsi de of t he housi ng remai ns
cl ean.

Warni ng:
Fai l ure t o keep t he MEP al ways cool ed wi t h LN
2
even
when not i n use, may permanent l y damage i t .

Overview Cleaning and Storage for Extended Plant Shutdown


Warni ng:
If t he radi oi sot ope source i s t o be removed, i t must be
st ored safel y and t he l ocal radi at i on aut hori t y not i fi ed of
i t s st orage met hod and l ocat i on.

The remai ni ng component s of t he anal yser syst em, i . e.
el ect roni cs, comput er equi pment , et c shoul d j ust be shut
down wi t h mai ns power t agged out (see phot o l eft ) t o al l
i n-pl ant equi pment .

Drai n t he anal ysi s zones and wash down t he anal yser. In
some si t uat i ons i t may be desi rabl e t o cover t he equi pment
wi t h t arpaul i ns or si mi l ar and/ or t ake measures t o prevent
condensat i on or ot her wat er damage.

It i s recommended t hat an i nvent ory of t he st ored
equi pment be mai nt ai ned.
Cleaning and Storage for Extended Plant Shutdown Overview




3
Specifications

Thi s sect i on det ai l s t he st andard speci fi cat i on of mat eri al
used i n fabri cat i ng t he on-l i ne sampl i ng and anal ysi s
equi pment . The sect i on al so provi des ot her equi pment
speci fi cat i on i nformat i on and i ncl udi ng anal yser t ypi cal
accuraci es.

3.1 Specification of Materials
The fol l owi ng surface mat eri al s and coat i ngs are t he
Companys st andards used for i n-pl ant equi pment . Ot her
mat eri al s and coat i ngs may be used i f request ed.

3.1.1 Wetted Parts
Mul t i -El ement Probes :
St andard: Grade 316 St ai nl ess St eel
Opt i onal : Grade 2RK65 St ai nl ess St eel for hi gh
chl ori de i on concent rat i ons
Li nat ex or equi val ent Coat i ng

3.1.2 Electronic Enclosures
Mat eri al : Grade 316 St ai nl ess St eel
Prot ect i on: IP66 AS1939-1986
Pai nt Speci fi cat i on: Ni l

Specification of Materials Specifications


3.1.3 Paint Specification

COLOUR:

Golden Yellow No. 43331

USED ON:

All Mild Steel (usually moving parts and guards)

CLASS OF BLAST:

To AS1627-4 Class 3 (grit blast)

PRIMER: TYPE - INTERGARD high build
epoxy grey
(International paint marine
coatings)
THICKNESS - 100 microns
OR (alternative only)
TYPE - Epoxy Val Chem Zinc
Phosphate

TOP COAT: TYPE - INTERFINE 629 (M245)
(2 pack high gloss anhydride
catalysed acrylic finish coat)
COLOUR - GOLDEN YELLOW TO
AS2700 No Y14

** Average total thickness must be 150 microns.
** Minimum acceptable total thickness is 125 microns.

Tabl e 3- 1 Saf et y Yel l ow Pai nt Speci f i cat i on

PROPERTIES:

1. Durabl e epoxy t ank l i ni ng for cont i nuous i mmersi on
requi rement s.
2. Wi de chemi cal resi st ance t o pet rol eum product s, sea
wat er and i nert gas.
3. Resi st ance t o caust i c soda and sol vent s (sui t abl e
choi ce for t he coat ed t ank of many sel ect i ve
chemi cal t ankers).
4. Top coat (Int erfi ne 629) provi des resi st ance t o
weat heri ng i n severe i ndust ri al envi ronment s such as
t ankage, handrai l s et c.
5. Top coat provi des out st andi ng gl oss and col our
ret ent i on i n severe envi ronment s.

Specifications Specification of Materials


COLOUR:

Sapphire Blue

USED ON:

All exposed Mild Steel

CLASS OF BLAST:

To AS1627-4 Class 3 (grit blast)

PRIMER: TYPE - Epoxy TFH684/THA044
(International paint marine
coatings)
(1st Coat) hb Surface grey
OR (alternative only)
TYPE - Epoxy Val Chem Zinc
Phosphate (M290)
(2 pack catalysed epoxy
primer)

TOP COAT: TYPE - INTERFINE 629 (M245)
(2nd coat) (2 pack high gloss catalysed
acrylic finish coat Part A
T7158, Part B T7159)
COLOUR - White tinted Sapphire Blue
Taubman
THICKNESS - 50 microns per coat (2 coats)

Tabl e 3- 2 Equi pment St andar d Pai nt Speci f i cat i on

PROPERTIES:

1. Durabl e epoxy t ank l i ni ng.
2. Wi de chemi cal resi st ance t o pet rol eum product s, sea
wat er and i nert gas.
3. Sui t abl e for exposure t o i nt ermi t t ent or sust ai ned
wet and i mmersed condi t i ons.
4. Top coat (Int erfi ne 629) provi des resi st ance t o
weat heri ng i n severe i ndust ri al envi ronment s such as
t ankage handrai l s et c.
5. Top coat provi des out st andi ng gl oss & col our
ret ent i on i n severe envi ronment s.

Mechanical Specifications Specifications


3.2 Mechanical Specifications
Number of Streams
3-12 (intermittent measurement).
Sequence of Stream
Any order or repetition pattern allowed, without time
restriction
Measurement
(resolution 1 second).
Re-positioning Time
Typically 12 seconds for adjoining zones and 25 seconds
between end zones (12 stream version).
Horizontal Drive
TEFC 400 Volt three phase 0.37kW motor with 50:1 worm
gearbox driving rack and pinion, Service factor: 2.3. Speed
control by 0.75 kW AC inverter.
Guards
Guards are provided all round as standard, including four
hinged doors. One door is electronically interlocked to freeze
all motion. The others are intended to be pad-locked as they
are not used for routine access.
Vertical Drive
The probe is raised by a self oiling pneumatic cylinder 500
mm stroke 100 mm diameter aluminium barrel with stainless
steel rod. Thrust 3020 N at 600 kPa. Lowered under gravity
by air release. Pneumatic safety latch prevents lowering on air
failure.
Noise
<80 dBA at 1m.
Proximity Sensors
Schmersal IFLIS Inductive.
Controller
Thermo Electron Remote Logic Controller (RLC) with I/O
cards.
Water
Clean plant water. 300 800 kPa at approximately 20 litres
per hour, intermittently
Probe Wash Down
Four self-clearing nozzles solenoid actuated as probe is
retracted from slurry. Wash water is collected by the most
recent stream analysed. Washing is inhibited during manual
indexing of the probe.
Service Position
A service bay, to which the probe will go when the PARK
button is depressed. This service position is useful for filling
the probe with LN
2
or other maintenance work. It can be
external to the MSA or any one of the analysing positions,
with or without a tank.
Communications (Data)
AIN compatible (EIA RS-485). Cable is screened twisted
pair, maximum total length 1.2 km. Other communication
options available.
Specifications Specification of Materials


Power (In-Plant)
Standard factory selectable 380/415/440/460 Volts AC 10%
3-phase 48-62 Hz 2Hz (3 wire plus earth). Optional 525
available on request.
Maximum Power Consumption:
3-stream MSA: 1.8kW
6-stream MSA: 2.9kW
9-stream MSA: 3.8kW
with standard 250W stirrer motors
Air
Instrument Quality Air (clean and dry to 0.1 microns with
dew point <2C).
Pressure nominally 600kPa (87psi) minimum 450kPa,
maximum 800kPa.
Consumption: <50 litres per hour at working pressure.
Secondary air filter built in.
MEP (Casing)
316 Stainless Steel (optional other steel for corrosive
applications) with Linatex on immersion section.
O Rings
Viton
Analysis Tank
Standard 300mm wide (1-15m
3
/hr): 316 grade stainless steel,
unpainted, 3.0 mm thick without rubber lining. Optional,
painted 3.0 mm mild steel with rubber lining. Optional larger
tanks can be specified for higher flow-rates: Standard larger
sizes are 400mm (up to 20 m
3
/hr) and 600mm (up to
50m
3
/hr).
Coatings
Refer to Materials Specification, section 3.1
Enclosures
Electronics: Stainless Steel rated IP66
Stirrers
The Company supplied 3-phase 0.25kW (standard) or 0.75
kW Helical Gear, with impellers to suit 300mm or larger size
tanks. All stirrers have individual lockable isolators. Other
stirrers may be specified depending on the tank size. Specific
Data Sheets are provided in Attachment 1.
Dimensions
Refer to equipment drawings in the Installation section for
dimensions.
Weights
MEP complete (excluding hoist): 60 kg
MSA (6-stream) static weight = 1950kg
Weight varies depending on size of the unit. Refer to
drawings in Installation section.

Tabl e 3-3 Mechani cal Speci f i cat i ons

Metallurgical Sampler Specifications Specifications


3.3 Metallurgical Sampler Specifications
Thi s sect i on i s onl y appl i cabl e i f a Met al l urgi cal Sampl er
has been suppl i ed wi t h t he equi pment .

3.3.1 AM643-300/400 Metallurgical Sampler

Type Linear horizontal cutter
Operation Modes
Manual by individual switch or Calibration or Shift modes of
operation, selectable from an Operator Interface (OI) panel on
the MSA.
Isolator
Individual isolators on each sampler. Isolator switch also
initiates manual operation.
Drive Electric.
Motor 90W DC with integrated reduction drive.
Stroke 300 or 400 millimetres.
Cutter
Type B horizontal fixed opening, 10mm wide, 250mm wide,
250mm long. Wear resistant polyurethane, 95 Duro.
Speed
Up to 330mm/sec selectable by DC voltage taps. Acceleration
and dynamic deceleration take place over approximately 10mm
at each end of stroke whilst the cutter is out of the stream.
Power
Variable DC voltage up to 180 volts, bipolar, as delivered by
controller.
Stalling Force 150 Newtons (motor protected by controller).
Weight 30 kg
IP Rating IP56

Tabl e 3- 4 Met al l ur gi cal Sampl er Speci f i cat i on

Specifications Analyser Accuracy Data


3.4 Analyser Accuracy Data
Measurement Accuraci es of t he anal yser syst em are gi ven
i n t erms of t he Relative Error (error i n chemi cal
l aborat ory assays are al so gi ven i n t erms of t hi s error but
usual l y at 2 st andard devi at i ons (s. d. ) or 95% confi dence,
whereas t he anal yser i s at 1 s. d. ).

100 x
Assay Mean
Deviation RMS
= Error Relative (%)

RMS Error (error at 1s. d, al so known as t he RMS
Devi at i on) i s t he absol ut e di fference bet ween t he anal yser
assay measurement and t he accept ed t rue l aborat ory
assay for a sui t e of sampl es.

1 N
) y -
x
(
= Error RMS
2
i
i
N
=1 i
2
1

N i s t he number of sampl es.
x
i
i s t he chemi cal l abor at or y assay of t he i
t h
sampl e.
y
i
i s t he assay f r om t he anal yser of t he i
t h
sampl e usi ng t he
cal i br at i on equat i on.

The RMS Error i ncl udes error cont ri but i ons from:

Sampl i ng
Sampl e Preparat i on
Laborat ory Assayi ng
St at i st i cal (count i ng) Error
Inst rument at i on Error

The Cust omer must ensure t hat al l care i s t aken so as t hat
t hese errors are i nsi gni fi cant so t hat t he RMS Error t rul y
represent s t he accuracy of t he on-l i ne anal yser.

It i s t herefore recommended t hat t he chemi cal l aborat ory
assays have an accuracy of bet t er t han one t hi rd (1/ 3rd) of
t he expect ed anal yser accuracy.
Analyser Accuracy Data Specifications


Typi cal Expect ed Accuraci es are:

Assay Range
Typical Accuracy(Rel Err)
of Analyser (%)
Elements in Slurries (%metal):
0.05-0.2 4 - 6
0.2- 1.0 3 - 5
1.0 10.0 2 - 4
10.0 80.0 1 - 2
Elements in Solution (metal):
Above 10 g/L 1 2
1-10 g/L 2 4
1 mg/L 1 g/L 3 6
Tabl e 3- 5 Typi cal Anal ysi s Accur aci es

Wi t h any XRF anal ysi s, t he accuracy depends on:
Part i cl e si ze di st ri but i on
mi neral ogy
mat ri x vari at i ons of an ore t ype

The Preci si on of t he anal yser i s defi ned as t he degree of
agreement bet ween repl i cat e measurement s of t he same
sampl e. The Precision i s t he same as Repeat abi l it y.

The Preci si on depends on t he vari at i on i n t he count -rat es
due t o t he random nat ure of t he X-ray emi ssi ons. For
seal ed radi oi sot ope sources, t he X-ray emi ssi on i s very
st abl e. Addi t i onal l y t he count i ng st at i st i cs are moni t ored
and report ed as t he St at isti cal Error. So t hat Precision i s
NOT a l i mi t i ng fact or i n t he overal l accuracy of t he on-
l i ne anal yser, t he cal i brat i on equat i ons used t ypi cal l y have
a Stat i st i cal Error of l ess t han one hal f t he RMS Error (at
1s. d. ).

Detect i on Li mi t i s t he mi ni mum concent rat i on t hat can be
di st i ngui shed from t he background measurement . Because
background measurement s are l ow wi t h t he cl ean
radi oi sot ope X-ray source used i n t he anal yser syst em, t he
det ect i on l i mi t i s t ypi cal l y much l ower t han t he
concent rat i on t o be measured and hence i s not a l i mi t i ng
fact or i n t he overal l accuracy of t he anal yser.

Det ect i on Li mi t (at 95% confi dence) i s 2 t i mes t he
st andard devi at i on of t he average background
measurement .

Performance accuraci es for your anal yser are provi ded i n
At t achment 2, Perf ormance Speci f i cat i on.


Section 3 - Specifications
Attachment 1Stirrer Data Sheets



Section 3 - Specifications
Attachment 2Performance Specification

CONTENTS

Performance Accuraci es



4
Installation

Thi s sect i on i s wri t t en for t hose personnel carryi ng out t he
physi cal i nst al l at i on of t he equi pment i n t he Cust omers
pl ant . It i s i nt ended t o be used by t he Cust omers
t radespeopl e and engi neeri ng cont ract ors and i s wri t t en on
t he assumpt i on t hat t he work wi l l be carri ed out wi t hout
t he presence of a Company engi neer. For some cont ract s
t he Company engi neer may be requi red t o be present t o
supervi se some or al l of t he i nst al l at i on phase and for such
cases any addi t i onal requi rement s are al so l i st ed.

At t achment s t o t he end of t hi s sect i on cont ai n t he
Equi pment Li st, Foundat i on and Inst al l at i on Drawi ngs and
Di agrams and t he Inst al l at i on Checkl i st . The Part s Li st
manual al so cont ai ns det ai l ed drawi ngs and part s
i nformat i on t hat may compl i ment t he i nst al l at i on process.

Warni ng:
El ect roni c equi pment i s suscept i bl e t o damage by st at i c
el ect ri cal charge. Handl e component s wi t h care.

Cauti on:
When arc wel di ng near t he anal yser, ensure t hat good
eart hi ng i s used t o prevent damage t o el ect roni c
component s.

Resources & Services to be Provided by the Customer Installation


4.1 Resources & Services to be Provided by the Customer
It i s t he responsi bi l i t y of t he Cust omer t o provi de t he
fol l owi ng resources duri ng t he i nst al l at i on of t he on-l i ne
sampl i ng and anal ysi s syst em unl ess ot herwi se speci fi ed i n
t he cont ract .

Tradespeopl e:
Fi t t ers and wel ders t o carry out pl ant modi fi cat i ons
such as pi pe work, fl oori ng, pl at forms, et c i n order t o
accommodat e t he anal ysi s equi pment .
Fi t t ers and wel ders t o carry out t he physi cal
i nst al l at i on of t he sampl i ng and anal ysi s syst em
met al ware (MSA frame, t anks, pi pe work t o/ from t he
t anks, probe carri age, et c. ).
El ect ri cal Techni ci an t o i nst al l t he el ect roni c
encl osures, and/ or carry out power wi ri ng and
t ermi nat i ons as necessary.
Inst rument Techni ci an t o i nst al l dat a communi cat i ons
cabl i ng, ai r and wat er suppl i es and carry out
t ermi nat i ons.
Project Responsi bl e Offi cer:
The Cust omer shoul d al l ocat e a person responsi bl e for
t he overal l proj ect and t he i nst al l at i on of t he
equi pment . Thi s person i s t o report back t o t he Company
for cl ari fi cat i ons and compl et e and ret urn t he
Inst al l at i on Checkl i st (refer t o At t achment 1).

Note:
The Cust omer shal l compl et e t he Inst al l at i on Checkl i st and
ret urn i t t o t he Thermo El ect ron Proj ect Manager, before
an engi neer i s sent t o si t e t o carry out commi ssi oni ng and
cal i brat i on.

Addi t i onal servi ces requi red t o be provi ded by t he
Cust omer i f a Company engi neer i s requi red t o be on si t e t o
supervi se t he i nst al l at i on i ncl udes:

Messi ng/ Transport:
Provi de sui t abl e accommodat i on, meal s and l ocal t ransport
for t he Company engi neers whi l e t hey are on-si t e t o
supervi se t he equi pment i nst al l at i on. Where appropri at e, a
hi re car shoul d be provi ded.

Installation Special Tools Required for Installation


Communi cati ons:
Provi de t el ephone/ facsi mi l e/ emai l servi ce t o Adel ai de,
Sout h Aust ral i a, from t he i nst al l at i on si t e.
Safety Inducti on:
Provi de si t e-speci fi c safet y i nduct i on t rai ni ng for t he
Company engi neers carryi ng out si t e work.
Safety Equi pment:
Suppl y any addi t i onal si t e-speci fi c safet y equi pment or
cl ot hi ng requi red as part of st andard si t e safet y
procedures. Thermo El ect ron wi l l suppl y Aust ral i an
St andard safet y hel met s, gl asses, cl ot hi ng and boot s for
t hei r engi neers.

4.2 Special Tools Required for Installation
No speci al t ool s are requi red t o i nst al l t he on-l i ne
sampl i ng and anal ysi s syst em. Al l t ool i ng requi rement s
are st andard i nt ernat i onal met ri c si ze.

4.3 Customer Scope of Work
Some cont ract s requi re t he cust omer t o fabri cat e t hei r own
sampl i ng equi pment . It i s t he responsi bi l i t y of t he
Cust omer t o ensure t hat t hei r scope of work for t he proj ect
i s compl et ed i n t i me t o carry out t he physi cal i nst al l at i on.
Ot her work t o be compl et ed by t he Cust omer i ncl udes:

Pi pe Work & Sampl i ng Equi pment
Provi de al l pi pi ng bet ween t he sampl i ng equi pment (i f
sampl ers are used, ot herwi se j ust re-di rect sl urry pi pi ng)
and each Anal ysi s Tank and al l pi pe work from t he
Anal ysi s Tank out l et s back t o t he process st reams.
Sampl i ng equi pment i s t o be i nst al l ed by t he Cust omer
where requi red t o l ower st ream fl ow-rat es.

Access
Provi de adequat e space around t he MSA uni t for
mai nt enance access. Typi cal l y at l east 1 met re shoul d be
al l owed on al l si des. Drawi ngs provi ded i n At t achment 2
i ndi cat e access space requi red.

Cover Over MSA
It i s recommended t hat a roof be i nst al l ed over t he MSA i f
i t i s t o be i nst al l ed out si de or under sl urry t anks t hat may
overfl ow.

Special Tools Required for Installation Installation


Customer Scope of Work Installation


Li ghti ng
Provi de adequat e l i ght i ng around t he anal yser and
el ect roni cs. When pl aci ng l i ght s be aware t hat t he
el ect roni cs encl osure doors open upwards and t hat
operat ors wi l l be requi red t o rout i nel y vi ew t he sl urry
fl owi ng t hrough t he anal ysi s t anks. Li ght ni ng around t he
servi ce bay i s al so i mport ant .

Mai ntenance Drai n
A bl anked, fl anged out l et i s provi ded at t he bot t om of each
anal ysi s t ank. A t ank can be drai ned by removi ng i t s
bl anki ng pl at e. Al t ernat i vel y t he Cust omer may i nst al l a
val ve on some or al l t anks so t hey can be more easi l y
drai ned for mai nt enance.

Sl urry Pi pe Connecti on
Each t ank i s fi t t ed wi t h fl anged sl urry i nl et s and out l et s t o
whi ch t he Cust omer connect s pl ant sl urry l i nes.
At t achment 2 det ai l s fl ange l ocat i ons and si zes.

Power Suppl i es
Provi de power suppl i es for i n-pl ant and cent ral cont rol
equi pment (refer chapt er 3 and sect i on 4. 10 for general
speci fi cat i ons). Your speci fi c power det ai l s are i n
At t achment 2 of t hi s chapt er.

Instrument Ai r
Provi de i nst rument qual i t y ai r for t he pneumat i cal l y
operat ed MEP hoi st (refer chapt er 3 for speci fi cat i ons and
sect i on 4. 8 for det ai l s).

Water
Provi de a cl ean wat er suppl y for t he MSA uni t for probe
wash down and wat er sprays. (Refer t o chapt er 3 for
speci fi cat i ons and sect i on 4. 9 for det ai l s).

Data Cabl es
Provi de and run a screened t wi st ed pai r cabl e for t he AIN
RS-485 mul t i -drop net work (bus). Thi s runs bet ween each
anal yser (MSA or ot her) and t he AM955 RS-232 t o RS-485
Convert er near t he Wi nISA comput er. Ot her AIN
compat i bl e i nst rument s may al so be dropped ont o t hi s bus.
In some cases ot her net work t echnol ogy such as copper or
fi bre opt i cal Et hernet may be used. Thi s wi l l requi re
adapt ers l i ke a Lant roni x CoBox, fi bre t ranscei vers et c.
(refer chapt er 4 for furt her det ai l s).
Special Tools Required for Installation Installation


Locate Mechani cal Assembl y
The MSA i s oft en shi pped i n a part i al l y knocked down
st at e t o al l ow for i t t o fi t i n a st andard sea frei ght
cont ai ner. The end bays and door guards and overhead
gant ry must be assembl ed on si t e. Part s are l abel l ed t o
al l ow easy assembl y. Thi s can be done by t he cust omer
pri or t o commi ssi oni ng or under supervi si on of a Company
engi neer duri ng i nst al l at i on.

Control Room
A cl ean, rel at i vel y dust free, offi ce t ype envi ronment i s
requi red for t he cent ral cont rol equi pment (comput er,
peri pheral s et c). The operat i ng t emperat ure shoul d be i n
t he range of 15-32C and t he operat i ng rel at i ve humi di t y
shoul d be i n t he range of 20-80% non-condensi ng.

Li qui d Ni trogen
Provi de l i qui d ni t rogen (LN
2
) at a rat e of about 10
l i t res/ week for each MSA i n t he pl ant . Refer t o
speci fi cat i ons provi ded by your l ocal suppl i er of LN
2
as
boi l -off rat es for l i qui d ni t rogen can vary dependi ng on t he
t ype of cont ai ner suppl i ed and t ransfer met hod.
Arrangement s must be made for t he cont i nued suppl y of
l i qui d ni t rogen duri ng t he operat i ng l i fe of t he anal yser.
The probe must never be al l owed t o run dry of LN
2
.

Warni ng:
Al ways use LN
2
i ncreases t he l evel of pot ent i al l y expl osi ve l i qui d oxygen
l evel s i nsi de t he MEP dewar. Use onl y LN
2
, do not use
subst i t ut e cool ant s.

DCS/ PLC Comms (Opti onal)
The anal yser soft ware can di st ri but e dat a usi ng t he
Modbus prot ocol or OPC t o a pl ant DCS or PLC Process
Cont rol Syst em. The Cust omer wi l l need t o provi de t he
dat a or net work cabl i ng bet ween t he comput er and t he
DCS/ PLC. There i s no ext ra opt i onal soft ware t o
purchase, t he opt i on i s whet her or not t o confi gure i t .

Tel ephone Modem Li ne (Opti onal)
Provi de a dedi cat ed phone l i ne for remot e support from t he
Company. It i s recommended t hat t hi s be a dat a/ fax qual i t y
l i ne wherever possi bl e.

Dimensions and Mounting Installation


Networked Computers (Opti onal )
For any addi t i onal pl ant comput ers requi ri ng connect i on t o
t he anal yser cont rol PC for di spl ayi ng assay dat a, t he
Cust omer shal l provi de t he servi ces of t he pl ant net work
admi ni st rat or t o securel y connect t hese t o t he syst em, t he
onus i s on t he Cust omer t o provi de net work securi t y.
General l y, t he cust omer i s responsi bl e for suppl yi ng t he
addi t i onal comput er. Oft en offi ce comput ers (e. g. i n t he
Shi ft Supervi sors or Met al l urgi st s offi ce) are used.

4.4 Dimensions and Mounting

Warni ng:
DO NOT i nst al l t he MEP det ect or (shown l eft ). Thi s
devi ce i s t he LN
2
cool ed component of t he anal yser and
shal l onl y be i nst al l ed under t he supervi si on of a Company
engi neer duri ng commi ssi oni ng. It must be kept fi l l ed
wi t h LN
2
i n a safe dry l ocat i on. DO NOT pour LN
2
i nt o t he
MEP casi ng shown i n fi gure 4-5 when t he det ect or i s not
i nst al l ed.

4.4.1 Mounting the MSA
Sect i on 4. 7 provi des det ai l s of t he sampl i ng requi rement s
and sl urry l i ne connect i ons t o t he MSA uni t and
subsequent sect i ons provi de det ai l s of power, ai r, wat er
and dat a (si gnal ) connect i on. A t ypi cal 6-st ream MSA
l ayout and t ank sect i on i s shown i n Fi gure 4-1 and Fi gure
4-2.

Suppl y t ermi nat i ons are i ndi cat ed i n Fi gure 4-3.

The MSA uni t can be i nst al l ed on t he ground l evel of t he
pl ant so t hat t he sl urry streams can gravi t at e t o i t .
Al t hough, t he MSA uni t can be i nst al l ed anywhere i n t he
pl ant , i t i s preferred t hat i t be mount ed on a rai sed
pl at form so t hat di scharges from each anal ysi s t ank can be
col l ect ed i nt o t he sump(s) of pump(s) or i nt o a pi pe or
l aunder for di sposal or ret urn t o i t s mai n st ream.
Al t ernat i vel y, t he MSA can be mount ed at ground l evel i f
most sampl ed st reams are t o be gravi t y fed t o t he anal ysi s
t anks.

Inst al l at i on drawi ngs for your MSA are gi ven i n
At t achment 2 show t he di mensi ons and mount i ng poi nt s of
your MSA uni t and i ndi cat e t he suppl y t ermi nat i on poi nt s.


PRIMARY GRAVITY
SAMPLER
FROM PLANT
STIRRER
TANK SECTION
RETURN TO
PLANT
METALLURGICAL
SAMPLER
CALIBRATE/SHIFT
SAMPLE
PRIMARY PRESSURE
SAMPLER
RETURN TO PLANT

Fi gur e 4- 1 Typi cal 6- St r eam MSA Layout
Installation Dimensions and Mounting


#
5

T
A
N
K

#
4

T
A
N
K

#
3
T
A
N
K

#
2

T
A
N
K

#
1
T
A
N
K

Fi gur e 4- 2 Typi cal MSA showi ng Locat i on of El ect r oni c Cont r ol
Encl osur es


Fi gur e 4-3 Typi cal I nst al l at i on Di agr am f or a 6- St r eam MSA
Installing the Probe Carriage and MEP Installation


Warni ng:
DO NOT l i ft t he MSA by i t s frame, i nst ead fi t t he speci al
l i f t i ng l ugs (see phot o t op l eft ) provi ded for each frame
end (refer t o MSA i nst al l at i on drawi ng i n At t achment 2).
Once t he frame(s) are i n pl ace remove t he l i ft i ng l ugs
and fi t one end pl at e t o each end of t he compl et e MSA
(vi z. , onl y 2 end pl at es are fi t t ed at t he ext remi t i es, see
phot o bot t om l eft ).

The MSA uni t i s usual l y del i vered compl et e wi t h
el ect roni c encl osures as shown i n Fi gure 4-2, al ready
mount ed. Dependi ng on shi ppi ng requi rement s, t he
anal ysi s t anks may not be al ready mount ed and so t hese
wi l l requi re bol t i ng ont o t he MSA frame as per your
i nst al l at i on drawi ng i n At t achment 2. Fi gure 4-3 shows a
t ypi cal 6-st ream MSA uni t compl et e.

Note:
If your MSA has more t han one 6 t ank frame modul e,
remove t he Cabl e Duct (square) end t ransport covers at t he
j oi n of t he MSA frames before mount i ng t he frames si de-
by-si de.

4.5 Installing the Probe Carriage and MEP
Aft er mount i ng t he t anks, t he probe carri age (see phot o
l eft and fi gure 4-5) needs t o be mount ed on t he gui de rai l .
The probe carri age i s heavy (around 200kg wi t hout shroud
or probe) and wi l l need t o be sl ung and l i ft ed wi t h a crane.

Cauti on:
Take care not t o damage cabl i ng at t he t op of t he carri age
when sl i ngi ng.

Installation Installing the Probe Carriage and MEP


If t he MEP casi ng (upper and l ower probe shroud) have not
been shi pped as part of t he probe carri age, t hen t hese part s
now needs t o be i nst al l ed i nt o t he carri age.

The MEP upper (st ai nl ess st eel dewar cover) and l ower
(l eg) shroud (see Figure 4-4 and phot os l eft ) may have been
packed separat el y and so requi re mount i ng i n t he probe
carri age. The bl ack anaconda probe cabl e wi l l al ready be
connect ed at t he base-pl at e as shown i n t he phot o,
however, t he ot her end of t he cabl e must be t ermi nat ed i n
t he cabl e t ermi nat i on box on t he probe carri age (see phot o
bot t om l eft ). The connect ors wi l l not be abl e t o be j oi ned
at t hi s st age i f t he umbi l i cal cabl e has not yet been
i nst al l ed (see sect i on 4. 6).

Note:
The MEP i s t he rugged st ai nl ess st eel / rubber l i ned out si de
casi ng for t he det ect or. The det ect or fi t s i nsi de t hi s MEP
casi ng oft en referred t o as t he upper dewar cover and t he
probe l ower shroud (l eg). The det ect or i s not i nst al l ed yet .

LIQUID NITROGEN FILLER CAP
DEWAR COVER

Weight 60kg
PROBE BASE
LOWER SHROUD
WINDOW ASSEMBLY

Fi gur e 4- 4 Di mensi ons and Wei ght of t he MEP.
Installation Installing the Probe Carriage and MEP


Fi gur e 4- 5 MSA Pr obe Car r i age Assembl y
Installing the Probe Carriage and MEP Installation


4.5.1 Procedure
Before proceedi ng, ensure t hat t he probe carri age i s
securel y mount ed on t he MSA frame (see phot o l eft ).
The procedure for i nst al l i ng t he probe i s as fol l ows:

The rei nforced bl ack pol yuret hane base-pl at e cont ai ni ng
t he bl ack anaconda probe cabl e i s t o be set i n t he frame
and bol t ed i nt o pl ace (Four M8 st ai nl ess st eel hex bol t s
wi t h nyl oc nut s).
If not al ready at t ached t o t he bl ack base pl at e, t he
l ower shroud i s t o be bol t ed t o t he under si de of t he
base pl at e usi ng t he 6 ret ai ni ng bol t s and t wo curved
pl at es (see phot o l eft ). The probe i s usual l y mount ed
so t hat i t s wi ndow i s faci ng t he cont rol uni t si de of t he
MSA. The probe wi ndow ori ent at i on can be changed by
l ooseni ng t he 6 ret ai ni ng bol t s. The det ect or shoul d not
be i n pl ace when doi ng t hi s.
Fi t t he wi ndow assembl y.
Connect t he l oose end of t he Probe Cabl e t o t he grey
t ermi nat i on box on t he carri age (see phot o l eft ).
This cabl e i s suppl ied by t he Company and consi st s of
fl exi bl e anaconda t ype condui t cont ai ni ng five cabl es.
Check that t he power i s off and connect t he foll owing
fi ve cabl es t o t he respect i ve connect ors in the
t ermi nat ion box (see phot o and bot t om left ).

BNC signal cable
9-pi n cabl e for l ow vol t age and al arms
MHV bi as cabl e
2 eart h cabl es (whi t e and green)

Fi t the upper dewar cover t o t he bl ack base pl at e and
l ock down wit h t he 8 st ai nless dome-head nut s and
washers provi ded. Cl ose t he fil l er cap at t he top of the
dewar t o keep dirt and moi st ure out .

Note:
To fit t he dewar cover, you may need t o manual ly move
the probe carri age to one end of t he MSA frame. To do
so, remove t he fly-wheel cover on t he mot or dri ve
assembl y at t he t op of t he carri age and t urn t he fl y-
wheel by hand (see phot o l eft ). Do not force t he
carri age. Repl ace t he fl y-wheel cover prompt l y.

Installing the MSA Umbilical Cable Installation


4.6 Installing the MSA Umbilical Cable
The mai n cont rol cabl e for suppl yi ng power, ai r and wat er
t o t he probe carri age i s cal l ed t he MSA Umbi l i cal Cabl e.
It consi st s of a number of si gnal and power cabl es as wel l
as t he ai r and wat er l i nes t o t he val ves l ocat ed on t he
probe carri age (see phot o l eft ).

If not al ready assembl ed, connect t he overhead gant ri es
and at t ach t he di amond cabl e t rol l ey rai l . Fi ve cabl e
t rol l ey wheel s are sl ot t ed ont o t he di amond rai l (refer t o
t he i nst al l t i on drawi ngs i n At t achment 2). These t rol l ey
wheel s support t he l ooped umbi l ical cabl e (see phot o l eft ).
The MSA umbi l i cal cabl e i s normal l y packed at t ached at
t he cont rol l er encl osure, t hen coi l ed up i n t he fi rst t ank. It
requi res careful mount i ng on t he cabl e t rol l ey.

Loop t he cabl e ont o t he t rol l ey wheel s so t hat you have
fi ve even si zed l oops.

Warni ng:
DO NOT unravel t he umbi l i cal cabl e. Loop i t careful l y
ont o t he cabl e t rol l ey wheel s so t hat i f fal l s nat ural l y i nt o
t he l oops al ready present i n t he cabl e.

Fi x t he cabl e t o t he MSA frame and t he end of t he t rol l ey
rai l at t he t ank #1 end of t he frame as shown i n t he phot o
bel ow l eft .

The mot or cabl e now runs di rect l y from i t s AC Dri ve t o
t he mot or wi t hout passi ng t hrough any i nt erveni ng
t ermi nal s or j unct i on boxes. Al so i t s copper screen i s
grounded at t he AC Dri ve end onl y. See t he fol l owi ng
Fi gure 4-6 showi ng connect i on at t he AC Dri ve end i n t he
MSA cont rol l er



Connect new screened motor cable direct to
AC Drive terminals as shown. Use minimum
unscreened length and connect yellow/green
screen wire to earth terminal at top of AC Drive

Fi gur e 4- 6 Wi r i ng Mot or Cabl e Umbi l i cal Gr ade

At t he mot or dri ve assembl y end (see phot o l eft ) cl amp t he
cabl e i nt o t he hal f-saddl e (suppl i ed) on t he carri age t o
hol d t he cabl e. Posi t i on t hi s saddl e roughl y as i n phot o so
i t cl amps on t he heat shri nk prot ect i ng t he fl exi bl e condui t .

Connect t he wi res t o t he mot or as per t he l abel l i ng of
phases U, V and W. Take care t hat screeni ng brai d i s not
exposed where t he sheat h i s cut and make sure i t cannot
cont act any t ermi nal s or met al ware.

Cauti on:
Incorrect wi ri ng of t he phases may prevent t he mot or dri ve
assembl y from movi ng, or may resul t i n t he mot or dri vi ng
i n t he wrong di rect i on.

Insi de t he l arger j unct i on box, at t ach t he cont rol wi ri ng
condui t and t ermi nat e t he vari ous conduct ors on t hei r
same-named t ermi nal s. There i s an eart h wi re wi t h a ri ng
t ongue whi ch shoul d be cl amped t o t he mount i ng pl at e
under a screw (see phot o l eft ).

Installing Slurry Samplers and Pipe Work Installation


At t ach t he remai ni ng condui t (t he one wi t h rect angul ar
pl at e) t o t he l eft hand undersi de of t he hori zont al l y
mount ed box usi ng t he gasket suppl i ed. Assumi ng t he
probe cabl e has al ready been i nst al l ed as i n sect i on 4. 5
t hen coupl e up al l fi ve connect ors and sl i de t he sl eevi ng
over t he coaxi al ones t o cover t hem t ot al l y (see phot o
l eft ). Then put t he l i d on and t i ght en t he cover screws.

The si gnal cabl es for movement , ai r (bl ue t ubi ng) and
wat er (green t ubi ng) are t ermi nat ed i n t he ri ght hand si de
vert i cal l y mount ed grey box (see phot o l eft ). Al l
power/ si gnal cabl es i nsi de t he grey box are l abel l ed as
shown i n t he phot o bot t om l eft .

4.7 Installing Slurry Samplers and Pipe Work
The sl urry sampl i ng and t ransport at i on syst em of a
mul t i pl exed anal yser syst em i s oft en t he hi ghest
mai nt enance cost and downt i me component . The
mai nt enance cost s and downt i me can be mi ni mi sed by
careful desi gn and i mpl ement at i on of t hi s syst em. The
fol l owi ng gui del i nes provi de a bri ef di scussi on of t he mai n
i ssues whi ch shoul d be consi dered when desi gni ng and
bui l di ng t hi s syst em. The Company can provi de more
speci fi c det ai l s and can provi de t he det ai l ed desi gn of t he
syst em i f requi red. The most i mport ant poi nt s are:

The number of addi t i onal pumps requi red t o t ransport
t he sl urry st reams around t he pl ant shoul d be
mi ni mi sed. Use shoul d be made of gravi t y fl ow and l i ne
pressure wherever possi bl e t o t ransport t he sl urry t o t he
anal yser uni t . Ret urn l i nes shoul d be ganged t oget her
and ret urned t o t he process vi a gravi t y fl ow where
possi bl e - oft en t hey can be dumped i nt o a coupl e of
pre-exi st i ng pump sumps on t he ground fl oor of t he
pl ant .

Installation Installing the Slurry Samplers and Pipe Work


The di st ance from t he mai n st reams t o t he anal yser
shoul d be mi ni mi sed. Thi s wi l l reduce bl ockages and
t he need for pi pe repl acement .

The sampl ers, pi pe work and anal yser shoul d be readi l y
accessi bl e i n case of mai nt enance.

The fol l owi ng poi nt s provi de a st ep-by-st ep met hod of
desi gni ng t he sampl i ng and sl urry t ransport syst em.

1. Det ermi ne whet her t he ful l fl ow of each st ream can
pass t hrough t he anal yser uni t . The fol l owi ng t abl e
provi des t he al l owed fl ow-rat e ranges for t he vari ous
anal ysi s t ank si zes. In many pl ant s i t i s advant ageous
t o pass t he whol e st ream t hrough t he anal yser because
i t avoi ds sampl i ng errors whi ch are i nherent i n
sampl i ng a sl urry st ream. However, for l arge st reams
i t wi l l be necessary t o use a sampl er t o cont i nuousl y
sampl e t he st ream t o provi de t he requi red fl ow-rat e t o
t he anal yser uni t . Lat er sect i ons provi de det ai l s on
t he most common sampl ers whi ch can be used i n
vari ous appl i cat i ons.

Not e t hat for frot hy st reams l i ke concent rat es, t he
frot h fact or must be t aken i nt o account when
cal cul at i ng t he fl ow-rat e and worki ng out t he si ze of
anal yser t ank whi ch i s sui t abl e. We normal l y
recommend a frot h fact or of 1. 5-2 for concent rat es.
For exampl e a concent rat e st ream wi t h a fl ow-rat e of
20 m
3
/ h and a frot h fact or of 2 has an effect i ve fl ow-
rat e of 40 m
3
/ h so i t woul d requi re a MSA-600mm
t ank for ful l fl ow anal ysi s.

Equipment Type

Recommended Range
(m
3
/h) (l/min)
MSA - 240 tank 0.5 - 4.0 8 - 70
MSA - 300 tank 1 - 15 17 - 250
MSA - 400 tank 5 - 20 80 - 330
MSA 500 tank 10 - 35 166 - 580
MSA - 600 tank 15 - 50 250 - 830

Installation Installing the MSA Umbilical Cable


2. Det ermi ne what t ype of sampl er i s best for each
st ream i n consul t at i on wi t h t he Company. The t ype of
sampl er used and t he posi t i on of t he sampl er wi l l
det ermi ne where t he anal yser must be pl aced i n t he
pl ant (see t he next poi nt ). Therefore i t may be
necessary t o l ook at a number of di fferent opt i ons for
t he l ocat i on and t ype of t he sampl ers i n consi derat i on
of t he l ocat i on of t he anal yser before maki ng a fi nal
deci si on.

3. The l ocat i on of t he anal yser (bot h el evat i on and pl an
posi t i on) i s det ermi ned based on:
a. Enabl i ng gravi t y fl ow t o and from t he anal yser
for as many as possi bl e of t he non pressure
sampl ed st reams and;
b. Mi ni mi si ng t he l engt h of al l of t he gravi t y fl ow
l i nes t o and from t he anal yser.
c. Mi ni mi si ng t he number of ext ra pumps requi red
i n t he sampl i ng del i very syst em.
d. Access requi rement s for bot h operat i on and
mai nt enance.
e. General cl eanl i ness of t he i nt ended i nst al l at i on
area e. g. excessi ve spl ashi ng from above can
cont ami nat e shi ft sampl er.

4. The pi pe work shoul d be desi gned t o mi ni mi se
mai nt enance. Desi gn rul es are provi ded i n sect i on
4. 7. 3.

Note:
The most i mport ant consi derat i ons are t hat t he sampl er
provi des a t rul y represent at i ve and unbi ased sampl e of
t he sl urry st ream and t hat t he sampl er i s rel i abl e and i s
easy t o mai nt ai n and use.



4.7.1 Primary Samplers
There are several t ypes of pri mary sampl ers avai l abl e and
t he part i cul ar t ype sel ect ed depends on t he appl i cat i on.
For pri mary sampl i ng of pi pes t hat t ransport sl urry t here
are basi cal l y t wo common t ypes of pri mary sampl er and
t hese are t he t ype usual l y suppl i ed wi t h t he on-l i ne
anal yser equi pment , i f ful l fl ows cannot be measured:

In-l i ne Pressure Sampl ers t hat are normal l y i nst al l ed
vert i cal l y aft er t he pump di scharge.
The sampl e st ream fl ow-rat e from a pressure pi pe
sampl er i s a funct i on of:
1. t he i nt ernal di amet er of t he sampl e nozzl e (whi ch
can be changed);
2. pressure i n t he mai n l i ne at t he sampl e out l et and
t he pressure drop bet ween t he sampl e out l et and t he
anal yser.

The i nt ernal di amet er of t he sampl e nozzl e and t he
pi pe-work bet ween t hi s and t he anal yser must be
sel ect ed so t hat t he Pressure Pi pe Sampl er wi l l provi de
t he requi red fl ow-rat e whi ch must not be more t han t he
maxi mum al l owabl e t hrough t he anal ysi s t ank.
and
In-l i ne Gravi t y Fl ow Sampl ers t hat are a fi xed cut t er
sampl er fi t t ed i n hori zont al or near-hori zont al gravi t y
fl ow l i nes. Represent at i ve sampl es are ext ract ed
t hrough vert i cal cut t ers.
A gravi t y t ype sampl er (hori zont al fi xed cut t er or
l aunder sampl er) i s normal l y i nst al l ed on a near
hori zont al sl urry pi pe or l aunder whi ch i s carryi ng t he
ful l sl urry st ream. The out l et from t he sampl er fl ows
under gravi t y t o ei t her t he anal yser or t o a pump whi ch
t hen pumps i t t o t he anal yser.

Thi s t ype of sampl er shoul d be used i n al l gravi t y fl ow
si t uat i ons i n a pi pe where t he sampl e can fl ow di rect l y
down t o t he anal yser or where a pressure pi pe sampl er
cannot be i nst al l ed. A gravi t y sampl er general l y has a
50mm (2") NB sampl e out l et (fl anged) and so a pi pe
l i ne wi t h t he same or l arger NB si ze shoul d be used.

Note:
Pri mary sampl ers suppl i ed by t he Company are t o be
i nst al l ed al ong wi t h any associ at ed pi pe work by t he
Cust omer.

Sampled
Flow
Main
Flow

Sampled
Flow
Main
Flow


Pri mary sampl ers provi ded by t he Company or manufact ured
under desi gn recommendat i ons from t he Company wi l l
i ncorporat e val ves and fi t t i ngs for back fl ushi ng t he
sampl er i n t he event t hat i t becomes bl ocked. If appl i cabl e,
drawi ngs of t he Pri mary Sampl ers are i n At t achment 2.

Note:
To ai d mai nt enance, i t i s hi ghl y recommended t hat t he
cust omer fi t s val ves t o t he fl anged out l et s at t he
mai nt enance drai n of each anal ysi s t ank i n t he MSA.

4.7.2 Slurry Pipe Connections to the Analysis Tank
The Cust omer i s t o provi de t he sl urry pi pe l i nes t o and
from t he anal ysi s t anks and provi de and i nst al l any
sampl i ng equi pment t hat may be requi red for t hese sl urry
l i nes.

The i nl et and out l et pi pes and fl ange si zes on t he t anks are
shown i n t he drawi ngs provi ded i n At t achment 2.

Al l sl urry i nl et pi pes (bot h hori zont al and vert i cal ) shoul d
di scharge bel ow t he sl urry l evel i n t he i nl et sect i on of t he
anal ysi s t ank, t hi s avoi ds spl ashi ng t hat may generat e ai r
bubbl es, part i cul arl y i n frot hy sl urri es. Thi s i nl et
di scharge pi pe i s al ready fi t t ed i n MSA t anks wi t h fl ange
t ype compat i bl e wi t h t abl e D Aust ral i an St andard and
ANSI, or as speci fi ed i n At t achment 2.

4.7.3 Guidelines for Slurry Sampling Pipe Work
If Pri mary Sampl ers or addi t i onal pi pe work t o t ransport
t he sampl es t o t he anal yser are t o be i nst al l ed, t he Company
recommends t he sampl i ng pi pe work i s i nst al l ed i n
accordance wi t h our recommendat i ons bel ow.

Note:
The Company hi ghl y recommends consul t at i on wi t h i t s
engi neers duri ng t he desi gn of t he sampl i ng syst em t o be
used wi t h t he on-l i ne anal yser syst em as i ncorrect
sampl i ng syst em desi gn may resul t i n poor performance of
t he on-l i ne anal yser.



Pi pe Work Desi gn
Pi pe work from t he sampl e poi nt t o t he anal yser and from
t he anal yser back t o t he process shoul d be desi gned t o
mi ni mi se bl ockages and mai nt enance. The mai n
requi rement s are:
1. To suppl y a suffi ci ent fl ow-rat e of sl urry t o t he
anal yser.
2. The t ransport vel oci t y must be hi gh enough t o avoi d
sandi ng.
3. Li ne/ pi pi ng di amet er must be l arge enough t o pass
t he l argest obj ect i n t he st ream.
4. Must be rel i abl e wi t h mi ni mal mai nt enance.

Pi pel i ne Si ze
The si ze of pi pes i s det ermi ned by t he fl ow-rat e requi red,
t he vel oci t y requi red t o avoi d sandi ng, t he pressure or
head avai l abl e t o dri ve t he sl urry and t he maxi mum
part i cl e si ze t hat needs t o be t ransport ed.

As a general rul e of t humb, t he mi ni mum pi pe si ze for
pressure l i nes shoul d be 3 t i mes t he maxi mum part i cl e si ze
goi ng t o t he gri ndi ng ci rcui t . For exampl e, i f t hi s
maxi mum part i cl e si ze i s 16mm, t hen t he l i ne si ze shoul d
be 3x16 = 48mm or 50mm NB.

Sl urry Vel oci ty
For Pressure Sampl e l i nes, t he mi ni mum sl urry vel oci t y i n
t he l i ne must be at l east t wi ce t he set t l i ng vel oci t y of t he
densest , l argest part i cl e of sol i ds i n vert i cal l i nes.

As a general gui de, most base met al s pl ant s requi re a
mi ni mum l i ne vel oci t y of 1m/ s.

To al l ow for surgi ng of t he pl ant and for pump wear, a
mi ni mum of 1. 5 m/ s i s normal l y used i n desi gni ng t he pi pe
work. Wi t h vel oci t i es above 1. 5 m/ s i n smal l l i nes, head
l oss i ncreases rapi dl y so al ways keep l i ne vel oci t i es as l ow
as possi bl e t o mi ni mi se pumpi ng power and t o reduce
wear.

For gravi t y fl ow l i nes, t he vel oci t y shoul d be at l east 0. 3
m/ s t o avoi d set t l i ng and bl ockages. These l i nes shoul d
have t he maxi mum possi bl e sl ope t o ensure t hi s.

The vel oci t y of fl ow requi red t o t ransport t he sl urry i n t he
sampl e l i ne depends on t he part i cl e si ze, t he speci fi c
gravi t y, t he percent sol i ds (di l ut i on) and t he shape of t he
part i cl es.


A mi ni mum sl ope of 5 degrees wi l l usual l y cat er for most
product s. However, t he Company recommends t he
Cust omer performs t est work or model s t hei r part i cul ar
appl i cat i on t o det ermi ne t he mi ni mum sl ope requi red for
t hei r part i cul ar product .

Instal l ati on of Pi pe Li nes
The pi pe work shoul d be designed t o avoi d set t l i ng and
bl ockages and shoul d be sel f drai ni ng on pl ant shut down.

Saggi ng shoul d be avoi ded. Not more t han hal f a pi pe
di amet er i s recommended. The l i nes from a pressure
sampl er shoul d reach t he hi ghest poi nt soon aft er t he
sampl er and t hen go st eadi l y downhi l l from t hat poi nt t o
t he anal yser uni t . The l i ne from a gravi t y sampl er shoul d
drop vert i cal l y i ni t i al l y and t hen onl y go st eadi l y downhi l l
t o t he anal yser. In al l l i nes avoi d bends as much as
possi bl e and do not use sharp or smal l radi us bends - onl y
use l ong sweep bends.

Part i cul ar care must be t aken wi t h support i ng of non ri gi d
pi pe l i ke HDPE (hi gh densi t y pol yet hyl ene).

Warni ng:
Avoi d t i ght bends i n sl urry pi pe l i nes, as t hey wi l l cause
regul ar bl ockages.

Si phoni ng
In some cases unwant ed si phoni ng may occur so t hi s
shoul d be engi neered out i f necessary.

Sampl i ng Pi pe Li ne Length
The sampl e l i ne l engt h shoul d be mi ni mi sed, part i cul arl y
for coarse st reams (i . e. , P
80
+150 mi cron).

Sampl er Back Pressure
The sampl e l i ne shoul d have l ess back-pressure due t o
fri ct i on and head l osses t han i n t he mai n l i ne. Thi s i s
requi red t o ensure t hat a st agnat i on zone does not occur
j ust upst ream of t he sampl e cut t er i n t he mai n l i ne, i n
whi ch case t he sampl ed st ream woul d not be represent at i ve
of t he ful l sl urry st ream. Thi s means t he sampl e l i ne must
not:
1. ri se as hi gh as t he mai n l i ne (appl i es t o Pressure
Sampl ers onl y);


2. have any const ri ct i on whi ch has a smal l er di amet er
t han t he di amet er of t he sampl e poi nt i t sel f - t he pi pe
di amet er shoul d preferabl y be sl i ght l y l arger t han t hat
of t he ID of t he poi nt of sampl i ng but not so bi g t hat
t he fl ow-vel oci t y decreases t o a poi nt where set t l i ng
may occur;
3. have sharp bends (t o mi ni mi se fri ct i on l osses, wear
and bl ockages) and shoul d preferabl y have l i ne-of-
si ght st rai ght sect i ons wi t h a mi ni mum number of
curves wi t h t he l argest reasonabl e radi us of curvat ure.

Sampl er Fl ushi ng Poi nt
For Pressure Sampl ers, a wat er i nj ect i on poi nt (pi pe st ub
wi t h fi t t i ng) shoul d be provi ded j ust downst ream of t he
sampl er so t hat t he l i ne can be cl eared by back-fl ushi ng
wi t h hi gh pressure wat er i n case of bl ockage. A val ve i s
requi red on t he st ub and al so on t he sampl e l i ne
downst ream from t he st ub. The pressure sampl er desi gn
i ncl udes a fl ushi ng val ve opt i on.

If a Gravi t y Sampl er does not cont ai n an i nspect i on port
whi ch can be used for cl eari ng t he sampl er i t sel f, t hen a
wat er i nj ect i on poi nt (pi pe st ub wi t h fi t t i ng) shoul d be
provi ded j ust downst ream of t he sampl er so t hat t he l i ne
can be cl eared by back-fl ushi ng wi t h hi gh pressure wat er.
A val ve i s requi red on t he st ub and al so on t he sampl e l i ne
downst ream from t he st ub. The gravi t y sampl er desi gn
i ncl udes a fl ushi ng val ve opt i on.

Note:
Avoi d usi ng a val ve t o l i mi t fl ow vol ume.

Installation Pneumatics


4.8 Pneumatics
Two pneumat i c ai r cyl i nders are used i n t he MSA uni t ; one
l arge uni t vert i cal l y mount ed on t he probe carri age hoi st
and a second smal l uni t for t he probe safet y l at ch, al so on
t he probe carri age hoi st (see phot o l eft ). Bot h of t hese ai r
cyl i nders operat e under aut omat i c cont rol ; however t hey
are compl et el y encl osed behi nd t he safet y guards t hus
prevent i ng any i nj ury t o operat ors. Because t he safet y
guard door t hat al l ows access t o t hese uni t s i s i nt erl ocked
t hen al l movement , i ncl udi ng t he pneumat i c operat i on
ceases when t he door i s opened and wi l l onl y resume when
t he door i s ful l y cl osed.

4.8.1 Air Requirement
Inst rument qual i t y compressed ai r i s requi red at al l t i mes
by t he MEP probe hoi st . Because t he probe hoi st act s as a
safet y devi ce t o prot ect t he probe i n t he event of wi ndow
rupt ure, a reservoi r ai r suppl y i s i ncorporat ed i nt o t he
hoi st desi gn.

In t he event of fai l ure of t he ai r suppl y t o t he hoi st , t he
probe wi ll be raised from t he sl urry. Fai l ure i s deemed t o
have occurred i f t he ai r pressure drops below 450 kPa,
control l ed by an i n-l i ne pressure swi t ch i n t he carri age
assembl y.

Ai r Pressure
Nomi nal l y 600 kPa (mi ni mum 450 kPa, maxi mum 800 kPa)

Note:
The Customer i s to provide an ai r regul at or i f requi red.

Ai r Speci fi cati on
Cl ean dry ai r t o 0. 1 mi crons and dew-poi nt l ess t han 2C.

Ai r Consumpti on
Less t han 50 l i t res per hour.

Note:
The MSA wi l l cease operat i on i f an ai r fai l ure or pressure
drop t o <450kPa occurs. An Ai rF1 message wi l l be
di spl ayed on t he Operat or Panel (OI) panel .

Pneumatics Installation


4.8.2 Air Connection
A schemat i c diagram of t he hoi st ai r syst em and
connect i ons poi nt s are shown i n fi gures 4-3 and 4-7. The
phot o left shows t he air connect or poi nt where t he blue
tube i s fi t t ed.

Note:
The Cust omer wi l l need t o provi de t he ext ernal ai r l i ne and
a mal e fi t t i ng i n BSP or NPT st andard for connect i on.

Ai r Isol ati on
Isol at i on i s vi a a bal l val ve l ocat ed at t he ai r connect i on
poi nt as shown i n your MSA i nst al l at i on drawi ng i n
At t achment 2.

Note:
The hoi st wil l rai se aut omat i cal l y when t he compressed ai r
l i ne i s fi rst at t ached t o t hi s syst em. It cannot be l owered
unti l t he pressure i n t he syst em reaches 450 kPa and t he 24
volt power suppl y i s present (i . e. El ect ronic Control l er is
turned on).

One ai r connect i on from t he mai n umbi l i cal cabl e i s
requi red on t he undersi de of t he l eft si de vert i cal l y
mount ed grey box (see phot o l eft ).

The ot her bl ue t ubi ng ai r l i nes (see phot os mi ddl e bot t om)
on t he probe carri age assembl y shoul d al ready be
connect ed. Check t hat t hey are by pul l i ng gent l y on t he
t ubi ng.

Installation Pneumatics


Fi gur e 4- 7 Pi pi ng and I nst r ument at i on Di agr am f or a Typi cal 6-
st r eam MSA.

Installation Water Requirement


4.9 Water Requirement
4.9.1 Water Requirement
A cl ean wat er suppl y i s requi red for washi ng t he probe and
suppressi ng frot h. One wat er spray i s suppl i ed per
anal ysi s t ank i n each MSA. A spray ri ng surrounds t he
probe and sprays wash wat er on t he probe as i t i s rai sed
from t he anal ysi s t ank.

Warni ng:
A very di rt y pl ant wat er suppl y may bl ock t he wat er
sprays, part i cul arl y for probe washi ng, and i ncorrect probe
measurement s may resul t .

Water Pressure
300 t o 800 kPa

Water Isol ati on
Each suppl y t o t he anal ysi s t anks and t he probe washi ng
sol enoi d have an i sol at i ng needl e val ve cont rol . These are
l ocat ed at t he wat er connect i on poi nt refer t o MSA
drawi ng provi ded i n At t achment 2 and phot o l eft .

Water Consumpti on
10 t o 20 l i t res per hour, dependi ng on t he number of t ank
wat er sprays i n use.

4.9.2 Water Connection
Pl umb t o t he sol enoi d bank on t he MSA frame vi a a i nch
BSP fi t t i ng refer t o MSA drawi ng i n At t achment 2 and
phot o shown l eft .

Note:
There are no wat er pressure sensors on t he MSA, t herefore
t here are no l ow wat er pressure warni ngs. Vi sual
i nspect i on i s requi red occasi onal l y t o ensure proper wat er
spray operat i on (refer t o sect i on 8, Mai nt enance).

Installation Analyser (In-Plant Power Requirement and Connection


4.10 Analyser (In-Plant) Power Requirement and Connection
4.10.1 3-Phase Power Requirement
Three phase (3-wi re + eart h) mai ns power suppl y i s used
for t he i n-pl ant anal yser. Figure 4-3 shows t he suppl y
connect i on poi nt t o t he MSA.

Warni ng:
DO NOT power-up t he el ect roni cs wi t hout t he supervi si on
of a Company engi neer.

It i s t he Cust omers responsi bi l i t y t o i nform t he Company
of t hei r mai ns vol t ages. The fol l owi ng vol t ages are
support ed:

Three Phase
380/ 415/ 440/ 460 V at 48 t o 62 Hz, opt i onal 525 V.

Tol erance
The 3-phase suppl y wi l l requi re a st abi l i sed vol t age
const ant t o wi t hi n 10% and a frequency const ant t o
wi t hi n 2. 0Hz because t he associ at ed el ect roni cs wi l l be
powered from t hi s suppl y al so, vi a an i nt ernal vol t age
t ransformer (t o st andard 240 vol t 1-phase) and 6A MCB
(Mi ni at ure Ci rcui t Breaker). Vol t age t o eart h shal l not
exceed
3
2
t i mes t he l i ne t o l i ne vol t age.

Three Phase Earthi ng
No speci al requi rement s are necessary due t o t he
el ect roni cs bei ng housed i n Faraday screeni ng met al
boxes. Nomi nal maxi mum i mpedance t o eart h of 1 ohm i s
recommended. A neut ral conduct or i s not requi red.

Maxi mum Power Consumpti on
3-st ream MSA wi t h st andard 250W st i rrers = 1. 8kW
(Refer t o manufact urer' s speci fi cat i on for non-Company
suppl i ed st i rrer mot ors).

Current vari at i on: 5-15 amp

Installation Analyser (In-Plant) Power Requirement and Connection


Note:
Al l ow an ext ra 500W per st i rrer i f usi ng 750W st i rrers i n
l arger t anks.

Power Fai l ure
In t he event of a power fai l ure, t he MEP wi l l be
aut omat i cal l y rai sed from t he sl urry by t he pneumat i c hoi st .

When power resumes, t he MSA wi l l preform a sel f-t est , t hen
resume normal operat i ons aut omat i cal l y provi ded t here were
no probl ems pri or t o t he power fai l ure (such as ai r pressure
fai l ).

4.10.2 3-Phase Power Supply Termination
Power cabl e i s t o be drawn t hrough t he st eel i nl et on t he
undersi de of t he mai n cont rol l er shown i n fi gures 4-3 and
4-8 (i nst al l at i on drawi ngs for your MSA i n At t achment 2).

Termi nat e t he power wi ri ng i n t he cont rol l er as i ndi cat ed
i n Fi gure 4-8 and as per your i nst al l at i on drawi ngs i n
At t achment 2.

Al l i nt ernal wi ri ng i s pre-wi red by t he Company wi t h t he
except i on of MSAs wi t h 2 frames, whi ch wi l l requi re
cabl es from frame 1 (t ank 6) of t he MSA t o be drawn
t hrough t he duct and t ermi nat ed as per t he associ at ed
wi ri ng t ermi nal numbers i n t he 2
nd
frame. Wi res and
screw t ermi nal s are numbered for ease of t ermi nat i on.
Thi s t ermi nat i on may be carri ed out under t he supervi si on
of a Company engi neer or t he Company can provi de
assi st ance i f requi red. Use of a cabl e snake i s
recommended and l engt h of t ube i s suppl ed for t hi s
purpose.

Installation Central Equipment Required


Fi gur e 4-8 Exampl e El ect r i cal Encl osur e and Connect i ons

Central Equipment Required Installation


4.11 Central (Computer) Equipment Requirements
The cent ral equi pment suppl i ed i s t o be i nst al l ed i n a cl ean
dry room such as an operat or cont rol room or a speci al i sed
cont rol equi pment room.

No physi cal mount i ng of t he cent ral equi pment i s requi red,
onl y suffi ci ent desk-t op space so t hat t he comput ers and
keyboards are readi l y accessi bl e. The pri nt er and t he RS-
485 t o RS-232 Convert er uni t are t o be sat as cl ose a
possi bl e t o t he mast er comput er.

Warni ng:
DO NOT unpack and i nst al l t he comput er equi pment and
peri pheral s. Thi s wi l l be done duri ng Commi ssi oni ng by
t he Company Engi neer.

Note:
Provi si on must be made for t he pl ant operat ors t o vi ew and
access on-l i ne di spl ay screens ei t her on t he mast er
comput er or on addi t i onal net worked PCs or vi a a
connect i on t o a process cont rol syst em screen.

A Company suppl i ed comput er wi l l have t he operat i ng
syst em and Wi nISA soft ware al ready l oaded. Ot herwi se,
t he soft ware wi l l al so need t o be l oaded fi rst , before i t can
be confi gured and t hi s wi l l be done by t he Company
engi neer on-si t e, duri ng Commi ssi oni ng.

4.11.1 Single-Phase Power Requirement and Connection

Power Requi rement
110 - 240V, 50-60 Hz si ngl e-phase st abi l i sed. Some
Company suppl i ed syst ems i ncl ude an Uni nt errupt i bl e
Power Suppl y (UPS), i f not , i t i s recommended t he
cust omer provi des UPS power for t he cent ral equi pment .
Installation Central Equipment Required


Warni ng:
Unst abl e power may cause i nt ermi t t ent operat i onal
probl ems wi t h t he comput er. In such cases t he Cust omer
shoul d provi de condi t i oned power or at mi ni mum an
Uni nt errupt i bl e Power Suppl y (UPS).

Mi ni mum Number Power Outl ets
Si x (6). General l y a 6-way surge prot ect ed di st ri but i on
board wi l l be suppl i ed wi t h t he cent ral equi pment when t he
Company suppl i es t he cent ral equi pment .

Maxi mum Power Consumpti on
Comput er/ Moni t or: 850 VA
Pri nt er: 115 VA (i nt ermi t t ent )
Dat a Int erface Uni t : 60 VA
Modem: 20 VA

(al l ow for ext ra capaci t y i f t wo comput ers are used)

Termi nati on
St andard Aust ral i an Power Pl ugs

Note:
Al l Company suppl i ed cent ral equi pment wi l l have st andard
Aust ral i an power pl ugs. The onus i s on t he Cust omer t o
provi de adapt ors or power cabl es sui t abl e for t hei r
count ry.

Instrumentation (Data) Cabling Installation


4.12 Instrumentation (Data) Cabling
The fi el d component s of t he on-l i ne anal yser syst em and
ot her i nst rument s communicat e wi t h a mast er ISA
comput er over t he AIN, a robust i ndust ri al dat a
communi cat i ons net work based on t he EIA st andard RS-
485. The hardware and soft ware prot ocol speci fi cat i ons
pert ai ni ng t o t he AIN have been devel oped by t he
Company.

Each devi ce connect ed t o t he AIN i s cal l ed a node. Some
i nst rument s are (i nt ernal l y) t wo nodes. At l east one node
wi l l be a mast er i nt erf ace whi ch connect s t he AIN t o t he
Thermo Electron Wi nISA comput er syst em. The mast er
i nt erface may be a si mpl e (AM955) RS-232 t o RS-485
convert er l ocat ed near t he comput er or i t may be one or
more Et hernet t o RS-485 t hi n servers (e. g. COBOX)
l ocat ed at poi nt s where t he AIN and a pl ant -wi de net work
(LAN) overl ap.

As a t hi rd possi bi l i t y, t he mast er i nt erface may be qui t e
remot e from t he Wi nISA comput er, bei ng l i nked back t o i t
by some ot her medi a such as fi re opt i c cabl e or spread-
spect rum wi rel ess t echnol ogy.

Due t o t he wi de vari et y of devi ces t hat are avai l abl e from
many di fferent vendors, t hi s document wi l l not at t empt t o
descri be how t o connect any one of t hem. Suffi ce t o say,
any sui t abl e devi ce wi l l have t hree t ermi nal s nomi nat ed
for RS-485 use. Refer t o t he manufact urers l i t erat ure for
connect i on det ai l s.

Note:
The Cust omer must provi de and run a screened t wi st ed pai r
dat a cabl e usi ng t he gui del i nes gi ven bel ow. Det ai l s
speci fi c t o your i nst al l at i on are provi ded i n At t achment 2.

Note:
In-Pl ant anal ysers must communi cat e wi t h t he mast er ISA
comput er whi ch i n t urn i nt erfaces t o t he pl ant PLC or
DCS. Di rect communi cat i on from Thermo Electron i n-pl ant
anal ysers t o DCS i s not possi bl e.

Installation Instrumentation (Data) Cabling


Note:
Al t hough t here are ot her manufact urers of RS232 t o RS485
convert er uni t s, t he Company strongl y advi ses agai nst usi ng
t hese i n-pl ace of t he AM955.

4.12.1 General Specification for the Data Cable
The physi cal arrangement or t opol ogy of t he dat a net work
i s t hat of a l i near mul t i -drop t wo wi re bus whi ch wi nds i t s
way around t he pl ant , st art i ng and endi ng wi t h a
t ermi nat i ng resi st or. Essent i al l y t he dat a cabl i ng requi res a
si ngl e t wi st ed pai r and a t hi rd wi re preferabl y i n t he form
of a met al l i c screen as i n screened t wi st ed pai r (STP)
cabl e. Thi s sect i on mai nl y refers t o t he act ual i nst al l at i on
of t he copper wi ri ng bet ween t he devi ces.

Ideal l y t wo pai rs shoul d be l ai d so as t o al l ow an ext ra
pai r as a spare or for fut ure expansi on opt i ons of t he
equi pment . Therefore, i t i s recommended t hat t wo (2) pai r,
t wi st ed pai r cabl e wi t h an overal l screen i s i nst al l ed
al t hough one pai r i s adequat e. The screen i s t o be
connect ed t o t he common t ermi nal at t he RS-485 Dat a
connect or provi ded on t he Thermo El ect ron equi pment .
The common t ermi nal of fi el d devi ces are i sol at ed from
eart h and provi de a si gnal reference for t he RS-485
t ranscei vers.

Conductor Si ze
Each conduct or of t he t wi st ed pai r cabl e shoul d have a
mi ni mum di amet er of 0. 5 mm (about 0. 2 mm
2
). Heavi er
cabl e i s oft en used for durabi l i t y. Indust ry st andard STP
(Screened Twi st ed Pai r) cabl i ng as frequent l y used for 4-
20mA current l oops i s general l y qui t e sui t abl e. Refer t o
t he cabl e speci fi cat i on sect i on fol l owi ng.

Maxi mum Length
The t ot al l engt h of t he AIN bus from t ermi nat i on resi st or
t o t ermi nat i on resi st or can be up t o 1. 2 km usi ng t he
cabl es recommended bel ow.

Maxi mum number of Devi ces (Nodes)
Due t o el ect ri cal l oadi ng const rai nt s, t here shoul d not be
more t han 32 nodes (or devi ces i f t hey are a si ngl e node)
on any one net work segment . Thi s number i ncl udes t he
mast er comput er i nt erface.

Not e t hat some Thermo Electron anal ysers act ual l y have t wo
nodes, t hi s i ncl udes MSAs. Thi s i s not t he case for MEPs
used i n dedi cat ed and ski d mount confi gurat i ons.


Note:
There can onl y be one mast er devi ce addressi ng or
cont rol l i ng t he ISA devi ces. If your want t o have t wo ISA
comput ers i n a Hot Backup confi gurat i on you must
ei t her:
1. Unpl ug t he AM955 and move i t t he ot her comput er
when i t becomes t he mast er, or:
2. Use a CoBox. Refer t o t he Sof t ware Manual for
confi gurat i on det ai l s.

The absol ut e l i mi t , based on l ogi cal addresses avai l abl e, i s
253 nodes.

4.12.2 Recommended Cable Specification for Data Network
Inst rument at i on cabl e, wi t h t wo t wi st ed pai rs, overal l
screened, conduct ors of about 0. 5 mm
2
(7/ 0. 30) are
recommended. Indi vi dual l y and overal l screened, st eel
wi re armoured cabl es, and l arger conduct ors are al so
sui t abl e. Thi s cabl e can be suppl i ed by Ol ex Dekoron, MM
Cabl es, Pi rel l i , and ot hers, where equi val ent .

Manufacturers Code Cable Description
Olex Dekoron MM Cables Pirelli
Two pair, overall screened. IEC183AA002 B5002 CS PE0 02C
Two pair, individual and
overall screened.
IED183AA002 B5002 ESCS PE0 02IC
Two pair, overall screened,
steel wire armoured
IEG183AA002 B5002 CS SWA PE0 02CA
Two pair, individual and
overall screened, steel wire
armoured.
IEH183AA002 B5002 ESCS SWA PE0 02ICA
Tabl e 4- 1 Recommended Cabl es f or I nt er connect i ng Devi ces

4.12.3 Terminating the Data Cable
Two 20mm di amet er hol es for dat a cabl e ent ry (and exi t
for dat a cabl e ext ensi on) are provi ded on t he l eft hand
undersi de of t he ri ght si de cont rol encl osure on t he MSA
(see Figure 4-8). Thi s cont rol l er al so cont ai ns t he Si gnal
Anal yser (see phot o l eft ) where t he dat a cabl e i s t o be
t ermi nat ed. The dat a cabl e i s t o be drawn t hrough t he
cabl e ent ry hol e and i nt o t he encl osure t hen t ermi nat ed at
t he 3-way screw t ype t ermi nal s provi ded i n t he t op ri ght
hand corner of t he Si gnal Analyser (Refer t o Fi gure 4-9).


Fi gur e 4- 9 Si gnal Anal yser Chassi s Layout Cent r al Equi pment
Requi r ement s


Note:
The dat a cabl e i s an ext ensi on of t he cabl e i nst al l ed for
ot her anal ysers i f more t han one anal yser uni t i s bei ng
i nst al l ed i n t he pl ant . The l ast i nst rument (devi ce) on t hi s
net work must be t ermi nat ed wi t h a 120 ohm resi st or at t he
Dat a Out t ermi nal .

Cabl e Termi nati on
The dat a t ermi nat i ons on Thermo El ect ron equi pment
consi st s of a t ermi nal bl ock wi t h t hree connect i on poi nt s.
Usual l y al l t hree t ermi nal s are dupl i cat ed so t hat onl y one
wi re has t o be i nsert ed i n each t ermi nal . In some cases t he
t ermi nal bl ocks are of t he removabl e pl ug t ype.

Consi st ent l abel l i ng i s used and assumi ng t he cabl e used
has bl ack and whi t e i nsul at ed conduct ors, t ermi nal s shoul d
be wi red as fol l ows at al l devi ces:

White

D+

Black

D-

Screen

S, SCR, or COM

Termi nati on Resi stor
In order t o prevent degradi ng si gnal refl ect i ons, each end
of t he AIN bus shoul d be t ermi nat ed wi t h a 120 ohm
0. 25 wat t non-i nduct i ve resi st or, connect ed across t he D+
and D- conduct ors. Sui t abl e resi st ors are i ncl uded wi t h t he
Thermo El ect ron equi pment al ready fi t t ed t o t he
appropri at e t ermi nal bl ocks. There must be no more t han
t wo resi st ors on t he bus. Surpl us resi st ors shoul d be
di scarded.
Fi gure 4-10 shows how and how not t o t ermi nat e t he bus.

Stubs
Any pi ece of cabl e whi ch forms a T-j unct i on wi t h t he bus
i s cal l ed a st ub. Al t hough i n pract i ce t he bus i s usual l y
made up of several sect i ons of cabl e j oi ned i n seri es, t he
bus shoul d effect i vel y appear as one cont i nuous l engt h of
cabl i ng and t here shoul d be no st ubs on t he bus exceedi ng
5 met res i n l engt h (see Fi gure 4-10).

Connect Data In
wires here
Connect Data Out
wires here terminate
with 120 ohm resistor
as shown
OR


Shared Cabl es
If t he AIN i s t o be i ncorporat ed wi t h ot her wi ri ng i n a
mul t i -pai r cabl e for al l or part of i t s l engt h t he fol l owi ng
must be t aken i nt o account . Fi rst l y, al l ci rcui t s i n t he cabl e
must be pai red, screened or coaxi al and carryi ng onl y l ow
l evel si gnal such as dat a, phone, current l oop or ot her
i nst rument si gnal s. If t he AIN pai r i s separat el y screened
from t he rest of t he cabl e t hen t he connect i on met hod i s
sel f evi dent . Ot herwi se, i t wi l l be necessary t o provi de for
t he t hi rd AIN (common) wi re. Thi s can be done by
dedi cat i ng anot her pai r for t he purpose or i f a t ri pl e (t hree
wi res t wi st ed t oget her) i s avai l abl e, t hi s may be used qui t e
successful l y. Take care t hat t he screen i s not grounded or
connect ed t o t he overal l screen at any poi nt .



The AIN Bus
1200m (max)
120R 120R
STP Cable
AIN Devi ces ( 32 Max)
(Master may be in any position)
Example of correct wiring of the AIN bus
Note that any node can be in any position on the bus. This includes the mast er
interface (eg AM955 or a Cobox). These are of ten at one end but that is not required.
Such nodes may not have IN and OUT terminals, however the conductors are simply
connected in parallel in that case.
Any stubs must not
exceed 5m in length
120R 120R
Showing a stub on the AIN
Termination resistors
must be at both ends!
120R
120R
Wrong termination of the AIN

Fi gur e 4- 10 AI N Dat a Cabl e Ter mi nat i on


4.12.4 High EMI (Noise) Environments
Where known sources of hi gh frequency el ect romagnet i c
i nt erference (EMI) exi st (eg. el ect rost at i c and magnet i c
separat ors and vari abl e speed dri ves or i nvert ers) i n t he
pl ant i t i s recommended t hat some form of overal l
screeni ng i s used i n addi t i on t o t he shi el d i ncl uded i n t he
AIN cabl e. Thi s overal l screen can opt i onal l y t ake t he
form of screwed or fl exi bl e met al condui t , st eel wi re
armour (SWA) or an overal l copper brai d or al umi ni um
foi l (wi t h drai n wi re). It must not be connect ed t o t he
i nner screen. In al l cases t he out er screen must be
grounded and fi rml y connect ed t o t he out si de of t he
equi pment encl osure. The expl anat i on for t hi s i s t hat we
have t o avoi d carryi ng noi se current s i nsi de t he encl osure
where t hey may radi at e and t hus i nduce noi se i nt o t he
sensi t i ve ci rcui t s t herei n. The RS-485 i nt erface i s opt i cal l y
i sol at ed t o 2000 vol t s but radi at ed noi se carri ed al ong t he
out er condui t or screen shoul d not be al l owed t o ent er t he
encl osure.

4.12.5 Proximity to Power and High Voltage Cables
Due t o hi gh noi se i mmuni t y of t he dat a net work, as
expl ai ned above, EMI from adj oi ni ng cabl es wi l l not
general l y affect communi cat i on on t he bus. Never-t he-l ess
t he user has t o t ake i nt o account t he possi bi l i t y of
abnormal noi se sources and l ocal wi ri ng regul at i ons i n
regard t o i nsul at i on and/ or separat i on of hi gh and l ow
vol t age cabl es. Such consi derat i ons may requi re t hat t he
dat a cabl es are l ai d i n a separat e duct or cabl e t ray, and
about 1m apart , or t hat a hi gher qual i t y cabl e i s used such
as t he SWA cabl e l i st ed i n Tabl e 1.

4.12.6 Use of Fibre Optic Cable
Where t here i s l i kel y t o be an ext remel y hi gh l evel of EMI
consi der usi ng opt i cal fi bre for some or al l of t he AIN
segment s. There are a number of t hi rd part y product s abl e
t o ext end an RS-485 net work usi ng ei t her one or t wo
fi bres. The Company i s abl e t o provi de t hese product s or
i ndi cat e how you may obt ai n t hem. Lant roni x Cobox
Adapt ors are avai l abl e wi t h copper or fi bre opt i c Et hernet
t o RS-232/ 485 funct i ons. They al l ow t he Wi nISA Server
comput er t o communi cat e wi t h t he In-St ream Anal yser
cont rol l ers i n t he pl ant over t he pl ant net work. A net work
connect i on usi ng copper wi ri ng (10base-T) wi t h RJ45
connect ors or ST t ype Fi bre Opt i c connect ors must be
made t o t he In-St ream Anal yser cont rol l er encl osure,
where i t i s t ermi nat ed at t he Cobox. The Cobox
communi cat es i n t urn wi t h t he In-St ream Anal yser usi ng
RS-485. Vari ous confi gurat i ons can be t ai l ored at t he t i me
of orderi ng t he ISA Syst em.



Section 4 - Installation
Attachment 1 Equipment Data Sheets

CONTENTS

Equi pment Li st

Instal l ation Checkli st



Section 4 - Installation
Attachment 2Installation Drawings

CONTENTS

Drawi ng & Di agram Li st

Instal lation/Foundation Drawing

Connecti on Drawi ng

P & ID Diagrams


5
Commissioning

Thi s sect i on i s wri t t en for t hose personnel carryi ng out t he
post -i nst al l at i on and pre-cal ibrat i on i nspect i on, t est i ng
and set -up of t he equi pment i n t he Cust omers pl ant . It i s
i nt ended t o be used by t he Company engi neer al ong wi t h
pl ant personnel . Duri ng thi s stage si gni fi cant hands-on
trai ni ng can be obtai ned by pl ant personnel .

The work carri ed out usual l y t akes bet ween 1 and 5 days,
dependi ng on t he si ze of t he anal yser syst em and i ncl udes
most l y t he t asks i n t he order shown bel ow:

1. Inspect i ng t he physi cal i n-pl ant i nst al l at i on work and
advi si ng of any requi red modi fi cat i ons, part i cul arl y
wi t h t he sampl i ng t anks, st i rrer mount s and pi pe work.

Note:
It i s i mport ant t hat any i nst al l at i on modi fi cat i ons are
compl et ed wi t hout del ay; ot herwi se si gni fi cant del ays i n
t he commi ssi oni ng and cal i brat i on can l ead t o ext ra cost s
for l ost t i me on-si t e.

2. Confi rmi ng power suppl y vol t ages and connect i ons
wi t h t he si t e el ect ri ci an bef ore poweri ng up. DO NOT
power up here.
3. Checki ng MEP and hoi st cabl e t ermi nat i ons.
4. Confi rmi ng ai r suppl y and connect i on wi t h si t e
personnel .
5. Confi rm wat er suppl y and connect i on wi t h si t e
personnel .

Commissioning


Note:
The MEP bi as wi l l not ramp up and t he MEP cannot be
el ect roni cal l y l owered on t he hoi st unt i l t he comput er i s
powered up and communi cat i ng wi t h t he anal yser.

6. Set t i ng up, poweri ng up and confi guri ng t he comput er
and i t s soft ware and compl et i ng AIN Dat a Cabl e
t ermi nat i ons. Refer t o sect ion 5. 3 for furt her det ai l s.

Note:
It i s most i mport ant t hat t he dat a cabl e has been l ai d pri or
t o t he commi ssi oni ng phase, bet ween t he i n-pl ant
equi pment and t he comput er, even i f not act ual l y
t ermi nat ed.

7. Poweri ng up t he i n-pl ant equi pment wi t h t he si t e
el ect ri ci an present . Refer t o sect i on 5. 5 for furt her
det ai l s.
8. Adj ust i ng hoi st ai r pressure set t i ngs i f requi red. Refer
t o sect i on 5. 6 for furt her det ai l s.
9. Check MSA safet y i nt erl ocks.
10. Inst al l i ng t he MEP det ect or i nt o t he anal yser and
t oppi ng up wi t h LN2. Refer t o sect i on 5. 6 for furt her
det ai l s. Onl y i nst al l t he probe when you are sure t he
safet y i nt erl ocks work.
11. Cal i brat i ng LN
2
Sensor el ect roni cs. Refer t o sect i on 5. 8
for furt her det ai l s.
12. Checki ng and t est i ng t he MEP el ect roni cs operat i on
agai nst fact ory set t i ngs wi t h a st andard. Fact ory
set t i ngs are provi ded i n At t achment 2. Refer t o sect i on
5. 9 for furt her det ai l s.
13. Adj ust i ng MEP el ect roni cs set t i ngs t o sui t pl ant sl urry
propert i es and cust omer requi rement s where needed.
Refer t o sect i on 5. 9 for furt her det ai l s.
14. St abi l i t y t est i ng t he syst em agai nst a st andard
overni ght or for about 12 hours. Refer t o sect i on 5. 10
for furt her det ai l s.
15. Where fi t t ed, checki ng t he operat i on of t he
Met al l urgi cal Sampl ers. Refer t o sect i on 5. 11 for
furt her det ai l s.

Commissioning Resource to be Provided by the Customer


The fol l owi ng sect i ons provi de procedures and det ai l s for
most of t he requi red work.

5.1 Resources to be Provided by the Customer
1. (Usual l y) Pl ant Met al l urgi st shoul d be avai l abl e
i nt ermi t t ent l y t hroughout commi ssi oni ng phase t o;
a) Ensure/ advi se on pl ant operat i on
b) Recei ve t rai ni ng from TGM engi neer
operat i on/ mai nt enance/ cal i brat i on
c) Assi st TGM engi neer wi t h cal i brat i on of t he MSA
d) As requi red by TGM engi neer
e) Aft er commi ssi oni ng- mai nt ai n cal i brat i on / oft en
t he percei ved owner / devel op a pl an or al gori t hm
for effect i ve pl ant cont rol usi ng t he MSAs assays.
2. Met Lab faci l i t i es and personnel
3. Assay l ab faci l i t i es and personnel

5.2 Special Tools & Equipment Requirements
The fol l owi ng speci al i t ems are requi red:
1. Tool box cont ai ni ng speci al t ool s and consumabl e
i t ems necessary for t he anal yser (At t achment 1).
(Wi t h every anal yser syst em a t ool box i s suppl i ed
whi ch cont ai ns essent i al consumabl e i t ems and
speci al t ool s needed t o commi ssi on and mai nt ai n t he
anal yser syst em. )
2. Mul t i -Channel Anal yser (MCA) wi t h Aust ral i an
power cabl e/ pl ug and BNC si gnal cabl e.
(An MCA i s requi red t o set up t he si gnal anal yser
el ect roni cs but i s not al ways suppl i ed wi t h t he
anal yser as i t i s an expensi ve pi ece of equi pment
t hat i s used i nf requent l y. The Company Engi neers
carry an MCA. )

NORLAND 5500 MCA
OFF ON
VIKING INSTRUMENTS
VERTI CAL SCALE
HORIZONTAL SCALE
CURSOR
ZERO ULD
LLD
AMP GAIN
INPUT
SET
UP COMPUTE PROG
+ 7 8 9
OPTIONS DISPLAY
GOES
INTO
==> - 4 5 6
CONT CANCEL CLEAR
NUM X 1 2 3
RUN TERM EXP 0 .
CONV
GAIN
OFFSET
AMP
DIRECT
Mechanical Checks Commissioning


5.3 Mechanical Checks
The fol l owi ng i mport ant mechani cal i nspect i on checks
must be done on t he MSA before proceedi ng wi t h
i nst al l i ng t he MEP det ect or:

Check t hat t he probe carri age i s si t t i ng on t he gui de
rai l s properl y. Al l carri age rol l ers must be t ouchi ng
t he gui de rai l s (see phot os l eft ). There are 4 x 75mm
di amet er wheel s and one l arger dri ven wheel .
Check t hat t here i s cl earance bet ween t he rear of t he
probe carri age and t he gui de rai l s. The carri age frame
must not t ouch t he gui de rai l s onl y t he rol l ers (see
phot o l eft ).
Check t hat t he cabl e t rol l ey rai l i s fi t t ed as per t he
i nst al l at i on di agram i n At t achment 2 and t hat al l cabl e
hooks are i nst al l ed.
If not al ready fi t t ed, fi t t he umbi l i cal cabl e ont o t he
cabl e t rol l ey by l oopi ng t he cabl e evenl y from t he end
t ank fi rst t hrough t o t he probe carri age. If i t has been
fi t t ed, check t hat i t i s l ooped correct l y and i f not fi x i t
now before proceedi ng as any undue fl exi ng of t he
cabl e may damage i t (see phot o l eft ).
Vi sual l y check t hat no cabl es, ai r or wat er l i nes wi l l
obst ruct t he movement of t he probe and carri age.
Check t hat t he ai r suppl y i f correct l y connect ed at t he
i nl et and t he pressure i s at l east 450 KPa. Do not open
t he bal l val ve yet . Check t hat t he bl ue pl ast i c ai rl i nes
have been fi t t ed t o t he ai r sol enoi d connect ors on t he
probe carri age (see phot o l eft ). Try pul l i ng on t hem t o
ensure t hat t hey wont come out . If t hey do t hen t hey
havent been fi t t ed properl y and i t must be fi xed.
Check t he Ai r Reservoi r drai n bal l val ve i s cl osed If
al l ai r connect i ons are okay t hen i t i s safe t o open t he
bal l val ve (see phot o l eft ). The probe wi l l rai se so do
not get i n t he way of i t . The ai r pressure shoul d now be
i ndi cat ed by t he gauge on t he t op of t he ai r cyl i nder on
t he probe carri age (see phot o t op l eft ).
Check t hat t he anal ysi s t anks are evenl y spaced al ong
t he MSA frame and bol t ed down t o t he frame t oo.
Commissioning Mechanical Checks


Check t he al i gnment of t he each proxi mi t y sensor on
t he gui de rai l . Each sensor shoul d be cent ral l y l ocat ed
wi t hi n t he wi dt h of i t s anal ysi s t ank (see phot o l eft ).
There i s one sensor per t ank and t hen an ext ra one on
each end of t he gui de rai l t o sense when t he probe
reaches t he ext remi t i es (t hese are t he l i mi t swi t ches).
If a servi ce bay has been suppl i ed, t hen anot her sensor
wi l l be cent ral l y posi t i oned wi t hi n t hat space.
Check t hat each st i rrer has been mount ed correct l y so
t hat i t s i mpel l or does not t ouch t he bot t om or si des of
t he t ank. Al so check t hat t he i mpel l er i s bol t ed on
fi rml y t o i t s shaft t o prevent i t fal l i ng off i n t he sl urry.
Check t hat wat er has been pl umbed t o t he MSA wat er
i nl et at t he bal l val ve on t he bot t om of t he mani fol d (as
shown i n phot o l eft ). Al so check t hat t he green pl ast i c
wat er l i nes have been correct l y connect ed at t he
sol enoi d on t he probe carri age and agai n at t he carri age
spray ri ng and t he t ank wat er sprays. Pul l on t he green
pl ast i c l i nes t o check t hat t hey have been connect ed
properl y, i f not t hen fi x before t urni ng on t he wat er
suppl y.
Check t hat t he End Pl at es have been bol t ed t o t he end
of t he MSA frame (see phot o l eft ). These are essent i al
t o prevent t he probe carri age fal l i ng off t he end of
t he gui de rai l i f a maj or carri age dri ve faul t occurs.
Turn t he st i rrer shaft s by hand t o check t hat t hey
operat e cl ear of obst ruct i on. Check t he four grub
screws are t i ght ont o t he col l ar usi ng a 3mm Al l en key.
If t he st i rrer mot ors have a breat her, check t hey are
open.

Setting up the Computer and Data Cable Terminations Commissioning


5.4 Setting up the Computer and Data Cable Terminations
Al l cent ral equi pment i s packed separat el y from t he mai n
equi pment and shoul d not have been unpacked duri ng t he
i nst al l at i on phase. Whet her or not i t has, i t i s most
i mport ant t hat t he packi ng l i st suppl i ed wi t h t he crat e/ box
be checked off agai nst t he act ual suppl y. Thi s must be
done by t he Company engi neer i n t he presence of t he
Cust omer.

Once al l equi pment i s account ed for, t he comput er,
moni t or, pri nt er, modem and dat a i nt erface uni t shal l be
unpacked and set -up on a t abl e or bench i n t he area
al l ocat ed by t he Cust omer.

Connect up al l component s and power t hem up. The
comput er, i f suppl i ed by t he Company, wi l l al ready be
confi gured for t he anal yser syst em. If not , t he soft ware
wi l l have t o be l oaded and confi gured before commenci ng
i n-pl ant equi pment power up. Fol l ow t he procedures i n t he
Sof t ware manual .

Termi nat e t he AIN RS-485 dat a cabl e i n t he cont rol room
vi a t he RS-485 screw t ype t ermi nal i n t he back of t he
Convert er uni t (refer t o fi gure 5-6).

Al so, check t hat t he dat a cabl e has been properl y
t ermi nat ed (no crossed over wi res) i n t he Si gnal Anal yser
out i n t he pl ant t oo. Connect i ons shoul d be D+ t o D+, D-
t o D- and SCRN t o SH. Not e t hat SCRN, SH and COM are
i nt erchangeabl e names.

The Convert er uni t i s t hen l i nked t o t he comput er usi ng t he
suppl i ed 2 met re RS-232 shi el ded cabl e.
Commissioning Setting up the Computer and Data Cable Terminations


DIMENSIONS:
Height = 55mm
Wdith = 150mm
Length = 200mm
FRONT VIEW
REAR VIEW
AM 955
PWR TXEN TXD RXD
RS-232 (DB25 NULL MODEM) MAINS IN
RS-485 (TWISTED PAIR SCREENED)
RS-232C
DCE
RS-485
SCRN D+ D-
POWER
VOLTS FUSE
230 0.25a
115 0.5A
50 / 60 Hz

Fi gur e 5- 1 AM955 Conver t er ( Dat a I nt er f ace) Uni t

Powering Up the In-Plant Equipment Commissioning


5.5 Powering Up the In-Plant Equipment
Essent i al checks bef ore poweri ng up:

The mai ns power t ermi nat i ons are correct l y i nst al l ed
and correct vol t ages are suppl i ed (check wi t h t he
pl ant el ect ri ci an).
The (orange) mai ns power swi t ch i n t he Si gnal
Anal yser (l eft ) i s t urned off.
Ensure t hat al l t he cards and modul es i nsi de t he
MSA cont rol uni t s are fi rml y i n pl ace.
Turn off t he Bi as swi t ch (see phot o l eft ) on t he Bi as
suppl y modul e i n t he Si gnal Anal yser.
The l ockabl e Mai ns Isol at or i s t urned bot t om on t he
front panel mai n MSA Cont rol l er (see phot o l eft ).
The door must be cl osed t o do t hi s.
The probe shroud i s fi rml y mount ed i n t he probe
carri age and t he carri age i s si t t i ng correct l y on t he
gui de rai l s.
The End Pl at es are fi rml y bol t ed on each end of
t he MSA frame (see phot o l eft ).

Warni ng:
If t he end pl at es are not i n pl ace when t he probe st art s
movi ng hori zont al l y, i t coul d fal l off t he end i f a
proxi mi t y sensor fai l s.

Ensure t he MSA umbi l i cal cabl e i s free t o move
al ong i t s gui de rai l .
The el ect ri ci an can now swi t ch t he mai ns power t o t he
MSA (Refer sect i on 5. 5. 1).

Commissioning Powering Up the In-Plant Equipment


5.5.1 Powering Up the MSA
On poweri ng-up t he MSA, a Posi t i on Test needs t o be
performed. To do t hi s, at t he OI panel (see phot o l eft ),
sel ect t he menu opt i on <Aut oMode> t o put t he MSA i nt o
aut omat i c cont rol . Make sure t he i nt erl ocked guard door
i s cl osed. The probe wi l l now move hori zont al l y t hrough
t he zones. Thi s aut omat i c procedure sel f-t est s t hat t he
MSA l at eral movement and posi t i on sensi ng component s
(proxi mi t y sensors, l i mi t swi t ches, et c), probe movement ,
carri age dri ve mot or, et c. , are worki ng. If a fai l ure i s
det ect ed an error message wi l l be di spl ayed on t he
operat or i nt erface OI panel and at t he comput er Fai l ed t o
Posi t i on Test or si mi l ar speci fi c message. Refer t o
Chapt er 9, Troubl e Shoot i ng for det ai l s.

Note:
If t he MSA has l ost i t s operat i onal embedded code (ANI
Code) t hen i t wi l l not perform a posi t i on t est but wi l l
i nst ead di spl ay a message on t he OI panel i ndi cat i ng t hat i t
i s t ryi ng t o down-l oad t he requi red code from t he
cont rol l i ng comput er. If t hi s happens t hen check t hat t he
comput er i s powered up and t he Wi nISA Server i s runni ng
(see sect i on 5. 3 and bel ow).

If a WndRpt message i s di spl ayed on t he OI panel of t he
MSA t hen check t hat t he Al armed Wi ndow Assembl y i s
properl y fi t t ed i n t he MEP and t hat al l cabl es t ermi nat i ons
on t he det ect or and i n t he Si gnal Anal yser Chassi s are
fi rml y connect ed. The 2 wi re fi ngers on t he cont act
assembl y (see phot o l eft ) must make cont act wi t h t he rear
of t he wi ndow assembl y. The wi ndow must al so be
i nsert ed so t hat i t i s fl ush wi t h t he head.

If t he MSA does not go i nt o a Posi t i on Test when
powered up t hen t he RLC may have l ost i t s fi rmware
confi gurat i on, i n whi ch case you wi l l need t o fol l ow t hese
st eps;

1. Re-ent er t he RLC Zone Mask (<ZneMask>) for your
MSA (t hi s i s provi ded on i nst al l at i on by t he Company
or i t can be found i n t he sect i on coveri ng t he OI RLC
menus) i n chapt er 7, Operati on.
2. If you have met al l urgi cal sampl ers t hen you wi l l al so
need t o ent er t he RLC maski ng for t hese by sel ect i ng
t he menu opt i on (<SMPMask>).
3. Re-ent er t he avai l abl e zones, i . e. t he zones, 1 t o 12
t hat you want t o measure (<ZneAvai l >, see OI RLC
menu sect i on) i n chapt er 7, Operati on.


4. Check t he (Servi ce Bay) has been correct l y set ,
usual l y i t i s t he l ast zone. If you prefer a di fferent
zone, ent er i t here. Not e: If your appl i cat i on code i s
an earl i er versi on number t han M221, t he servi ce bay
defaul t i s 99, whi ch i s past t he forward l i mi t swi t ch.
If you have pre M221 code and no dedi cat ed servi ce
bay past t he forward l i mi t swi t ch, you must ent er a
val i d st ream (zone) number as t he servi ce bay,
ot herwi se a posi t i on t est may fai l wi t h t he message
st uck at l ast zone. Check t he appl i cat i on code
versi on i n t he <Debug> screen on t he OI.
5. If you want t he MSA t o resume normal operat i on
aut omat i cal l y aft er a power fai l ure, check now t hat
<Aut oSt art > has been set t o YES. Now sel ect
<Aut omode>.
6. Re-set t he RLC (<Reset RLC>), t he MSA shoul d t hen
perform a Posi t i on Test , i f not t urn off t hen on t he
MSA power. If a Posi t i on Test i s st i l l not possi bl e,
t hen check t he OI panel di spl ay for any error
messages. If an error message i s di spl ayed t hat
i ndi cat es t here i s i nformat i on bei ng down-l oaded t hen
t hi s means t he RLC i s obt ai ni ng i t s embedded code
(ANI code) from t he ISA comput er, of course t hi s
cant happen i f t he comput er i s down, or t he dat a l i ne
bet ween t he MSA and comput er (or convert er uni t ) i s
faul t y, i n whi ch case t he RLC wi l l t ry i ndefi ni t el y t o
obt ai n t he ANI code i t requi res so check t he ISA
comput er and dat a comms (AIN).

Note:
When ANI code (appl i cat i on code) i s bei ng downl oaded
from t he comput er t he TXEN, RXD and TXD LEDs wi l l
fl ash on t he AM955 convert er unit (see fi gure 5-6). Al so
t he LEDs on t he AM092 card i n t he si gnal anal yser wi l l
fl ash at t he same t i me as t he AM955 uni t (see Fi gure 5-2).



5.5.2 Powering Up the Signal Analyser
The Si gnal Anal yser i s t he probe cont rol el ect roni cs and
i t s el ect roni cs chassi s i s mount ed i n t he t op ri ght hand
corner of t he Cont rol l er (see Fi gure 5-3 and phot o l eft ).

Provi di ng t he probe BIAS swi t ch i s OFF t hen power up
t he Si gnal Anal yser by pressi ng t he POWER but t on (see
phot o l eft ). The orange col oured POWER but t on and t he
red LN TEST but t on t o i t s ri ght shoul d l i ght up i ni t i al l y
t hen ext i ngui sh aft er about 15-20 seconds.

If t he LN TEST but t on does not ext i ngui sh of i t s own
accord wi t hi n t he fi rst mi nut e, and t here i s LN
2
i n t he
probe, t hen t he LN
2
Sensor needs t o be adj ust ed and t hi s
procedure fol l ows i n sect i on 5. 8. The Bi as cannot be
appl i ed t o t he probe when t hi s LED i s red.

For normal operat i on, no red l amps (eg LN TEST, WR
TEST or HOIST RESET) shoul d be on provi ded t he
comput er i s runni ng; however, i f t he probe i s ful l y rai sed
t hen t he HOIST RESET but t on wi l l be l i t red and wi l l
onl y ext i ngui sh when t he probe i s l owered i nt o t he sl urry.
There may be ot her red LEDs on dependi ng on t he reason
for t he hoi st bei ng rai sed.

Note:
If t he WR Test but t on i s l i t red t hen check t he WR ci rcui t
cont i nui t y and check t hat t he met al (wi re) fi ngers on t he
bot t om of t he det ect or, see Fi gure 5-8, are maki ng proper
cont act wi t h t he i nsi de edge of t he Wi ndow Assembl y.



Fi gur e 5- 2 Si gnal Anal yser Chassi s Layout


Fi gur e 5- 3 Exampl e MSA Cont r ol l er Chassi s Layout


Not e t hat on power up t he red LEDs on t he AM092 card i n
t he Si gnal Anal yser may bl i nk for a few mi nut es whi l e i t s
memory chi p ret ri eves t he l at est appl i cat i on code from t he
comput er. Once fi ni shed, t he TX (second from t op) and
RX (t hi rd from t op) LEDs on t he AM093 card (shown l eft )
shoul d fl ash about every mi nut e. Thi s i s normal operat i on.

Note:
If t he four red LEDs cont i nue t o bl i nk i n uni son for many
mi nut es t hen check t he dat a communi cat i on cabl e and
t ermi nat i ons bet ween t he i n-pl ant equi pment and t he
comput er. Al so check t he AIN code bei ng used i n t he
soft ware t oo (refer t o t he Soft ware User Manual ).

5.5.3 Applying HV Bias to the MEP
Provi di ng t he mai ns power i s on at t he Si gnal Anal yser and
t he LN TEST but t on i s not l i t red t hen, swi t ch t he power
t o t he MEP ON by set t i ng t he fol l owi ng swi t ches i n t he
Si gnal Anal yser:

BIAS VOLTAGE on t he AM963 (shown l eft ) t o ON
PROBE/ INJECT t o PROBE

The BIAS ON LED shoul d l i ght red as t he bi as vol t age
comes up i ni t i al l y at 30 vol t s. Thi s i s enough t o st art up a
normal det ect or and wi t hi n 5-10 seconds t he OPTICAL
RESET LED shoul d l i ght . It may be ei t her red or green or
al t ernat i ng bot h col ours. The BIAS ON LED shoul d begi n
t o bl i nk red as t he bi as i s sl owl y i ncreased t o t he vol t age
set on t he di al t o (-)500 vol t s. Wai t unt i l bot h LEDS t urn
green.

The OPTICAL RESET may set t l e t o a fl ashi ng or
fl i ckeri ng green, dependi ng on i nci dent X-ray i nt ensi t y.
Now i t may be assumed t hat t he bi as i s st abl e at t he
operat i ng pot ent i al .

Once bot h LEDs are green t he el ect roni cs and MEP are
operat i ng normal l y and you are ready t o proceed wi t h
ot her syst em checks and t est i ng.



Warni ng:
If t he Bi as LED st ays red t hen t he det ect or pre-
amp/ vol t age feed-t hrough may have moi st ure i n i t . The
moi st ure wi l l normal l y dry out aft er a few hours or
overni ght , provi di ng t he LN
2
fi l l i ng cap i s cl amped down
and t he foam Dewar pl ug i s removed. If i t does not dry out
t hen fol l ow t he dryi ng out procedure i n t he Mai nt enance
sect i on.

Warni ng:
If t he Opt i cal Reset LED st ays red t hen t here may be
i mproper cabl e wi ri ng or t ermi nat i on t hus causi ng noi se
pi ckup whi ch wi l l overl oad t he si gnal processi ng OR t he
det ect or may have been damaged i n t ransi t . Check wi ri ng
t ermi nat i ons fi rst and i f i t cannot be fi xed, cont act t he
Company.

Testing and Adjusting the Pneumatic Hoist Commissioning


5.6 Testing and Adjusting the Pneumatic Hoist
The purpose of t he hoist is to rai se t he probe from t he
sl urry t o prevent damage t o the det ect or i n t he event of a
wi ndow rupture as well as t o al low mai ntenance on t he
probe such as window cl eani ng and changi ng.

The hoi st pneumat i c syst em layout i s schemat i cal l y shown
in fi gure 5-9.

5.6.1 Testing
The pneumat ic hoi st wi ll have been fact ory t est ed but aft er
instal l ati on i n t he pl ant (and assumi ng the ai r l ine i s
connect ed and provi di ng the correct pressure and t he
el ectronics is powered up) i t s operat ion shoul d be re-
test ed.

The regul ator gauge mounted on t he probe carri age (see
phot o left ) should i ndi cate t here is air pressure avail abl e.
The reserve Air Reservoir has stored suffi ci ent ai r t o raise
the hoi st (i f i t is less t han 450kPa suffi ci ent ai r pressure
has not yet been achieved, so check t he supply l i ne
pressure and t he pressure swi t ch sett i ng (see sect i on
5. 6. 2).

If t he probe has not been mount ed i nt o t he anal yser yet ,
t he wi ndow sel f t est ci rcui t wi l l prevent t he probe from
l oweri ng. To t est t he hoi st operat i on you wi l l need t o
t emporari l y overri de t he sel f t est ci rcui t by fi t t i ng an
AM185 Dummy Di ode Pl ug t o t he LV/ Al arm pl ug on t he
Si gnal Anal yser, or sel ect <ForceRl y> on t he OI, forci ng
rel ay number 204 open. Ensure t he probe i s cent red over a
zone or parked.

Now t he hoi st pl at form can be l owered by sel ect ing at t he
OI panel, the menu opt i on key <MoveProbe> t hen sel ect
<down>. A rushi ng sound wi ll be heard as ai r from t he Ai r
Reservoi r i s rel eased from t he sol enoi d. You may al so hear
a cl unk noi se as t he aut omati c safet y cat ch releases to
al l ow t he hoi st t o l ower. The plat form shoul d lower
smoot hl y ont o an ai r cushi oned rest .

Now rai se t he probe by sel ecti ng at the OI panel, t he menu
opti on <up> key. When t he probe is in the rai sed posit i on
the hoi st wil l si t above the aut omati c safet y l at ch.

Note:
If the movement i s not smoot h or i s too sl ow go t o t he
sect i on Hoi st Adj ust ments, sect ion 5. 6. 2.

Commissioning Testing and Adjusting the Pneumatic Hoist


Fi gur e 5-4 Pi pi ng & Connect i on di agr am f or a t ypi cal 6- st r eam
MSA
Testing and Adjusting the Pneumatic Hoist Commissioning


Take not e that t he reed swi t ch sensors come on at t he t op
(see phot o left ) and t he bot tom of the ai r ram when t he
probe is i n the rai sed or l owered posit i on respect ivel y.

These sensors i ndi cat e t o t he RLC and comput er t hat t he
probe is eit her ful l y rai sed or full y l owered i . e. normal
st at us. If sensor does not l ight, t hen an error message wil l
be displayed (see Chapt er 9, Trouble Shooting). The probe
hoist shoul d now be operat i ng correct l y. If you forced
rel ay 204 or fi t t ed an AM185 Dummy Di ode Pl ug, t hi s
must be removed before cont i nui ng.

5.6.2 Hoist Adjustments

Hoi st Speed Control
The ai r regul at or regul at es air pressure t o t he hoi st ram
and al so cont rol s t he hoi st speed. It i s manual l y
adj ust abl e by pul l i ng t he handl e up on t op of t he regul at or
body besi de t he gauge (see phot o l eft ). The regulat or i s
normall y factory set t o 450kPa. It al so mini mi ses the ai r
consumpt ion.

Pressure Switch
Thi s swi t ch is l ocat ed on t he probe carri age on t op of t he
regulat or (see phot o l eft) and i s fact ory set t o 400kPa so it
does not normal ly requi re adjust ment. The pressure swi t ch
monit ors the i ncomi ng l ine pressure. If adj ust ment is
necessary, in order t o make t he pneumat i c syst em operat e,
the fol l owi ng procedure should be fol l owed.

The pressure swi t ch i s adj ust ed by rot at i on of t he screw
wi th a screwdri ver. The swi t ch i s fact ory set t o operate at
fai l between 350-400kPa fal l ing and recovery at 400-
450kPa ri si ng. To check and/or readj ust t hi s, proceed as
foll ows:
1. Rai se t he probe.
2. Check t hat pl ant ai r pressure i s avai l abl e above
450kPa Maxi mum i s 800kPa.
3. Isol at e ai r i nt o Hoi st Cont rol l er encl osure by t urni ng
off t he bal l val ve before fi l t er (see phot o l eft ).
4. Connect a mul t i met er across t he cont act s i n t he
pressure swi t ch and check for cl osed ci rcui t (pressure
above 450 kPa).
5. Gradual l y decrease t he pressure i n t he syst em by
rel easi ng ai r from t he ai r reservoi r usi ng t he bal l
val ve on t he bot t om. Wat ch t he mul t i met er unt i l t he
cont act s open. Thi s shoul d happen bet ween 400 and
350 kPa.
6. Cl ose t he bal l val ve on t he ai r reservoi r and sl owl y
Commissioning Installing the MEP Detector


i ncrease t he pressure i n t he syst em by openi ng t he
bal l val ve ai r i nl et . Wat ch t he mul t i met er unt i l t he
cont act s cl ose. Thi s shoul d happen bet ween 450 and
450 kPa.
7. Adj ust t he pressure swi t ch by rot at i on of t he screw
unt i l 5 and 6 are achi eved.

Note:
An al ternat ive t o using a mul t i met er i s t o moni t or t he OI
<St at us> t o see Ai rF1 (Ai r Fai l ure) or Ai rOK,
al t hough t hi s requi res a second person.

Note:
Never decrease t he ai r pressure swi t ch cut off bel ow a
pressure t hat wi ll be i nsuffi ci ent t o rai se t he probe.

8. Rest ore t he ai r recei ver and suppl y l i ne connect i ons.

Note:
Overri de but t ons are fi t t ed t o t he sol enoi d val ves (mount ed
near t he t op of t he yel l ow pl at e i n t he phot o l eft ) can be
used t o manual l y move t he probe up or down when t he
el ect roni cs i s off or t he probe i s not i nst al l ed.

Installing the MEP Detector Commissioning


5.7 Installing the MEP Detector
Check fi rst t hat t he probe carri age i s fi rml y mount ed (see
phot o l eft ) and t hat t he mai n umbi l i cal cabl e has been
l ooped ont o t he gui de rai l correct l y.

Warni ng:
If t he cabl e i s not sl ung correct l y t hen excessi ve pressure
may be exert ed on t he cabl e and spl i t or break i t .

Usi ng t he OI, move t he probe carri age t o t he servi ce bay
and check t hat i t l owers. If i t does l ower, refer t o sect i on
5. 6. 1for overri de i nst ruct i ons. Remove t he Upper Dewar
cover, i f i t has been i nst al l ed, as i t i s heavy and easi er t o
remove when t he probe i s down.

Check t hat ai r has been connect ed at t he val ve (as per
sect i on 5. 3) and t urn t he suppl y on. The Ai r Reservoi r
(bl ue t ank i n phot o l eft ) on t he probe carri age wi l l fi l l
wi t h ai r and because t he el ect ronics i s not t urned on at t hi s
st age, t he hoi st wi l l aut omat i cal l y rai se. When ful l y
rai sed, i sol at e the ai r into t he hoi st by t urni ng off t he
isolat i on bal l val ve at t he ai r connect i on poi nt see sect i on
5. 3 and phot o l eft ). Then dump t he ai r from t he Air
Reservoi r by opening the bal l valve on t he bot t om of i t
(see phot o). The hoist wi ll l ower sli ght l y (approxi mat el y
20mm) and si t on t he aut omat ic safet y l at ch. If t he hoi st
cont i nues t o l ower t hen t here i s a f aul t wit h t he saf et y
lat ch, and t hi s wi l l need t o be repai red, cont act t he
Company.

Cauti on:
When ai r i s connect ed and t urned on, t he hoi st probe
carri age wi l l aut omat i cal l y rai se, i f t here i s no probe
i nst al l ed.



Cauti on:
Check t hat t he probe or movi ng part of t he hoi st frame,
when l owered, wi l l not hi t t he si des or bot t om of t he
Anal ysi s Tanks, nor wi l l i t hi t any st i rrers. Doi ng so may
cause damage t o t he probe.

Cauti on:
Check t hat t he MEP cabl e i s fl exi bl e enough t o al l ow t he
probe t o be l owered ot herwi se t he cabl e may st ret ch and
t ear.

Note:
The MEP det ect or wi l l have been shi pped i n a separat e
crat e and shoul d have been unpacked and kept safe i n i t s
met al st and fi l l ed wi t h LN
2
.

Inst al l t he MEP det ect or i nt o t he probe shroud (refer t o
fi gure 5-1) as fol l ows:

1. Wi t h t he probe hoi st up (t he probe carri age can be
down i f i t i s parked i n t he servi ce bay) and t he base-
pl at e and l ower shroud al ready fi t t ed, remove t he
AM232 Wi ndow Assembl y (l eft ) from t he l ower
shroud by wi ndi ng t he t wo square head bol t s
ant i -cl ockwi se wi t h t he spi got t ool provi ded i n t he
t ool box. The wi ndow must be removed even i f t he
l ower shroud has not yet been fi t t ed t o t he base-
pl at e.

2. Check t he condi t i on of t he Myl ar (pl ast i c) wi ndow
and t he O-ri ng on t he AM282 Wi ndow Assembl y and
repl ace as necessary (see Figure 5-9). Check t hat t he
wi ndow i s not t orn, scrat ched, or cri nkl ed. Fol l ow
t he procedure provi ded i n chapt er 8, Mai nt enance.
Check t hat t he O-ri ng i s not spl i t or damaged and
t hat i t i s l ubri cat ed l i ght l y wi t h Vasel i ne (from t he
t ool box).

Warni ng:
Inst al l i ng t he det ect or wi t h t he Wi ndow assembl y fi t t ed
can t ear and damage t he backup wi ndow.



3. If al ready fi t t ed, remove t he Dewar cover (l eft ) by
removi ng t he dome nut s t hat fi x i t t o t he bl ack base
pl at e.

Warni ng:
DO NOT l ower t he probe i f t here i s sl urry fl owi ng t hrough
t he t ank.

WINDOW ASSY
SOLID STATE DETECTOR
LN SENSOR
SOURCE
PREAMPLIFIER
WINDOW RUPTURE
END PLUG
LOCATING BLOCK
LOCATING SPRING
LOWER SHROUD ASSY
SIGNAL BNC
PREAMP POWER
IN-LINE FILTER
RETAINING
BOLT
WINDOW
BIAS
SPIGOT TOOL
LN DEWAR
LN FILLER COLLAR
LN SENSOR
DEWAR PLUG
DEWAR COVER
WINDOW
ALIGNMENT TOOL

Fi gur e 5- 5 MEP and Det ect or Expl oded Vi ew

4. The det ect or/ dewar i s normal l y del i vered wi t h t he
radi oi sot ope source i n pl ace (t hi s i s i ndi cat ed by t he
presence of t he i nsert i on guard shi el d). If t he
radi oi sot ope source has been del i vered separat el y
t hen i nsert t he source hol der wi t h shi el d before
cont i nui ng wi t h i nsert i ng t he det ect or i nt o t he MEP
l ower shroud. Refer t o chapt er 8, Mai nt enance for
det ai l s.


Cauti on:
Fi t t i ng or removi ng t he radi oi sot ope source hol der and
shi el d i s a speci al i sed t ask and shal l be supervi sed by t he
Company engi neer.

Warni ng:
A whi t e pl ast i c cover wi l l be fi xed i n pl ace of t he source
hol der i f t he i sot ope has been del i vered separat el y (see
phot o l eft ). Thi s must be removed fi rst and st ored i n a
safe pl ace for future use. The purpose of t hi s cover i s t o
prot ect t he del i cat e cent ral beryl l i um wi ndow whi ch i f
broken wi l l rel ease t he vacuum and severel y damage t he
det ect or. Beryl l i um i s t oxi c. Avoi d t ouchi ng t he Beryl l i um
wi ndow.

The hoi st usual l y needs t o be l owered t o al l ow cl earance
bet ween t he base pl at e and overhead t rol l ey gant ry t o fi t
t he probe. If t he carri age i s i n t he l ast zone or end park
bay t here may be suffi ci ent cl earance from t he umbi l i cal
di amond rai l . In any case i t i s i mport ant t hat you are abl e
t o i nst al l t he probe wi t hout t i l t i ng t oo much, as Li qui d
Ni t rogen mi ght spi l l . Therefore t he carri age must be
posi t i oned ei t her i n t he park bay or i n an empt y anal ysi s
zone wi t h no sl urry fl owi ng.

Wi t hout a wi ndow assembl y t he i nt erl ocks on t he RLC wi l l
not al l ow t he hoi st t o be l owered, so t o overri de use a
screwdri ver t o press t he overri de but t on on t he sol enoi d as
shown i n t he phot o l eft . (Al t ernat i vel y, use an AM185
Dummy Di ode pl ug on t he Si gnal Anal yser, and press t he
Park Probe but t on).

5. Li ft t he det ect or uni t upri ght ont o t he MEP base-
pl at e (rei nforced bl ack pol yuret hane, see phot o l eft )
i n t he hoi st carri age. DO NOT l ower i t i nt o t he
MEP l ower shroud at t hi s st age, j ust rest i t on t he
base-pl at e and go t o 6. (Al l packi ng i ncl udi ng
pol yt hene bags, t ape and Si l i ca Gel shoul d have
been removed f rom t he det ect or uni t . Al so check t hat
t he vacuum pump-out val ve i s unobst ruct ed - t he
met al pl ug wi t h a cent ral t hreaded hol e shoul d be
vi si bl e, i t must not have a pl ast i c cap or any
adhesi ve t ape over i t . See Figure 5-6. )


6. Get an assi st ant t o connect t he four cabl es
(MHV/ BNC/ D9/ Level Sensor) t o t hei r appropri at e
recept acl es on t he upper face of t he preampl i fi er.
Ensure t hat t he l arger coaxi al connect or t hat carri es
t he bi as vol t age goes t o t he l arger coaxi al
recept acl e, marked MHV Bi as. There i s a short
ext ensi on (400mm) from t he MHV bul khead
connect or. The requi red cabl es are shown i n Figure
5-6. Wi nd t he cabl es around t he neck of t he probe
t hen gent l y l ower t he det ect or i nt o t he shroud. Twi st
i t gent l y t o get i t t o go t o t he square bot t om. Ensure
t he four cabl es are not squashed by t he col l ar and
are fed up t hrough t he gap i n t he col l ar.

4 HOLES M6 x 12 DEEP
EQUISPACED ON 66.7 PCD
LIQUID NITROGEN DEWAR
11.2 LITRE VOLUME
SIGNAL BNC
400mm
PREAMP POWER
400mm (D9)
LN SENSOR
1100mm
IN-LINE FILTER
COLLAR
PUMP VALVE
BIAS MHV BULKHEAD
FEMALE CONNECTOR
SOURCE HOLDER
3 HOLES M3x4

Fi gur e 5- 6 MEP Det ect or Component s and Cabl e Connect i ons

7. Swi ng t he ret ai ni ng arm across t he col l ar and
t i ght en t he nut on t he base pl at e (see phot o l eft ).
Ensure cabl es are not caught and t he dewar cover
neoprene gasket (bl ack) can be posi t i oned properl y
t o form a wat erproof seal .



8. Ensure conform-a-sl eeve i s fi t t ed over t he MHV
and si gnal cabl es (see phot o l eft ) t o i nsul at e t he
connect ors from t he grounded met al pl at e. Do t he
same i n t he grey t ermi nat i on box, i f i t hasnt al ready
been fi t t ed (see phot o l eft ).

9. Once t he det ect or i s posi t i oned, check t he spaci ng
bet ween t he base of t he det ect or and t he whi t e
pl ast i c l ocat i ng bl ock i n t he bot t om of t he l ower
shroud l eg (see and phot o l eft ). It shoul d be about 3
t o 4mm so t hat t he beryl l i um wi ndow of t he det ect or
i s cent red t o t he Myl ar wi ndow of t he Wi ndow
Assembl y when fi t t ed. Not e t hat i t may be easi er t o
do t hi s l at er when t he probe i s rai sed on i t s hoi st .
Loosen t he M4 Al l en Head bol t s i n t he si de of t he
col l ar t o adj ust t he probe hei ght , i f needed.

10. Check t hat t he four vent hol es (smal l pi n hol es)
on t he pol yuret hane LN
2
fi l l er AM249/ 10 (usual l y
col oured red) are not obst ruct ed. These hol es al l ow
t he vent i ng of very dry LN
2
vapour i nt o t he probe
cavi t i es t o keep moi st ure out and prevent
pressuri si ng t he probe dewar when t he LN
2
fi l l i ng
fl i p-t op l i d i s cl osed.

11. Re-fi t t he MEP upper (st ai nl ess st eel dewar
cover) shroud. Thi s bol t s ont o t he t op of t he bl ack
base-pl at e usi ng t he st ai nl ess dome head nut s and
washers provi ded by t he Company. Open t he fl i p-t op
l i d and check t he LN
2
fi l l er (red) i s not deformed.

12. Top up t he probe wi t h LN
2
, i f i t i s not ful l .



13. Cl amp shut t he LN2 fi l li ng cap (l eft ) on t he
dewar cover usi ng t he t ri angl e cl amp provi ded. Thi s
cap prevent s excessi ve LN2 boi l -off and keeps t he
det ect or i nsi de dry as i n poi nt 10. Do not adj ust t he
cl amp t o be excessi vel y t i ght as t he neoprene gasket
can be deformed beyond i t s el ast i c recovery l i mi t ,
whi ch can cause a l eak.

14. Turn on t he ai r suppl y (open t he bal l val ve) and
wai t for t he hoi st t o rai se t he probe. Al t ernat i vel y,
press t he Rai se Hoi st but t on. The whol e assembl y
shoul d now l ook l i ke t hat i n Figure 5-7, except t he
wi ndow assembl y st i l l needs t o be i nst al l ed.

Cauti on:
If t here i s sl urry fl owi ng i n t he anal ysi s t ank when
carryi ng out t hi s procedure t hen t he ai r must be connect ed
fi rst and t he hoi st rai sed so t hat sl urry doesnt ent er t he
probe.

IN-LINE FILTER
BERYLLIUM WINDOW
SOURCE HOLDER
WINDOW ASSEMBLY
CABLE ASSEMBLY
LN2 DEWAR
X-RAY DETECTOR
LN2 SENSOR CABLE
MEP UPPER SHROUD
ASEMBLY
(DEWAR COVER)
LN SENSOR
LN FILTER CAP

Fi gur e 5- 7 Compl et ed MEP/ Det ect or Assembl y


15. Once rai sed, gent l y push t he det ect or (push on t he
source hol der shi el d or pul l on t he t op of t he probe)
backwards and rel ease t o check t hat i t ret urns t o i t s
ori gi nal posi t i on. There i s a l eaf spri ng at t ached t o
t he i nsi de of t he l ower l eg for t hi s purpose. If t he
det ect or does not spri ng back, remove t he det ect or
and check for t he l ocat i ng spri ng (see Figure 5-5
and phot o l eft ).

16. Check t hat t he t hree M3 screws hol di ng t he
source hol der i n pl ace i n t he det ect or are t i ght t hen
remove t he source shi el d by unscrewi ng t he t wo M3
screws. Figure 5-8 shows how t he source hol der and
shi el d are fi t t ed. The phot o l eft shows t he un-
shi el ded source hol der mount ed i n t he det ect or.

Cauti on:
Fi t t i ng or removi ng t he radi oi sot ope source hol der and
shi el d i s a speci al i sed t ask and shal l be supervi sed by t he
Company engi neer i n t he fi rst i nst ance. Thereaft er onl y
t he t rai ned and l i censed pl ant personnel shal l carry out t he
procedure.

Multi-Element Probe
Beryllium
Window
Source Holder
634048
Shield
43403
M3x12
Csk Screw
57565 (2)
Source
(3 possible positions)
M3x10
Csk Screw
57564 (3)
Window Contact
Fingers

Fi gur e 5- 8 Fi t t i ng t he MEP Sour ce Hol der and Shi el d


17. Smear a very smal l amount of pet rol eum j el l y
around t he O-ri ng on t he AM282 Wi ndow Assembl y
and refi t . Figure 5-9 shows an expl oded vi ew of t he
wi ndow assembl y. Cl i p t he St andard Bi scui t t o t he
probe head (shown l eft ). If necessary, fi t a cabl e t i e
around t he st andard cl i p so i t cant fal l off if
knocked.

Note:
If t here i s more t han one probe i n t he pl ant , ensure you are
usi ng t he correct st andard bi scui t . If t here i s a chance of
sl urry spl ashi ng, i t i s suggest ed t hat a pl ast i c bag be fi t t ed
over t he l ower probe t o prevent cont ami nat i on of t he
measurement s.

Cauti on:
Handl e t he wi ndow from underneat h and work from t he
back of t he probe t o prevent unnecessary l ow-l evel
radi at i on exposure.

The whol e probe assembl y on i t s hoi st wi l l now l ook l i ke
t hat i n t he phot o l eft . Not e t hat t he hoi st wi l l be rai sed i f
ai r i s t urned on.

18. Remove t he Wi ndow Rupt ure ci rcui t bypass, i f
done at St ep 4, by ei t her removi ng t he AM184
Dummy Di ode pl ug and repl aci ng t he D9 cabl e or by
sel ect i ng <FreeRel ay> on t he Operat or Int erface and
freei ng Rel ay 204.


Fi gure 5-9 Expl oded Vi ew of t he MEP Wi ndow Assembl y

Calibrating the LN
2
Sensor Commissioning


5.8 Calibrating the LN
2
Sensor
If t he LN TEST but t on has ext i ngui shed t hen t he LN
2

Sensor i s al ready cal i brat ed t o t he el ect roni cs and t here i s
no need t o fol l ow t hi s procedure.

If t he LN TEST but t on has not ext i ngui shed t hen t he
probe safet y (Low Li qui d Ni t rogen Warni ng) ci rcui t wi l l
not work i f t he sensor has not been cal i brat ed. In some
ol der anal ysers bi as cannot be appl i ed t o t he probe i n t hi s
case. Refer t o Fi gure 5-2 t o l ocat e t he but t ons and cards.

5.8.1 Functional Description of the LN
2
Sensor Circuit
The Li qui d Ni t rogen Level Sensor gi ves a hi gh or l ow
i ndi cat i on of t he l evel of Li qui d Ni t rogen i n t he probe
dewar. If t he l evel i s l ow, t he Si gnal Anal yser gi ves a
Li qui d Ni t rogen Low WARNING, whi ch usual l y means
t here i s 1 l i t re or l ess Li qui d Ni t rogen i n t he dewar (i . e.
l ess t han about 10%).

Two red LEDs are l ocat ed on t he AM092/ 10 card i n t he
Si gnal Anal yser, one above t he ri bbon cabl e and one
bel ow. They are named SNSSC (above) and SNSOC
(bel ow), whi ch are acronyms for Sensor Short Ci rcui t and
Sensor Open Ci rcui t , al t hough t he LEDs can have di fferent
meani ngs under ot her ci rcumst ances.

For i nst ance, when t hey di spl ay t he LN
2
Level Sensor
readi ng t he SNSSC LED i ndi cat es vol t s measured on t he
Level Sensor mul t i pl i ed by 1 and t he SNSOC LED
i ndi cat es vol t s mul t i pl i ed by 0. 1, vi z. i f t he SNSSC LED
fl ashes 7 t i mes and t he SNSOC LED fl ashes 5 t i mes t hi s
i ndi cat es 7. 5 vol t s on t he Level Sensor. Nomi nal readi ngs
are 7. 5 vol t s i n LN
2
or 8. 2 vol t s i n ai r (i . e. when LN
2
l evel
i s l ow), but t he AM092/ 10 card can read anywhere from 0
t o 12 vol t s, where 0 (or cl ose t o 0) i ndi cat es a short ci rcui t
and 12 (or cl ose t o 12) i ndi cat es open ci rcui t .

Under normal operat i ng condi t i ons, t he SNSOC LED on
t he AM092/ 10 card l i ght s i f t he readi ng i s more t han 1 vol t
above t he st ored val ue, and t he SNSSC LED l i ght s i f t he
readi ng i s more t han 1 vol t bel ow t he st ored val ue.

It i s possi bl e t o st ore al most any val ue i n t he AM092/ 10
cards memory, even a val ue measured wi t h a faul t y LN
2

Level Sensor, such as open ci rcui t , short ci rcui t or empt y
of Li qui d Ni t rogen. For t hi s reason i t i s i mport ant t o
check t he readi ng before st ori ng i t .

Commissioning Calibrating the LN
2
Sensor


5.8.2 Procedure for Calibrating the LN
2
Sensor
Fami l i ari se yoursel f wi t h t hi s procedure before st art i ng.
1. Ensure t he probe dewar i s ful l of Li qui d
Ni t rogen.
2. Press and hol d t he LN Test but t on. Do not
rel ease t he but t on unt i l st ep 6. It i s t he l eft red
push-but t on l ocat ed on t he panel above t he t op
row of cards i n t he Si gnal Anal yser (see phot o
l eft square orange but t on i s t he power).
3. The LN Test but t on wi l l l i ght wi t hi n a few
seconds. The Si gnal Anal yser t hen proceeds t o
measure t he LN Sensor val ue, whi ch t akes a few
seconds.
4. Now observe t he number of fl ashes of t he t wo red
LEDs t hat are l ocat ed on t he AM092/ 10 card, one
above t he ri bbon cabl e (SNSSC = vol t s x1) and
one bel ow (SNSOC = vol t s x0. 1). Di agnosi s i s:

VOLTS INTERPRETATION
7. 0 or l ess Shor t ci r cui t , need t o r epai r LN Sensor
7. 1 t o 7. 9 Nor mal , OK t o St or e - go t o St ep 5
8. 0 t o 8. 5 Go t o Pr ocedur e St ep 1
8. 6 or more Open ci r cui t , need t o r epai r LN Sensor
or cabl e

5. When t he SNSSC and SNSOC LEDs have ceased
fl ashi ng, t he t op LED on t he AM092/ 10 card
(STF1) wi l l l i ght . If t he readi ng i ndi cat ed by
Procedure st ep 4 was not OK, rel ease t he LN
Test but t on and resol ve t he probl em.
6. Provi ded t he readi ng i ndi cat ed from st ep 4 was
OK you now have t he opport uni t y t o st ore t he
val ue i nt o AM092/ 10 memory. Do t hi s by
pressi ng t he WR Test red push-but t on (t he
mi ddl e one) t wi ce qui ckl y whi l e t he STF1 LED i s
l i t . If you are t oo sl ow, go back t o st ep 1.
7. Rel ease t he LN Test push-but t on. The Si gnal
Anal yser wi l l t ake a few seconds t o measure t he
LN Level Sensor and compare t he readi ng t o t he
val ue you j ust st ored. If i t i s Normal t he LN
Test l amp wi l l go off.

Warni ng:
If t he probe compl et el y dri es out of LN
2,
a separat e
t emperat ure sensi ng safet y devi ce (RTD) i nsi de t he
det ect or wi l l cause t he Bi as t o shut down aut omat i cal l y and
on-l i ne assay dat a wi l l cease.

Checking and Testing the MEP Electronics Set Up Commissioning


5.9 Checking and Testing the MEP Electronics Set Up
Once t he equi pment i s powered up and operat i onal , t he
fact ory set t i ngs are t o be checked usi ng t he St andard
Bi scui t suppl i ed wi t h t he equi pment . Fact ory set t i ngs are
suppl i ed i n At t achment 2. Performi ng t hese checks wi l l
confi rm i f t he probe and el ect roni cs are operat i ng
normal l y.

Warni ng:
Aft er swi t chi ng on t he probe for t he fi rst t i me or aft er an
ext ended peri od i t can t ake about an hour for t he det ect or
t o set t l e down and operat e i n a st abl e manner, t hus
affect i ng t he resol ut i on. Therefore i t i s best t o wai t for 1
t o 2 hours before performi ng t hese t est s.

A Mul t i -Channel Anal yser (MCA) i s used t o check t he X-
ray spect rum from t he anal yser, measure t he probe
resol ut i on and t o make adj ust ment s t o t he Si ngl e Channel
Anal ysers (SCAs) whi ch defi ne t he regi on of i nt erest
around t he energy spect rum peaks for measurement on-
l i ne.

An MCA i s a compl ex, expensi ve and del i cat e i nst rument
and coul d not be expect ed t o operat e rel i abl y i n t he pl ant
envi ronment for very l ong. For t hi s reason, an MCA i s not
bui l t i nt o t he Si gnal Anal yser, but a commerci al MCA may
be connect ed t emporari l y i n order t o vi ew t he X-ray
spect rum and t o check SCA set t i ngs rel at i ve t o t hat
spect rum.

Di fferent makes of MCA may be used and so i t i s
necessary t o cal i brat e t he MCA t o t he Si gnal Anal yser
el ect roni cs. Thi s procedure i s done i n t he fact ory, but i t
shoul d be rechecked i f a di fferent MCA i s used on-si t e and
t he reference set t i ngs updat ed (refer At t achment 2).

5.9.1 Connecting & Calibrating the MCA

Overvi ew and Connecti ng the MCA
In a mul t i pl e SCA syst em such as the Si gnal Anal yser i t i s
most i mport ant t o provi de for t he set t i ng of t he SCA l i mi t s
LL and UL rel at i ve t o t he appropri at e spect ral feat ures.
Furt hermore, i t i s advant ageous t o be abl e t o observe t he
X-ray energy spect rum i n a convent i onal graphi cal form (a
t ypi cal X-ray energy spect rum for a MEP i s shown i n
Fi gure 5-10).
NORLAND 5500 MCA
O FF O N
VIKING INSTRUMENTS
VERTI CAL SCALE
HORIZONTAL SCALE
CURSOR
ZERO ULD
LLD
AMP GAIN
INPUT
SET
UP COMPUTE PROG
+ 7 8 9
OPTIONS DISPLAY
GOES
INTO
==> - 4 5 6
CONT CANCEL CLEAR
NUM X 1 2 3
RUN TERM EXP 0 .
CONV
GAIN
OFFSET
AMP
DIRECT
Commissioning Checking and Testing the MEP Electronics Set Up


MEP ENERGY X-RAY SPECTRUM
0
250
500
750
1000
1250
1500
1750
2000
2250
2500
1
.
0
0
0
3
.
0
0
0
5
.
0
0
0
7
.
0
0
0
9
.
0
0
0
1
1
.
0
0
0
1
3
.
0
0
0
1
5
.
0
0
0
1
7
.
0
0
0
1
9
.
0
0
0
2
1
.
0
0
0
Energy (KeV)
C
o
u
n
t
s
PuL Coh
PuL Coh
PuL Coh
BrK
AsK
CuK
CuK
FeK
FeK

Fi gur e 5- 10 Typi cal Ener gy X- Ray Spect r um f r om a MEP
The mai n purpose of t he AM994 MCA Access Modul e i n
t he Si gnal Anal yser i s t o convert t he probe si gnal i nt o a
form t hat shoul d sui t most MCAs (MCAs of di fferent
manufact ure vary consi derabl y i n t hei r i nput ci rcui t
charact eri st i cs).

The AM994 MCA Access Modul e has a RUN/ TEST
swi t ch t o enabl e user access t o t he t est mode funct i ons
descri bed here. It must be kept i n t he posi t i on RUN
except when t he syst em i s under t est . Thi s prevent s
erroneous dat a bei ng sent t o t he comput er because i t
over-ri des al l t he moni t or funct i ons. Duri ng al l set t i ng-up
operat i ons t hi s swi t ch i s set t o TEST.
The si gnal must go di rect l y t o t he MCAs Anal og-t o-Di gi t al
Convert er (ADC) ci rcui t . Many commerci al MCAs are
provi ded wi t h pul se-shapi ng ampl i fi ers ahead of t he ADC.
The pul se out put of t he Si gnal Anal yser i s al ready
opt i mi sed for an ADC and any furt her shapi ng or
ampl i fi cat i on wi l l onl y produce errors. Every MCA i s
di fferent , of course, but one shoul d fi nd a menu sel ect i on,
swi t ch, PCB j umper l i nk or l i nks or a separat e i nput on t he
i nst rument whi ch wi l l enabl e DIRECT or HIGH LEVEL
i nput si gnal s t o bypass t he i n-bui l t ampl i fi er. The correct
connect or may be l abel l ed ADC IN or si mi l ar. Consul t t he
MCA manufact urer' s handbook for det ai l s.

At t achment 3 provi des addi t i onal det ai l s on usi ng t he
MCA i f one was purchased wi t h your syst em.


The MCA i s connect ed t o t he BNC socket , marked MCA
on t he AM994 MCA Access Modul e (shown l eft ), usi ng a
coaxi al cabl e of up t o 5 m i n l engt h and 50 ohms or great er
i mpedance.

Cal i brati ng the MCA
Int ernal l y, t he range of pul se hei ght s present ed t o t he
SCAs i s 0-10 vol t s posi t i ve. The LL and UL
pot ent i omet ers (shown l eft ) may be set t o any poi nt i n t hi s
range. An i nt ernal t est si gnal i s generat ed and t hi s can be
i nj ect ed i nt o t he SCAs i n l i eu of t he probe si gnal . The
ampl i t ude of t hi s si gnal i s al so vari abl e from 0 t o 10 vol t s
usi ng t he cal i brat ed 10-t urn REF VOLTS di al . Most
MCAs are desi gned t o accept an i nput vol t age l ess t han
10 vol t s (e. g. 0-8 V, 0-8. 192 V, 0-4 V et c. ) at t he ADC. In
order t o accommodat e t hese possi bi l i t i es, a screwdri ver
adj ust ed pot ent i omet er (MCA CAL) i s provi ded. Usi ng
t he i nt ernal reference si gnal , whi ch al so appears on t he
MCA, t he user may easi l y set t he i nt ernal max vol t age
(10 V) t o any sui t abl e channel on t he MCA (say
channel 2000).

Thi s wi l l not upset any of t he ot her set t i ngs i n t he Si gnal
Anal yser box. Once t he pot ent i omet er i s set i t wi l l not
need adj ust i ng unl ess a di fferent MCA i s used or t he
AM994 MCA Access modul e i s repl aced.

To cal i brat e t he MCA fol l ow t hese st eps:

1. Connect a Mul t i -channel Anal yser (MCA) t o t he
AM994/ . . MCA Access modul e i n t he Si gnal Anal yser
vi a a coaxi al cabl e of up t o 5m i n l engt h (connect i on of
t he MCA i s di scussed above). The si ngl e-phase power
out l et provi ded wi t h t he MSA encl osure i s t o provi de
power for t he MCA.

Note:
Ground l oop current s may be caused t hough t he mai ns
power i f t he MCA i s on a different circui t t o the Signal
Anal yser, so use of the suppl ied power out let i s
recommended.

Cauti on:
Check t he mai ns power suppl y of your MCA i s set t he
same as t he Si gnal Anal yser. In an MSA, t hi s i s usual l y
240VAC or 110 VAC.



2. Set t he fol l owi ng swi t ches:
RUN/ TEST t o TEST
PROBE/ INJECT t o INJECT
BIAS VOLTAGE t o ON
BIAS VOLTAGE pot ent i omet er t o probe' s rat ed
vol t age.
press but t on SPECTRUM
press but t on ACQUIRE t o i l l umi nat e i t s red LED

3. Swi t ch on t he MCA and prepare i t t o operat e i n Pul se
Hei ght Anal ysi s (PHA) mode (refer t o t he i nst ruct i on
manual for t he MCA or At t achment 3).

4. Set t he REFERENCE VOLTS di al t o about 500 di vi si ons
(5 vol t s) and col l ect a spect rum on t he MCA. Inj ect ed
reference pul ses shoul d appear on t he MCA screen as a
needl e-l i ke peak.

5. Increase t he REFERENCE VOLTS di al t o 1000 di vi si ons
(10 vol t s). Thi s l evel on t he MCA corresponds t o t he
upper l i mi t of X-ray energi es t hat t he Si gnal Anal yser wi l l
be abl e t o process. The out put of t he Si gnal Anal yser t o
t he MCA can be al t ered so t hat t hi s l evel corresponds t o
t he t op end of t he MCA scal e by adj ust i ng t he
MCA CALIBRATE pot ent i omet er on t he MCA Access
modul e. For exampl e i f one has a 2048 channel MCA i t
shoul d be set t o around channel 2045. Thi s gi ves a 1: 1
correspondence bet ween di fferent MCAs. Such adj ust ment
i s opt i onal of course and does not affect t he accuracy
ul t i mat el y achi eved. Never t he l ess t here i s meri t i n usi ng
most of t he avai l abl e channel s over whi ch t o spread t he
spect rum.

Note:
In a pl ant where several probes are i nst al l ed i t i s useful t o
cal i brat e al l of t hem preci sel y t he same, so t hat t he
vari ous peaks appear at t he same MCA channel for each
probe.

6. On compl et i on t he TEST/ RUN swi t ch must be ret urned t o
t he RUN posi t i on and t he PROBE/ INJECT swi t ch
ret urned t o PROBE put t he syst em back on-l i ne i f no
furt her adj ust ment s are t o be made.



5.9.2 Checking the Probe X-Ray Spectrum
The spect rum of t he probe must be measured wi t h t he
st andard bi scui t i n pl ace so as t o check, and adj ust i f
necessary, t he Gai n of t he AM001 Li near Ampl i fi er, and
t he LL and UL SCA di scri mi nat or set t i ngs. These are
fact ory set but t hey may have al t ered duri ng shi pment , so
you wi l l now check t he spect rum and SCA set t i ngs agai nst
t hose fact ory set t i ngs.

The spect rum of a probe shows t he di st ri but i on of energy
of t he X-rays i n t he det ect or. The spect rum i s a pl ot of
i nt ensi t y of t he X-rays on t he ' y' axi s versus t hei r energy
on ' x' axi s (refer t o Fi gure 5-10). At t achment 2 cont ai ns a
copy of your probe(s) spect rum. The spect ral peaks
coi nci de wi t h t he X-ray energi es of t he el ement s i n t he
st andard (or sl urry) sampl e. Common el ement al X-ray
energi es are gi ven i n Table 5-1 Common Elemental Fluorescent
X-Ray Energies. A ful l l i st of energi es i s provi ded i n
At t achment 3.


Element in
Sample
X-Ray Emission Energy (keV)
K
K

L

L

Calcium 3.691 4.012
Titanium 4.507 4.931
Vanadium 4.952 5.427
Chromium 5.414 5.946
Manganese 5.898 6.490
Iron 6.403 7.057
Cobalt 6.930 7.649
Nickel 7.477 8.264
Copper 8.047 8.904
Zinc 8.638 9.571
Arsenic 10.543 11.725
Yttrium 14.957 16.736
Zirconium 15.774 17.666
Niobium 16.614 18.621
Molybdenum 17.478 19.607
Palladium 21.175 23.816
Silver 22.162 24.942
Tin 25.270 28.483
Caesium 30.970 34.984
Barium 32.191 36.376
Lanthanum 33.440 37.799
Cerium 34.717 39.255
Praseodymium 36.023 40.746
Neodymium 37.359 42.269
Samarium 40.124 45.400
Hafnium 7.898 9.021 10.514
Tungsten 8.396 9.670 11.283
Indium 9.173 10.706 12.509
Platinum 9.441 11.069 12.939
Lead 10.549 12.611 14.762
Bismuth 10.836 13.021 15.244
Thorium 12.966 16.200 18.977
Pu-238
(UL Scatter)
13.613 17.218 20.163
Cm-244
(PuL Scatter)
14.279 18.278 21.401
For lower X-ray energies Plutonium-238 or Curium-244 sources
are usually used for excitation.

At higher energies (> about 13 keV) Americium-241 sources are
used.

Tabl e 5- 1 Common El ement al Fl uor escent X- Ray Ener gi es



The procedure for pl otti ng the spectrum i s as fol l ows:

1. Open t he Si gnal Anal yser uni t . It i s assumed t hat t he
bi as vol t age i s on (Bi as LED wi l l be l i t yel l ow/ green,
see poweri ng up t he equi pment sect i on 5. 5. 1).

2. Connect a Mul t i -channel Anal yser (MCA) t o t he
AM994/ . . MCA Access modul e i n t he Si gnal Anal yser
vi a a coaxi al cabl e of up t o 5m i n l engt h.

3. Swi t ch on t he MCA and prepare i t t o operat e i n Pul se
Hei ght Anal yser (PHA) mode (refer t o i nst ruct i on
manual for your MCA or At t achment 3).

4. Set t he fol l owi ng swi t ches:

RUN/ TEST t o TEST
press but t on ACQUIRE t o i l l umi nat e i t s red LED.

5. Swi t ch t he MCA t o COLLECT mode. An X-ray
spect rum shoul d now appear on t he MCA screen. A
t ypi cal spect rum was shown i n Fi gure 5-10 and your
probe' s spect rum i s gi ven i n At t achment 2. That
spect rum i s what you shoul d now see on t he MCA
screen. If t he spect rum i s di fferent t hen proceed t o st ep
6, ot herwi se proceed t o t he sect i on on adj ust i ng t he
SCAs.

6. If t he X-ray spect rum doesn' t span t he 10 vol t range
(MCA screen wi dt h) set duri ng MCA cal i brat i on, t hen
t he Gai n of t he AM001 Li near Ampl i fi er (shown l eft )
may need adj ust i ng, but before doi ng so proceed t o t he
sect i on Adj ust i ng t he SCA LL and UL Di scri mi nat ors
t o see i f t hese are set okay, i n whi ch case you wont
need t o adj ust t he Gai n; ot herwi se adj ust t he Gai n and
t hen proceed t o t he sect i on on adj ust i ng t he SCAs.
Aft er adj ust i ng t he Gai n, cl ear t he spect rum from t he
MCA screen and begi n col l ect i ng agai n.

Note:
Once set , t he Gai n of t he Li near Ampl i fi er, AM001 card,
shoul d not need any furt her adj ust ment unl ess t he det ect or
or AM001 card i s repl aced.



5.9.3 Checking and Adjusting the SCAs
Duri ng fact ory t est i ng t he SCA UL and LL di scri mi nat ors
are set wi t h t he st andard bi scui t i n pl ace. These l evel s
shoul d be checked on-si t e i ni t i al l y wi t h t he st andard and
adj ust ed i f necessary and t hen re-checked i n t he sl urry
before performi ng a st abi l i t y t est . The fol l owi ng procedure
provi des for checki ng and mi nor adj ust ment s onl y. For
new SCAs set t i ngs anot her procedure fol l ows t hi s one.

Col l ect a spect rum on your MCA by set t i ng t he fol l owi ng
swi t ches:

RUN/ TEST t o TEST
t hen put t he MCA i n COLLECT mode.

Col l ect a spect rum for about 60 seconds so t hat al l t he
peaks are easi l y vi si bl e. Then i n t urn press t he press
MARK but t on on each SCA t wi ce. The fi rst t i me you
press t hi s but t on t he LL di scri mi nat or wi l l be di spl ayed
and t hen on t he second press t he UL wi l l be di spl ayed.
These set t i ngs are di spl ayed as an i nj ect ed spi ke at t he
marker vol t age set t i ngs on each SCA (reference vol t s).

The di scri mi nat ors shoul d si t i n t he val l ey ei t her si de of a
want ed spect ral peak or Regi on of Int erest (ROI). They
shoul d normal l y not si t part i al l y up t he peak and t hey
shoul d not overl ap wi t h nei ghbouri ng SCA LL or UL
di scri mi nat ors (i . e. , neat l y i n t he ski rt s of t he peaks
wi t hout overl appi ng).

If t he di scri mi nat ors are si t t i ng sat i sfact ori l y around t he
requi red peaks t hen t here i s no need t o do any furt her
adj ust ment and you can proceed t o Measuri ng t he Probe
Resol ut i on.

Ot herwi se, i f a di scri mi nat or needs some adj ust ment t o
al i gn i t properl y around t he peak t hen hol d depressed t he
MARK but t on for LL or UL, whi ch ever i s requi red and
whi l st hol di ng t hi s but t on i nsert t he smal l screw dri ver
i nt o t he LL or UL t ri m pot (agai n whi ch ever i s bei ng
adj ust ed) and t urn t he t ri m pot screw very sl i ght l y ei t her
cl ockwi se for ri ght movement or ant i -cl ockwi se for l eft
movement on t he spect rum di spl ayed on your MCA (make
sure t he MCA i s st i l l i n COLLECT mode) unt i l t he
i nj ect ed di scri mi nat or marker spi ke si t s where you want i t
t o be.


Repeat t hi s for al l di scri mi nat ors t hat requi re a smal l
amount of adj ust ment . When compl et e, col l ect a fresh
spect rum and re-check t he SCA di scri mi nat ors before
proceedi ng t o Measuri ng t he MEP Resol ut i on.

Note:
Adj ust ment t o SCAs or Gai n wi l l di rect l y affect t he sl urry
cal i brat i on i f al ready commenced.

Recordi ng Reference Vol t Setti ngs
Once t he SCAs have been checked or re-set i t i s advi sabl e
t o make a record of t he l i mi t s of each channel rel at i ve t o
t he i nt ernal REFERENCE pot ent i omet er on t he MCA
Access modul e. Thi s i s done by set t i ng t he swi t ch
PROBE/ INJECT t o INJECT and t hen scanni ng t hi s
pot ent i omet er from 0 t o ful l scal e and not i ng t he posi t i ons
at which LL<<UL LEDs l i ght on each SCA (when t he LED
i s on i t i ndi cat es t hat pul ses are bei ng accept ed by t hat
SCA). The l i mi t s are found from t he pot ent i omet er
posi t i ons at whi ch t he LED j ust comes on and j ust goes
out .

Note:
Record t he new reference vol t set t i ngs and al l ot her
set t i ngs i n t he dat a sheet s provi ded i n At t achment 2.

The procedure to set up new SCAs i s as fol l ows:

1. Wi t h t he st andard bi scui t at t ached col l ect a fresh
spect rum on t he MCA over a peri od about 200 seconds)
t o get a good out l i ne of t he spect ral feat ures. Fol l ow
t he procedure gi ven above for col l ect i ng a spect rum on
the MCA.

2. Move t he MCA' s cursor across t he screen and not e
down t he l ower and upper l i mi t s of each peak whi ch i s
requi red. As an exampl e, for a t ypi cal copper-l ead-zi nc
ore, t hese SCA channel s woul d normal l y be used:
SCA1. i ron (FeK)
SCA2. i ron (FeK)
SCA3. copper (CuK)
SCA4. zi nc (ZnK)
SCA5. zi nc (ZnK)
SCA6. l ead (PbL)
SCA7. background
SCA8. L scat t er (compt on+coherent )
SCA9. L scat t er (compt on+coherent )


The l i mi t s shoul d be set wel l down on t he ski rt s of each
peak but t hey shoul d not overl ap i nt o anot her peak or
ext end over t he background. Symmet ry i s usual l y
desi rabl e t oo.

3. The channel s (SCAs) are now set up i n t he fol l owi ng
manner.

Press and hol d t he MARK but t on on fi rst SCA

The l ower l i mi t marker of channel number 1 wi l l appear on
t he MCA screen. Markers appear as a narrow peak 1 t o 3
channel s wi de, si mi l ar t o t he INJECT si gnal used earl i er.
Thi s marker can be adj ust ed so t hat i t corresponds t o t he
l evel chosen i n 2 above, by adj ust i ng t he LL pot ent i omet er
on t he front of t hi s SCA modul e.

Not e t hat i f t he but t on i s rel eased and re-pressed, t he
upper l evel marker wi l l appear on t he screen. The upper
and l ower l evel markers al t ernat e wi t h subsequent
re-pressi ng of t he but t on.

The upper l evel di scri mi nat or i s set by t he above
procedure except t hat t he UL pot ent i omet er on t he SCA i s
adj ust ed. The ot her SCAs can t hen be set up i n a si mi l ar
manner. As t he markers are moved around t hey wi l l
obl i t erat e any part or t he spect rum over whi ch t hey pass.
Thi s may necessi t at e t hat t he spect rum i s erased and
col l ect ed afresh. Wi t h pract i ce and vert i cal ful l scal e of
16K or 32K one can mi ni mi se t hi s effect and hence t he
need t o refresh t he spect rum.

Once t he SCAs have been checked or re-set i t i s advi sabl e
t o make a record of t he l i mi t s of each channel rel at i ve t o
t he i nt ernal REFERENCE pot ent i omet er on t he MCA
Access modul e. Thi s i s done by set t i ng t he swi t ch
PROBE/INJECT t o INJECT and t hen scanni ng t hi s
pot ent i omet er from 0 t o ful l scal e and not i ng t he posi t i ons
at whi ch LL<<UL LEDs l i ght on each SCA (when t he LED
LED i s on i t i ndi cat es t hat pul ses are bei ng accept ed by
t hat SCA). The l i mi t s are found from t he pot ent i omet er
posi t i ons at whi ch t he l i ght j ust comes on and j ust goes
out .

Note:
Record t he new reference vol t set t i ngs and al l ot her
set t i ngs i n t he dat a sheet s provi ded i n At t achment 2.



5.9.4 Measuring the Probe Resolution
The X-ray spect ral resol ut i on of t he probe shoul d remai n
rel at i vel y const ant for a gi ven probe. A si gni fi cant change
i n t he resol ut i on of t he probe i ndi cat es a defi ni t e probl em
wi t h t he probe or Si gnal Anal yser and so i t i s very
i mport ant t hat t he probes resol ut i on be measured duri ng
commi ssi oni ng. Al so i t wi l l i ndi cat e i f any damage has
occurred t o t he probe det ect or duri ng shi pment .

The resol uti on of the probe i s measured as fol l ows:

1. Connect t he MCA t o t he MCA Access modul e of t he
Si gnal Anal yser and set t he swi t ches:

TEST/ RUN t o TEST
press ACQUIRE but t on
press SPECTRUM but t on
and col l ect a spect rum on t he MCA over a peri od
of about 300s.

2. Move t he MCA cursor t o one of t he hi gh spect ral peaks
(normal l y FeK) and not e i t s peak posi t i on (C
0
) on t he
MCA scal e and t he number of count s i n t hi s channel .

3. Di vi de t he count s at channel C
0
by 2 t o get t he hal f
peak hei ght and fi nd t he MCA channel s (C
1
and C
2
) on
ei t her si de of t he peak for whi ch t hi s number
corresponds. The act ual hal f peak val ue may be i n
bet ween t wo channel s so est i mat i ng t he part i al channel
posi t i on (i nt erpol at i on) of t hese poi nt s wi l l gi ve great er
accuracy.

4. The resol ut i on i s expressed i n t erms of t he Ful l Wi dt h
Hal f Maxi mum (FWHM) of t he peak and i s gi ven by t he
fol l owi ng equat i on:
C
2
- C
1

FWHM resol ut i on = E
p
x
C
0

Where E
p
i s t he act ual energy of t he X-rays.

Some common X-ray energi es are:
FeK = 6403 eV ZnK = 8638 eV
CuK = 8047 eV PbL = 10549 eV

The resol ut i on wi l l normal l y be measured on t he FeK
peak. The FWHM resol ut i on of t hi s peak shoul d be
bet ween 160 and 220 eV. A probl em i s i ndi cat ed i f t he
resol ut i on i ncreases t o great er t han 270 eV. Record t he
val ue, t he dat e and t he peak on whi ch i t was measured.

FW HM
C1 C0 C2
Half Peak
Height
Peak
Height


Note:
Use a cl ean peak where possi bl e t o avoi d erroneous
resol ut i on compari sons eg. MnK can overl ap FeK.

However, C2 and C1 are not as easi l y found. The poi nt at
whi ch we requi re i s somewhere bet ween t wo channel s i . e. ,
consi der t he fol l owi ng exampl e:

Peak (C0) i s at channel 555, count s 5000
Therefore, hal f C0 count s i s 2500

However, cl osest we can get t o C1 i s 2360 count s at
channel 546 and 2580 at channel 547. Si mi l arl y C2 i s
2620 count s at channel 562 and 2400 count s at channel
563.

We need t o est i mat e t he exact channel for bot h C1 and C2
where hal f t he peak count s are 2500.

Cal cul at i ng C1:

Low Channel : Channel 546, 2360 count s
Hi gh Channel : Channel 547, 2580 count s
C1=546+((2500-2360) / (2580-2360))=546. 636

Cal cul at i ng C2:

Low Channel : Channel 562, 2620 count s
Hi gh Channel : Channel 563, 2400 count s
C2=562+((2500-2620) / (2400-2620))=562. 545

General l y for C1 & C2,

=Low Channel +((1/ 2 peak count s Low Channel count s) /
(Hi gh Channel count s Low Channel count s))

Therefore, t he probe resol ut i on i s:
6403*(562. 545-546. 636)/ 555=183. 5eV

5.9.5 Checking the Standard Count-Rates at the Computer
When al l t est work i s compl et ed al ways rest ore t he
RUN/ TEST swi t ch t o RUN. Thi s posi t i on overri des most
of t he cont rol s on t he front panel of t he Si gnal Anal yser
and mi ni mi ses erroneous resul t s due t o i ndi scri mi nat e
t amperi ng or wrongl y set cont rol s. As l ong as t hi s swi t ch
i s on TEST, a warni ng message wi l l be di spl ayed at t he
comput er.


Note:
Leave t he St andard Bi scui t i n pl ace at t hi s st age.

Now check t hat t he st andard count -rat es are bei ng
t ransmi t t ed each mi nut e t o t he comput er by sel ect i ng t he
count -rat es t abul ar screen whi ch wi l l di spl ay a t abl e of
channel s cont ai ni ng raw count -rat es t hat are bei ng
t ransmi t t ed from t he probe. Provi di ng onl y mi nor
adj ust ment s were done t o t he SCAs, t he 1-mi nut e count -
rat es shoul d l ook cl ose t o t hose gi ven i n t he dat a sheet s i n
At t achment 2, i . e. , t he fact ory numbers.

If compl et el y new SCA set t i ngs were found t hen t he
numbers wi l l be di fferent but t he mai n number t o check i s
t he Li ve-Ti me-Rat i o (LTR) whi ch i s di spl ayed i n t he fi rst
col umn. Thi s number i s usual l y around 0. 75 t o 0. 95 but
many be as l ow as 0. 65 i n some cases. Al so check t hat
numbers are appeari ng i n each channel (t here are usual l y 9
SCA channel s).

If numbers are appeari ng and l ook t o be correct (i n
compari son t o t he si ze of t he peak i n t he spect rum) t hen
proceed t o re-checki ng t he set t i ngs i n t he sl urry.

If t here i s no dat a bei ng di spl ayed t hen check t he
fol l owi ng:
1. Soft ware confi gurat i on (refer t o t he Sof t ware
Manual ).
2. Dat a cabl e connect i ons and dat a i nt erface uni t .
3. Reboot t he comput er and wat ch t he dat a i nt erface
uni t t o see i f t he recei ve and t ransmi t LEDs fl ash
t hen wai t at l east 5 mi nut es t o see i f dat a
appears.

5.9.6 Re-Checking Settings in the Slurry
Once t he whol e syst em has been t est ed as above and has
shown t o be operat i ng as expect ed wi t h t he st andard
bi scui t i n pl ace t hen t he bi scui t can be removed and t he
probe can be i mmersed i nt o t he sl urry, an XRF spect rum
col l ect ed and t he SCA set t i ngs adj ust ed (i f necessary) i n
t he sl urry.


To do t hi s fol l ow t hese st eps:

1. Col l ect a spect rum and l ook for any st eep noi se
shoul der at t he st art of t he spect rum decreasi ng
exponent i al l y. If t here i s one t hen i t shoul d not ext end
t o under t he fi rst peak of i nt erest . i . e. , i t shoul d not
ext end t o under t he FeK i f t hat i s t he fi rst peak
requi red t o be measured. If i t does t hen t he det ect or
may be mi crophoni c, so check for any excessi ve
vi brat i ons at t he anal yser mount i ng and t hen consul t t he
Company.

2. Remeasure t he probe resol ut i on i n t he sl urry and record
t hi s val ue i n t he dat a sheet s i n At t achment 2. If t he
probe i s very mi crophoni c t hen t he resol ut i on wi l l be
degraded t oo.

3. Col l ect a spect rum for about 300 seconds and check t he
upper l evel and l ower l evel SCA markers si t neat l y
around t he peaks of i nt erest (i . e. , i n t he val l eys and not
on t he shoul ders). Somet i mes one or more peaks may
be hi gher (i n whi ch case t hey may al so broaden
sl i ght l y), or l ower, so t he SCA channel markers wi l l
have t o be broadened or t i ght ened t o sui t . Record t he
new set t i ngs i n t he set up sheet s i n At t achment 2.

4. If you i dent i fy any new peaks i n sl urry not al ready
measured by an SCA, and t hat are not present i n t he
st andard bi scui t , furt her i nvest i gat i on i s recommended.
By cal i brat i ng t he MCA for energy and usi ng t he X-ray
Energy Tabl e (0), deci de i f t he peaks are i mport ant .
Consul t t he Company i f you are unsure. It may be
possi bl e t o re-assi gn an SCA t o measure a new peak of
i nt erest .

Note:
Be aware of t he approxi mat e sl urry concent rat i ons and
pl ant condi t i ons whi l st maki ng t hese checks and/ or
adj ust ment s. Somet i mes MSAs measure bot h t ai l s and
concent rat e st reams, so t he SCAs must be checked i n bot h.

5. Once al l set t i ngs are okay i n t he sl urry (vi z. , probe
resol ut i on and SCA set t i ngs t hen proceed wi t h St abi l i t y
Test i ng t he syst em (sect i on 5. 8).

Note:
SCA set t i ngs must be fi nal i sed pri or t o st andardi si ng and
commenci ng cal i brat i on.

Stability Testing (Standardising) Commissioning


5.10 Stability Testing (Standardising)
The probe(s) must be st abi l i t y t est ed bef ore cal i brat i on
begi ns. Thi s t est i ng serves t wo purposes, one i s t o
performance t est t he syst em t o ensure t hat t he probe and
el ect roni cs are st abl e and secondl y t o provi de t he
reference mean count -rat es (st andard count s) requi red for
source decay compensat i on. The st andard count s are used
i n cal i brat i on as wel l as i n t roubl e shoot i ng t he syst em.

The procedure i s done wi t h t he st andard bi scui t i n pl ace
and for up t o 12 hours or overni ght where possi bl e. The
fol l owi ng procedure shows how t o measure t he st andard
count -rat es and run a st abi l i t y t est .

1. Rai se t he probe from t he sl urry by pressi ng t he orange
Park Probe but t on on t he rear of t he MSA uni t (see
phot o l eft ). If t he probe parks over an anal ysi s t ank on
your MSA, t hen press t he green Rai se Probe but t on t o
l i ft t he probe cl ear of t he t ank.
2. Wash and dry t he probe head and wi ndow. If t he
wi ndow i s scrat ched or di rt y aft er cl eani ng i t shoul d be
repl aced, because a di rt y wi ndow wi l l adversel y affect
t he st andard count s you obt ai n. Observe safe radi at i on
worki ng pract i ces.
3. Check t he bi scui t i s cl ean, t hen pl ace t he st andard
bi scui t on t he probe. Make sure t hat t he correct
st andard for t hat probe i s used ot herwi se t he st andard
count -rat es wi l l be wort hl ess. If t here i s l i kel y t o be
sl urry spl ashi ng ont o t he probe t hen wrap a pl ast i c bag
around t he probe l eg but do not seal t i ght l y i f t he
ambi ent ai r i s very humi d.
4. Go t o t he comput er and sel ect t he Wi nISA Cl i ent
Cont rol Panel t hen connect t o t o t he probe t o be
st andardi sed. Sel ect st op measurement s t hen at t ach
st andard t hen st art measurement s. The st abi l i t y t est
but t on wi l l l i ght green on t he Cont rol Panel t o
i ndi cat e t hat t he probe i s i n fact i n st andardi se mode.
Repeat t hi s for each probe t o be st andardi sed. Refer t o
the Sof t ware Manual for addi t i onal det ai l s.
5. Bri ng up t he count -rat e t abul ar di spl ay and wai t at l east
5 mi nut es for t he fi rst count -rat es t o appear (defaul t
count i ng t i me i s 300 seconds i n st andardi se mode). If
t hey dont appear t hen check you are confi gured
properl y for st andardi se mode. Refer t o t he Sof t ware
Manual for furt her det ai l s.
6. Leave t he probe for about 12 hours, i f possi bl e, or at
l east overni ght .
Commissioning Stability Testing (Standardising)


Note:
Assays are not produced when a probe i s i n st andardi se
mode.

7. At t he end of t he st andardi si ng peri od go t o t he
comput er and open t he Wi nISA Cl i ent Cont rol Panel
t hen connect t o t o t he probe t o be t aken out of
st andardi se mode. Sel ect st op measurement s t hen
det ach st andard. Repeat for each probe.

8. Go t o t he probe and remove t he st andard bi scui t and
ret urn t he MSA t o normal operat i on by rel easi ng t he
Park Probe but t on.

9. Ret urn t o t he comput er and sel ect st art measurement s
on t he Wi nISA Cl i ent Cont rol Panel t o rest art t he
measurement cycl e. The machi ne wi l l now st art and be
ret urned t o normal operat i on usi ng t he normal anal ysi s
t i me. Aft er a short t i me t he st ream cycl e l i ght wi l l
come on. The Cont rol Panel can be cl osed now i f
desi red.

10. Run t he St abi l i t y soft ware program t o produce a
t abl ed summary of t he st andard count -rat es and
st abi l i t y st at i st i cs. The Sof t ware Manual provi des
det ai l s for runni ng t hi s program, where t o fi nd t he dat a
base fi l es and how t o i nt erpret t he dat a. If t he st andard
count -rat es fai l t he st abi l i t y t est t hen i nvest i gat e why
before proceedi ng wi t h cal i brat i on. Thi s may requi re
repeat i ng t he st andardi si ng procedure.

11. If t he st andard count -rat es pass t he st abi l i t y t est
sel ect t he Appl y but t on on t he summary panel i n t he
st abi l i t y program and t he mean count -rat es wi l l
aut omat i cal l y be ent ered i nt o t he soft ware confi gurat i on
as t he St andards. If t hi s i s t he fi rst t i me st andards
have been ent ered you may see a warni ng t hat t he new
st andards dont agree wi t h t he previ ous st andards
whose val ues wi l l be (1), you shoul d Appl y anyway.

Note:
If t he st abi l i t y t est report s any unst abl e channel s, t he
reason shoul d be i nvest i gat ed before you appl y t he
st andards. Refer t o Chapt er 9, Trouble Shooting.

12. You are now ready t o st art cal i brat i on but fi rst check
t hat your Met al l urgi cal Sampl ers (i f fi t t ed) work
Commissioning Testing the Metallurgical Samplers


correct l y (refer sect i on 5. 11).
Testing the Metallurgical Samplers Commissioning


5.11 Testing the Metallurgical Samplers
If t he Company suppl i ed cross-cut Met al l urgi cal Sampl er
has been fi t t ed at t he overfl ow of t he anal ysi s t ank (see
phot o l eft ) t hen i t needs t o be set -up and t est ed for t he 2
modes of aut omat i c operat i on before Cal i brat i on begi ns:
Aut o (for shi ft sampl i ng)
Aut o for Cal i brat i on (comput er cont rol l ed)
Manual Cut

The sampl er modes are confi gured at t he OI panel (see
phot o bot t om l eft ) or at t he swi t ches (l eft ).

The manual cut i s user sel ect abl e at t he sampl er swi t ch
(see phot o l eft ). Set t he Sampl er Swi t ch t o Aut o for
shi ft or cal i brat i on sampl i ng. Sampl ers can be l ocked off
for mai nt enance i f requi red.

5.11.1 Calibration-Mode
Set t he Sampl er Swi t ch t o Aut o.

Cont rol over t he sampl ers i s vi a t he OI panel on t he MSA
uni t , wi t h t he except i on of t he cal i brat i on sampl e t i me
peri od and t he number of sampl e cut s requi red i n any
gi ven sampl i ng peri od (t hi s i s defi ned i n t he soft ware on
t he cont rol l i ng comput er, refer t o t he Soft ware Manual ).
By sel ect i ng t he Smp-Mode OI menu opt i on, t he user can
sel ect t he "cal i brat i on" mode (see phot o bel ow l eft ). The
user shoul d al so refer t o t he sect i on on usi ng t he OI panel ,
i n chapt er 7 Operat i on.

In "cal i brat i on" mode a sampl e wi l l aut omat i cal l y be t aken
from t he next st ream (zone) whi ch i s sel ect ed from t he OI
panel . The correspondi ng probe count -rat es wi l l t hen be
st ored aut omat i cal l y i n a fi l e for t hat st ream name cal l ed
Cal i brat i onDat a. dbf.

The number of sampl e cut s t aken whi l st t he probe i s i n t he
zone depends on t he "number of cut s per sampl e" defi ned
i n t he comput er confi gurat i on soft ware and t hi s i s t urn wi l l
depend on t he measurement t i me peri od whi ch i s usual l y 5-
mi nut es.

Check t hat t he cal i brat i on mode works for al l MSA
st reams and make adj ust ment s t o t he sampl er cut t er speed
and number of sampl e cut s t aken where necessary t o
cont rol t he vol ume of sampl e col l ect ed (refer t o sect i on
5. 11. 3).


5.11.2 Shift Sample
Set t he sampl er swi t ch t o Aut o. Sel ect t he sampl er
number and mode at t he OI panel and t hen sel ect shi ft .
To do t hi s press t he arrow, t hen t he F4 <MenuMode>
key and t ype password 416 t hen press Ent er. Press
unt i l you see F1 <Sel Smpl r>. Press F1 unt i l you see t he
sampl er number you wi sh t o t est . Press F2 <SmpMode>
t hen arrow for Shi ft Mode, t hen Ent er.

There are t wo furt her modes for shi ft sampl es; one i s t he
"st andard shi ft " mode whi ch provi des t he operat or wi t h a
composi t e shi ft sampl e t hat i s col l ect ed over a pl ant shi ft
(confi gured i n t he comput er) wi t h sampl e cut s bei ng t aken
at regul ar t i me i nt erval s pre-set by sel ect i ng <Smp-Ti me>
at t he OI (t hi s sampl e cut i nt erval need onl y be set once
per st ream). The ot her mode provi des shi ft sampl es
composed of sampl es whi ch are cut randoml y wi t hi n a pre-
set t i me i nt erval i n case cycl i c pl ant behavi our i s
suspect ed. The user i s prompt ed t o pre-set a mi ni mum
t i me requi red bet ween such sampl es so as t o avoi d t he
possi bi l i t y of t wo sampl es bei ng t aken very cl ose t oget her.

Ask t he pl ant supervi sor what sampl e i nt erval s are
requi red over t hei r shi ft and set t he sampl er t i me
accordi ngl y. Make sure t he shi ft set up i n t he comput er
soft ware. Test t hat al l st reams work i n shi ft mode.
Adj ust t he number of sampl es (i . e. Vol ume of sampl e per
shi ft ) t aken by changi ng t he sampl er t i me bet ween cut s.

5.11.3 User Adjustments
Adj ust ment s requi red t o opt i mi se t he sampl e vol ume can
be made by changi ng t he speed of t he sampl e cut t er. Thi s
affect s al l sampl ers.

Setti ng the Sampl e Cutter Speed
Sampl e cut t er speed shoul d be set t o mat ch t he fl ow rat e
t hrough t he sampl er. Opt i mum sampl er speed i s a bal ance
of t he amount of sampl e requi red at t he end of each shi ft
and t he frequency of cut s requi red t o obt ai n a represent -
at i ve sampl e. The Sampl e Cut t er Speed Cont rol (phot o
l eft ) i s a 6 posi t i on swi t ch mount ed on t he AM664 i n t he
encl osure. Each posi t i on has i t s own speed (zero i s off).

Note:
If a sampl er i s request ed t o operat e and t he speed i s set t o
zero, i t wi l l cause a sampl er t i meout faul t , whi ch can be
reset by pressi ng t he whi t e Reset but t on on t he rel evant
sampl er reversi ng modul e.



Setti ng the Ti me Between Cuts for Shi ft Sampl es (Auto
Mode)
To change t he vol ume of sampl e col l ect ed over a shi ft ,
adj ust t he t i me bet ween sampl es for t hat st ream.

Cal i brati on Sampl i ng
The number of sampl e cut s i n t he cal i brat i on sampl i ng
peri od defi ned i n t he Wi nISA soft ware can be user set t o
provi de sui t abl y si zed sampl es. If no user defi ned number
i s set t hen t he defaul t number of cut s i s 15 and t he
cal i brat i on sampl e t i me i s 5 mi nut es t ot al per sampl e. The
Sof t ware Manual provi des det ai l s of how t o set t he
cal i brat i on sampl e cut s.

Cal i brat i on sampl es can onl y be t aken i f t he sampl er
swi t ch i s set t o Aut o, and a cal i brat i on sampl e i s
request ed at t he OI.

Warni ng:
Dependi ng on l ocal regul at i ons, access t o t he i nsi de of t he
MSA cont rol l er may be rest ri ct ed t o l i censed el ect ri cal
workers.

There are no exposed t ermi nal s i nsi de whi ch can be easi l y
t ouched by humans. Al l i nt ernal component s compl y wi t h
AS1939-1990 IP20 however, t ake care not t o use a t ool
such as a screwdri ver i n l i ve t ermi nal s.

Cauti on:
The mai ns t ermi nal s remai n l i ve wi t h t he door mount ed
swi t ch i n t he OFF posi t i on.

5.11.4 Tests to be Performed

To t est t he Met al l urgi cal Sampl ers you wi l l need a bucket
t hen fol l ow t hese st eps.

1. To t est t he manual Cut funct i on put a bucket at t he
sampl e out l et , set t he sampl er sel ect or swi t ch t o Cut .
The cut t er shoul d move i n one di rect i on onl y and cut
sampl e i nt o t he bucket . Sel ect i ng Cut agai n wi l l move
t he sampl er i n t he opposi t e di rect i on, agai n cut t i ng
sampl e i nt o t he bucket . The vol ume of sampl e wi l l
depend on t he cut t er speed (see 5. 11. 3) and t he sl urry
fl ow rat e.


2. Shi f t sampl es. Set t he t i me bet ween sampl es t o a short
peri od for t est purposes and t hen check wi t h t he si t e
met al l urgi cal l aborat ory as t o t he shi ft sampl e t i mi ng
t hey requi re and reset t he t i mer aft er t est i ng. Set t he
sampl er sel ect or swi t ch t o Aut o and check t hat t he
sampl er cut s are as per your sel ect i on.

If probl ems occur duri ng t est i ng, refer Chapt er 9
Troubl e Shoot i ng.

3. To t est t he cal i brat i on sampl i ng funct i on, perform t he
fol l owi ng;
a) Set t he sampl er sel ect or swi t ch t o Aut o.
b) On t he OI sel ect t he st ream number and put i t s
sampl er i n Cal i brat i on Mode.
The MSA wi l l cont i nue wi t h normal measurement
sequence and t i mi ng unt i l i t arri ves at t he sel ect ed
st ream. The Wi nISA comput er wi l l change t he
sampl er t o cal i brat e mode. Thi s al so means t he
count i ng l i ne wi l l change t o t he cal i brat i on
count i ng t i me (user sel ect abl e but defaul t i s 5
mi nut es) and t he sampl er wi l l be armed.
c) Wat ch t he sampl e-out l et nozzl e and count t he
number of cut s t aken i n t he measurement peri od.
Wi t h t he defaul t set t i ng at 15 cut s i n 5 mi nut es,
cut s shoul d be t aken every 20 seconds.
d) Check t he amount of sampl e col l ect ed i n t he bucket .
Sampl e Si ze must be manageabl e by t he si t e
met al l urgi cal l aborat ory for sampl e preparat i on and
suffi ci ent for t he assay l aborat ory. Usual l y around
2 t o 5 ki l ograms i s sat i sfact ory. If t he vol ume
requi res changi ng, t he number of cut s shoul d be
i ncreased or decreased for t hi s st ream i n t he
Wi nISA soft ware. It i s not recommended t o t ake
l ess t han 10 cut s or more t han around 60 cut s per
sampl e. Maxi mum i s l i mi t ed by t he cut t er speed.

If al l of t he t est s fai l t hen check t he sampl er wi ri ng and
el ect roni c cards. There shoul d not be any Red overl oad
LEDs on t he sampl er cards l ocat ed i n t he mai n MSA
cont rol l er (see phot o l eft ).

If t he cal i brat i on sampl e fai l s t hen check t he comput er
soft ware confi gurat i on. For exampl e, t here may be t oo
many cut s request ed t o fi t i nt o t he cal i brat i on count i ng
t i me. Refer al so t he Wi nISA User Manual and Chapt er 9,
Troubl e Shoot i ng.




Section 5 Commissioning
Attachment 1Consumables & Tools List

CONTENTS

Li st of Speci fic Tool s and Consumables
As Suppl i ed with the Anal yser


Attachment 2Test Data Sheets

CONTENTS

MEP/ Si gnal Anal yser Set-Up Detai l s (Form-042)

MEP Detector/Channel Setti ngs (Form-052)

MEP X-Ray Spectrum

Commi ssi oni ng Checkl i st MSA (Form-178)


Attachment 3MCA

CONTENTS

Pocket MCA Operati on Technical Note 24


6
Calibration

Thi s sect i on provi des t he basi c i nformat i on needed t o
cal i brat e an on-l i ne anal ysi s syst em i ncorporat i ng a Mul t i -
El ement Probe (MEP). It assumes t hat a Met al l urgi cal
Sampl er i s fi t t ed t o each anal ysi s t ank of t he MSA. If not ,
t hen you wi l l need t o fol l ow t hi s procedure but i nst ead
manual l y cut a sampl e yoursel f from t he overfl ow wei r
under t he i nspect i on cover of t he t ank. It covers t he
physi cal t aki ng of cal i brat i on sampl es from t he i n-pl ant
anal yser. The soft ware manual shoul d be used i n
conj unct i on wi t h t hi s manual for speci fi c det ai l s about
cal i brat i ng t he anal yser usi ng t he Wi nISA regressi on
anal ysi s soft ware program (RARP).

6.1 Overview
The anal yser syst em must be cal i brat ed when i t i s fi rst
i nst al l ed and commi ssi oned i n t he pl ant . Cal i brat i on
i nvol ves t he t aki ng of at l east 30 sampl es from t he st ream
t o be cal i brat ed. These sampl es are t hen chemi cal l y
assayed i n a l aborat ory ei t her on-si t e or el sewhere and t he
assays are t hen correl at ed wi t h t he correspondi ng count -
rat es from t he probe t hat were measured duri ng t he peri od
t hat t he sampl e was t aken, usual l y t hi s i s 5 mi nut es.

Note:
The anal yser shoul d be st andardi sed before cal i brat i on
begi ns. Fol l ow t hat procedure i n t he Commi ssi oni ng
sect i on.

Overview Calibration


To obt ai n cal i brat i ons for t he anal yser syst em, count -rat es
measured from each MEP (st ream) of t he syst em are
correl at ed wi t h anal ysed mi neral cont ent and densi t y usi ng
a mul t i pl e l i near regressi on anal ysi s soft ware program.
When a sui t abl e cal i brat i on i s obt ai ned i t s performance i s
checked by compari ng t he cal cul at ed val ues agai nst t he
observed assays for subsequent sampl es, usi ng st at i st i cal
and pl ot t i ng rout i nes.

The l i ne of best fi t t o t he dat a i s det ermi ned by t he
met hod of l east squares for a number of sel ect ed funct i ons.
The resul t s are obt ai ned as a pl ot of cal cul at ed val ues for
each dependent vari abl e agai nst t he val ues obt ai ned by
anal ysi s.

Cal i brat i ng an on-l i ne anal yser syst em i nvol ves t he
fol l owi ng st eps:
Equi pment & resources needed for cal i brat i on.
Taki ng a sui t e of approxi mat el y 30Cal i brat i on
Sampl es from each anal ysi s poi nt (st ream) where a
probe has been i nst al l ed.
Prepari ng t he sampl es, fi l t eri ng and dryi ng.
Chemi cal l y assayi ng t he Cal i brat i on Sampl es.
Ent eri ng t he Dat a i nt o Cal i brat i on Fi l es for anal ysi s
wi t h t he RARP soft ware program.
Runni ng regressi ons t o fi nd t he best Cal i brat i on
(Assay) Equat i ons, i ncl udi ng i nt erpret i ng t he
resul t s.
Usi ng t he Cal i brat i on (Assay) Equat i on on-l i ne.
Checki ng t he accuracy and reliability of the calibration
equat i on.

Each of t hese st eps i s covered i n t hi s sect i on.

6.2 Equipment & Resource Requirements
The fol l owi ng i t ems are requi red for cal i brat i ng an on-l i ne
anal yser syst em:
20 or more cl ean bucket s of at l east 10 l i t re
capaci t y, wi t h l i ds. Each bucket must be wei ghed,
wi t hout i t s l i d, t o 0. 1g accuracy and t he wei ght
wri t t en i n permanent pen on t he bucket .
Calibration Equipment & Resource Requirements


Effi ci ent on-si t e Sampl e Preparat i on Faci l i t i es and
personnel t o handl e at l east 30 sampl es per anal yser
(st ream) t o be cal i brat ed over a peri od of up t o 2
weeks, dependi ng on t he pl ant vari at i ons and scope
of work. Typi cal l y, up t o 10 sampl es per st ream per
day wi l l be t aken. For exampl e a syst em compri si ng
t hree anal yser st reams wi l l requi re at l east 90
sampl es i n t ot al t o be t aken i n a peri od of up t o one
(1) week t hen furt her sampl es woul d be t aken t o
check t he cal i brat i on accuracy and rel i abi l i t y.
Equi pment and resources requi red for sampl e
preparat i on shal l i ncl ude:
- pressure fi l t ers
- wei ghi ng scal es t o at l east 0. 1 g accuracy and
capabl e of wei ghi ng up t o 5 kg (wet ) sampl es
- effi ci ent sampl e dryi ng ovens or l amps
- sampl e t rays and sampl e bags
- l og-book for sampl e i nformat i on and t racki ng
- personnel t o prepare t he sampl es

Note:
The %sol i ds of each sampl e must be measured wi t h an
accuracy of bet t er t han 0. 1 %sol i ds usi ng t he wet and dry
wei ght s met hod.

Chemi cal assayi ng faci l i t i es, ei t her on-si t e or off, t o
provi de chemi cal assays for al l requi red el ement s
from al l t he cal i brat i on sampl es. The t ot al t urn-
around t i me i ncl udi ng sampl e preparat i on must not
be more t han 48 hours so as t o mi ni mi se t he t i me
requi red t o cal i brat e t he anal yser syst em. Usual l y
anal ysi s woul d be requi red for bet ween 20 and 40
cal i brat i on sampl es dai l y. Because t he anal yser
accuracy i s dependent on t he chemi cal assays t hen
t he error associ at ed wi t h t he chemi cal assays (and
sampl e preparat i on) of t he sampl es must be as smal l
as possi bl e.

Note:
Chemi cal assay accuracy must be bet t er t han one t hi rd of
t he expect ed accuracy of t he on-l i ne anal yser (at 1s. d. ) t o
avoi d cont ri but i ng t o t he apparent errors of t he anal yser.
i . e. an expect ed anal yser accuracy of 5% rel at i ve error at
1s. d. wi l l requi re a chemi cal assay accuracy of about 3% at
2s. d. , or 95% confi dence.

Taking Calibration Samples Calibration


6.3 Taking Calibration Samples
Some soft ware confi guri ng i s needed t o enabl e on-l i ne
measurement s from t he anal yser t o be aut omat i cal l y
appended i nt o t he cal i brat i on dat a fi l e for each st ream t o
be cal i brat ed duri ng cal i brat i on sampl i ng. The fi l e t ype
and name i s Cal i brat i on. DBF for every st ream and t hey
are found i n t he di rect ory fol der creat ed duri ng i ni t i al set -
up for each st ream. Thi s fi l e al so cont ai ns t he st andard
count -rat es and t hese are updat ed each day t hat cal i brat i on
dat a i s added t o t he fi l e.

It i s i mport ant t hat st andard count -rat es are obt ai ned
bef ore st art i ng cal i brat i on and t hat t hese are ent ered i nt o
t he soft ware dat a base so t hat t hey can be aut omat i cal l y
added by t he soft ware t o t he Cal i brat i on. DBF fi l es
duri ng t he cal i brat i on phase. Chapt er 5, Commi ssi oni ng
det ai l s t he st andardi sat i on procedure.

Note:
Pl ease read t he i nst ruct i ons i n t he soft ware confi guri ng
sect i on of t he Sof t ware Manual before at t empt i ng t o t ake
sampl es.

To obt ai n a cal i brat i on t hat wi l l work for al l pl ant
condi t i ons t he sampl es must cover t he compl et e range of
pl ant operat i ng condi t i ons where possi bl e however t hi s i s
not normal l y possi bl e nor pract i cal duri ng t he
commi ssi oni ng vi si t and may t ake many weeks or mont hs.
Hence, duri ng t he commi ssi oni ng and cal i brat i on peri od
pl ant personnel are t rai ned i n all aspect s of t he cal i brat i on
process so t hat t hey can cont i nue mai nt ai ni ng and updat i ng
t he cal i brat i ons where necessary.

For correl at i on, t he sampl es must correspond wi t h t he
t i med measurement s of t he anal yser i t sel f. The
measurement i s usual l y performed for fi ve mi nut es and
t hi s i s t aken care of by t he bui l t i n cal i brat e mode of t he
anal yser.

The procedure fol l ows.

Calibration Taking Calibration Samples


6.3.1 Taking Samples

1. Pl ace a cl ean and dry t ared bucket at t he Met al l urgi cal
Sampl er out l et of t he anal yser.

2. Ensure t he sampl e sel ect or swi t ch i s set t o Aut o
(see phot o l eft ). Then go t o t he OI panel and sel ect
t he menu opt i on <Sel Sampl er> (see OI panel phot o
l eft ) t hen sel ect t he sampl er number t hat you want
sampl e t o be t aken from. Now sel ect t he sampl er
mode <SmpMode> and set t o cal i brat e. Sel ect yes
t o t he quest i on change bucket (see phot o bot t om
l eft ). When t he probe next vi si t s t he zone, comput er
st art s i t s next count i ng (measurement ) peri od for t hat
st ream you wi l l see t he Taki ng Sampl e message.

Note:
Be aware of t he probe sequence when request i ng
cal i brat i on sampl es.

3. A pre-defi ned number of sampl e cut s wi l l be
aut omat i cal l y t aken over t he measurement peri od
(normal l y 5 mi nut es). Thi s number i s defi ned i n t he i n
t he Wi nISA soft ware. Shoul d t here be t oo much or
t oo l i t t l e sampl e col l ect ed, you may choose t o al t er
t he number of cut s (from t he Wi nISA soft ware
confi gurat i on, defaul t i s 15 cut s) or t he speed of t he
sampl e cut t er. The l at t er i s set on t he sampl er speed
sel ect or swi t ch l ocat ed i nsi de t he mai n MSA
Cont rol l er. In most cases t he l aborat ory wi l l requi re
at l east 100 grams of sol i d for assayi ng.

4. When t he sampl i ng or measurement peri od i s fi ni shed
t he OI panel wi l l di spl ay Sampl e Taken and t he
sampl er wi l l revert t o off mode. If t he anal yser has
been set up t o t ake shi ft sampl es t hen ensure t he
sampl er sel ect or swi t ch i s l eft set t o Aut o (i . e. do not
t urn i t off) and sel ect <SmpMode>, shi ft and repl ace
t he shi ft sampl e bucket

5. At t he end of t he peri od t he number of cut s t aken by
t he sampl er wi l l be checked by t he soft ware. If al l i s
okay t he cal i brat i on sampl e count -rat es wi l l be saved
aut omat i cal l y i n t he cal i brat i on dat a fi l e
(Cal i brat i on. DBF) for t hat st ream.
Taking Calibration Samples Calibration


6. Record t he end t i me ( 1 mi nut e i s accurat e enough),
dat e and sampl e st ream name. If you have more t han
one bucket i n t he pl ant , t ake care not t o confuse
bucket s!

7. Pl ace t he l i d on t he bucket and careful l y t ake t he
sampl e t o t he l aborat ory wi t hout spi l l i ng or ot herwi se
cont ami nat i ng or changi ng t he nat ure of t he sampl e.
Record sampl e det ai l s i n t he l og sheet i n t he
met al l urgy l ab.

You wi l l now have a si ngl e composi t e sampl e whi ch i s
represent at i ve of t he sampl e fl owi ng t hrough t he anal yser
duri ng t he cal i brat i on measurement peri od. The sampl e
wi l l normal l y cont ai n bet ween 1 and 5 l i t res dependi ng on
t he fl ow-rat e, t he openi ng of t he sampl e cut t er (10mm i s
st andard), t he speed and frequency of cut t i ng t he st ream,
and t he sampl i ng peri od.

6.3.2 Rules for Calibration Sampling

1. The compl et e set of cal i brat i on dat a must cover al l of
t he range of condi t i ons whi ch occurs i n t he st ream.
For exampl e, t he sampl es must cover t he whol e range
of el ement al concent rat ions, mi neral ogy and mat ri x
vari at i ons as wel l as vari at i ons i n t he densi t y of t he
sol ut i on. If t he sampl es do not cover t hese ranges,
t hen t he anal yser may not gi ve accurat e resul t s when
t hese condi t i ons are met i n t he fut ure.

2. It i s i mport ant t o keep i n mi nd t hat t he cal i brat i on
equat i on has been made for t he part i cul ar operat i ng
condi t i ons covered by t he sampl es i n t he dat a set . If a
new set of condi t i ons i s encount ered, t he accuracy of
t he anal yses from t he cal i brat i on equat i ons wi l l
det eri orat e. In ot her words, accurat e anal yses can
onl y be expect ed when i nt erpol at i ng wi t hi n t he range
of condi t i ons represent ed by t he cal i brat i on dat a.

It i s general l y (t heoret i cal l y) accept ed t hat you can
safel y ext rapol at e about 30% of t he range on ei t her
si de of a part i cul ar cal i brat i on wi t hout t oo much error.
The ext ent t o whi ch you can ext rapol at e depends on
t he correl at i on coeffi ci ent of t he cal i brat i on equat i on
so t hat i f t he CC i s > 0. 99, you can safel y ext rapol at e
70% of one whol e range ei t her si de of t he present
cal i brat i on range (see Correl at i on Coeffi ci ent l at er i n
t hi s chapt er). Set t he l i mi t s of t he assay equat i on
appropri at el y. If CC i s <0. 9, ext rapol at i on i s not
recommended (refer t o sect i on 6. 5. 6).
Calibration Assaying the Calibration Samples


3. Cal i brat i on sampl es must be col l ect ed and anal ysed
wi t h t he maxi mum of care t o avoi d cont ri but i ng t o
errors i n t he cal i brat i on equat i ons. A poor resul t from
t he regressi on anal ysi s shoul d not be bl amed on t he
anal yser wi t hout a t horough i nvest i gat i on of al l of t he
procedures used i n obt ai ni ng t he cal i brat i on dat a.

Note:
If t he equat i ons are gi vi ng i naccurat e resul t s, addi t i onal
cal i brat i on sampl es shoul d be t aken and added t o t he
cal i brat i on dat a set and new cal i brat i on equat i ons shoul d
be found whi ch cover t he new operat i ng condi t i ons.

6.4 Assaying the Calibration Samples
Each sampl e must be chemi cal l y assayed for t he
requi red met al concent rati ons (by %wei ght ) and i t s
percent sol i ds cal cul at ed.
1. The %sol i ds of t he sampl e i s best measured by t he
wet and dry wei ght s met hod so t o st art wi t h, t he
sampl e must be accurat el y wei ghed i n t he bucket
before i t i s dri ed. Dont forget t o t ake t he bucket l i d
off i f t he bucket wei ght was measured wi t hout t he l i d
on, ot herwi se l eave i t on. Try t o use t he same
wei ghi ng scal es as used t o wei gh t he empt y bucket s.
2. Wei gh a number of cl ean fi l t er papers, i f usi ng a
pressure fi l t er t o fi l t er t he sampl es and wri t e t he
wei ght t o 1 deci mal pl ace on t he out si de edge of t he
paper. It i s best t o use very fi ne fi l t er paper,
especi al l y where fi ne mil l i ng i s carri ed out as t here
may be a l arge percent age of sl i mes i n t he sampl es t o
be fi l t ered.
3. Fi l t er t he sampl e t o remove most of t he wat er. Thi s i s
best done i n a pressure fi l t er as i t i s far qui cker and
more effi ci ent , but t he met hod chosen wi l l depend on
what gi ves t he best resul t for t he part i cul ar sl urry. If
t here i s a l arge amount of sl i me i n t he sampl e (evi dent
i f t he fi l t rat e i s col l ect ed) t hen col l ect t he fi l t rat e
from each sampl e and pour i t back on t op of t he fi l t er
cake so as t o mi ni mi se errors i n t he fi nal assay t hat
may be due t o sl i mes l oss.
4. Dry t he sampl e: Put t he fi l t er cake (sampl e and
paper) ont o a met al t ray or di sh and pl ace i n an oven
or under heat l amps t o speed up t he dryi ng process.
However, care must be t aken t o ensure t hat t he oven
(or l amps) i s not so hot t hat t he mi neral s oxi di se.
Definition of Terms Used in Calibrating Calibration


5. Wei gh t he dry sampl e and t hen cal cul at e t he %sol i ds
rememberi ng t o subt ract t he bucket , t ray and fi l t er
paper wei ght s. Make sure t hat t he sampl es are at
ambi ent t emperat ure before wei ghi ng so t hat ai r
current s due t o t he heat from t he sampl e wi l l not
di st ort t he measured wei ght .
6. Assay t he sampl es i n t he normal manner i n t he
l aborat ory. Sampl i ng and anal yt i cal errors by t he
l aborat ory must be l ess t han one t hi rd t he expect ed
accuracy of t he anal yser ot herwi se t hese errors wi l l
cont ri but e si gni fi cant l y t o t he t ot al error of t he
cal i brat i on. Assays t hat t he MSA i s not requi red t o
produce are not requi red from t he assay l ab ei t her.
7. Ent er t he l aborat ory assays i nt o your regressi on assay
fi l e as soon as you can. Refer t o t he cal i brat i on
sect i on of t he Sof t ware Manual for det ai l s on how t o
creat e t hese dat a base fi l es.

6.5 Definition of Terms Used in Calibrating
6.5.1 Measurement Time
Regressi on Anal ysi s uses t he measurement t i me i n
cal cul at i ng t he reproduci bi l i t y error i n t he assays (due
t o t he reproduci bi l i t y of t he count -rat es) for each
equat i on. The reproduci bi l it y of t he count -rat es i s
dependent on t he measurement t i me. The assay
reproduci bi l i t y i s cal cul at ed at one st andard devi at i on
and i s di spl ayed i n t he out put fi l e as t he "St at s Error",
meani ng t he St at i st i cal Error. The measurement t i me i s
normal l y 300 seconds (5 mi nut es), but i f you use a
di fferent measurement peri od, you can ent er t hi s i nt o
t he regressi on program so i t cal cul at es st at s error
correct l y.

The use of t he measurement t i me ari ses wi t h al l
nucl eoni c measurement equi pment because t he
reproduci bi l i t y of t he measurement s i mproves as t he
square root of t he count i ng t i me. Thi s means t hat i f t he
count -rat e averagi ng t i me i s i ncreased by a fact or of 4,
t he reproduci bi l i t y of t he resul t wi l l i mprove by a
fact or of 2. The St at s Error i s used t o eval uat e
whet her t he accuracy of t he i nst rument i s l i mi t ed by t he
reproduci bi l i t y of t he count -rat es or whet her i t i s
l i mi t ed by some ot her fact or.
Calibration Definition of Terms Used in Calibrating


If i t i s l i mi t ed by t he measurement t i me, t hen t he t i me
may be i ncreased t o i mprove t he resul t s. In pract i ce, i f
t he "St at s Error" i s l arger t han hal f of t he RMS Error
(see defi ni t i on i n sect i on 6. 5. 5), i ncreasi ng t he
measurement t i me of t he i nst rument shoul d
si gni fi cant l y i mprove t he RMS Error. On t he ot her
hand, i f t he "St at s Error" i s much l ess t han hal f of t he
RMS Error, t he measurement t i me of t he i nst rument
may be decreased wi t hout si gni fi cant l y reduci ng t he
accuracy or reproduci bi l i t y of t he measurement s. Thi s
woul d gi ve a hi gher t hroughput of sampl es wi t h t he
i nst rument .

As an exampl e of changi ng t he measurement t i me,
assume t hat t he measurement t i me i s 100 seconds, t he
RMS Error cal cul at ed by t he regressi on program for a
part i cul ar equat i on i s 0. 035% Cu and t hat t he St at s
Error i s 0. 008% Cu. In t hi s case t he St at s Error i s
much l ess t han hal f of t he RMS Error. Thi s means t hat
t he measurement t i me can be decreased wi t hout addi ng
si gni fi cant l y t o t he RMS Error. We are al l owed t o
i ncrease t he St at s Error t o hal f of t he RMS Error
whi ch i n t hi s case i s 0. 017%Cu (i . e. doubl e t he present
val ue). Increasi ng t he St at s Error by a fact or of 2
means decreasi ng t he measurement t i me by a fact or of 4
t o 25 seconds. Maki ng t hi s change woul d be hi ghl y
benefi ci al because i t woul d al l ow t he operat or t o
measure up t o 4 t i mes as many sampl es on t he
i nst rument i n t he same t i me wi t hout si gni fi cant l y
affect i ng t he accuracy of t he resul t s.

Note:
For very l ow concent rat i on measurement , i ncreasi ng t he
measurement t i me may not i mprove t he st at i st i cal error
because t he concent rat i on i s bel ow t he det ect i on l i mi t of
t he anal yser.

6.5.2 Standard Count-rates
The cal i brat i on equat i on al ways uses normal i sed
count -rat es. The count -rat es are normal i sed by
di vi di ng t he act ual (on-l i ne) count -rat es i n each
channel for each sampl e col l ect ed, by t he st andard
count -rat e for each part i cul ar channel . The st andard
count -rat es are aut omat i cal l y i nsert ed i nt o t he
cal i brat i on dat a fi l e each day t hat cal i brat i on sampl es
are t aken. Source decay i s aut omat i cal l y compensat ed
for, provi di ng source det ai l s have been ent ered i nt o t he
Definition of Terms Used in Calibrating Calibration


Wi nISA soft ware confi gurat i on (refer t o t he Sof t ware
Manual for det ai l s).
The st andard count -rat e i n each col umn of t he
Cal i brat i on. DBF fi l e i s used as a di vi sor for al l
subsequent count -rat es i n t hat col umn unt i l a new
st andards l i ne i s encount ered. Hence, al l count -rat es
from t he sampl es are normal i sed wi t h respect t o t he
count -rat es from t he reference sampl e.

The use of t he st andard l i ne al l ows for l ong t erm
changes i n t he performance of t he i nst rument due t o
such fact ors as source decay and det ect or effi ci ency.
When t he performance of t he i nst rument changes t he
count -rat es for any sampl e wi l l change i n t he same rat i o
as t he count -rat es for t he reference sampl e (st andard).
Hence, t he rat i o of t he count -rat es from t he sampl es t o
t he count -rat es from t he reference st andard i s al ways
const ant , i ndependent of al l ot her fact ors.

The dat a fi l e may cont ai n as many st andard l i nes as
requi red t o compensat e t he dat a for changes i n t he
effi ci ency of t he i nst rument det ect or over t i me.
Normal l y, Thermo El ect ron i nst rument s are st abl e for
very l ong peri ods of t i me (i . e. years) so onl y a few
st andard l i nes are requi red t hroughout t he fi l e (or for
each new day when cal i brat i on sampl es are t aken).

Note:
Not e t hat assays are not expressed as a rat i o and so no
st andards need t o be ent ered i nt o t he assay fi l e.

6.5.3 Calibration Data
Each dat a l i ne i n t he Cal i brat i on Dat a. DBF fi l e
corresponds wi t h t he measurement of one cal i brat i on
sampl e. Each l i ne begi ns wi t h t he sampl e' s
i dent i fi cat i on, consi st i ng of a st ri ng of up t o 8
al pha-numeri c charact ers. A Dat e/ Ti me st amp i s al so
i ncl uded i n each sampl e l i ne. Then fol l ows t he count -
rat e dat a col umns for each channel of t he Si gnal
Anal yser.

The fi rst cel l i s l eft bl ank for each sampl e, t hi s i s
where t he sampl es i dent i fi cat i on must be ent ered.

St andards l i nes wi l l be i nsert ed i n bet ween t he
cal i brat i on dat a l i nes. Each dat e change wi l l show a
new st andards l i ne when cal i brat i on sampl es are
act ual l y t aken on t hat day.

Calibration Definition of Terms Used in Calibrating


6.5.4 Assay Data
Each dat a l i ne i n t he Assay. DBF fi l e corresponds
wi t h t he l aborat ory assays for t hat sampl e. Each l i ne
begi ns wi t h t he sampl e' s i dent i fi cat i on whi ch MUST be
t he same as t hat used i n t he Cal i brat i on Dat a. DBF fi l e
for t hat st ream. Ent er l ab assay val ues and sampl e i ds
usi ng t he RARP regressi on program Refer t o t he
Sof t ware Manual for det ai l s on set t i ng up your assay
dat a base fi l es.

6.5.5 RMS Error
RMS Error i s t he st andard devi at i on bet ween t he
chemi cal l aborat ory assays and t he i nst rument assays
for a sui t e of sampl es and i s cal cul at ed by:

1 N
) y -
x
(
= Error RMS
2
i
i
N
=1 i
2
1

where N i s t he number of sampl es.
x
i
i s t he chemi cal assay of t he i t h sampl e.
y
i
i s t he assay from t he i nst rument of t he i t h
sampl e usi ng t he cal i brat i on equat i on.

In general , t he equat i on chosen wi l l have t he l owest
RMS Error of al l possi bl e equat i on forms (see ot her
rul es al so).

The RMS Error i s al so known as t he anal yser
Cal i brat i on Error. Thi s error i s compri sed of t he
fol l owi ng errors:
St at s error (as descri bed i n sect i on 6. 5. 1)
Part i cl e Si ze Error
Mi neral ogy Error
Segregat i on Error
Sampl i ng Error of t he anal yser
Laborat ory Errors i n sampl e preparat i on and anal ysi s
Ot her Inst rument Errors such as el ect roni c
i nst abi l i t y, di rt y wi ndows, et c
The Tot al Cal i brat i on (RMS) Error i s t he square-root of
t he sum of t he squares of al l t hese errors.

6.5.6 Correlation Coefficient
Thi s coeffi ci ent i s a measure of t he l i near rel at i onshi p
bet ween t he ISA predi ct ed val ues and t he l aborat ory
resul t s. The correl at i on coeffi ci ent i s dependant upon
t he range of t he cal i brat i on assays and t he RMS error:

As t he range i ncreases, CC 1
As t he RMS Error decreases, CC 1

Running a Regression Calibration


If t he correl at i on coeffi ci ent approaches 1, t hen you can
safel y ext rapol at e t he ISA predi ct ed assay val ues
beyond t he range of t he cal i brat i on dat a set .

CC < 0. 9 do not ext rapol at e beyond dat a range
CC > 0. 95 can ext rapol at e 30% of range on ei t her si de

The l i mi t s for each assay equat i on shoul d be set
accordi ng t o t hese cri t eri a. However, i t i s al ways
recommended t hat addi t i onal cal i brat i on sampl es be
t aken t hat fi t t he real operat i ng range.

6.5.7 Relative Error
The Rel at i ve Error i s defi ned as t he RMS Error di vi ded
by t he mean assay oft en expressed as a percent age. For
a good cal i brat i on, t he Rel at i ve Error shoul d be l ess
t han 10% and may be as l ow as 1% or l ess. In general
t he hi gher t he mean assay t he l ower t he Rel at i ve Error.

6.6 Running a Regression
Fol l owi ng i s a general descri pt i on of t he Regressi on
Anal ysi s Program (RARP) t hat i s used t o fi nd t he best
cal i brat i on equat i on for produci ng rel i abl e accurat e on-
l i ne assays from your anal yser.

The exact form of t he best cal i brat i on equat i on depends
on a range of fact ors such as t he mi neral ogy, mat ri x
and part i cl e si ze of t he mat eri al whi ch i s t o be
measured. Therefore, each anal yser has t o be
i ndi vi dual l y cal i brat ed over t he range of ore bl ends and
operat i ng propert i es so t hat i t wi l l gi ve t he best
possi bl e measurement accuracy.

To fi nd t he best form of t he cal i brat i on equat i on, t he
regressi on program cycl es t hrough al l val i d
combi nat i ons of equat i ons based on t he dat a from t he
sui t e of cal i brat i on sampl es. Thi s i nformat i on i s t hen
present ed t o t he user who can t hen compare/ rei t erat e or
choose a part i cul ar equat i on t erms. The best equat i on
shoul d be chosen based on a compari son of t he RMS
Error, Correl at i on Coeffi ci ent , Rel at i ve Error and t he
Number of Terms used i n t he equat i on.
Calibration Running a Regression


For each st ream t o be cal i brat ed, t he program uses t he
Cal i brat i on Dat a. DBF fi l e for t hat st ream t o obt ai n
t he count -rat e dat a and al so uses t he assay dat a base
fi l e t hat was creat ed by t he user ent eri ng t he l aborat ory
assays. The Sof t ware Manual provi des furt her det ai l s
on usi ng t he RARP program.

Regressi on program shoul d be run on t he Wi nISA
server comput er so chosen assays can be easi l y
Appl i ed t o t he Wi nISA server confi gurat i on. If you
run a regressi on on anot her comput er, equat i ons must
be manual l y ent ered i nt o t he Wi nISA server
confi gurat i on, usi ng ei t her t he Wi nISA Del phi Cl i ent
Confi gurat i on Wi zard or t he Wi nISA Panel .

6.6.1 Deleting Samples in the Regression
The user can del et e some sampl es from a part i cul ar
equat i on. The program al l ows t he user t o do t hi s i nt er-
act i vel y by ei t her:

1. Looki ng at t he t abl e of t he resi dual s and sel ect i ng
t he poi nt (s) wi t h t he hi ghest resi dual s.
2. Looki ng at a pl ot (exampl e i n Fi gure 6-1) of t he
cal cul at ed assays versus t he act ual l aborat ory assay.
The pl ot hel ps you t o see i f t here are any sampl e
poi nt s whi ch do not seem t o fi t t he same
rel at i onshi p as t he rest of t he sampl es (i . e. one or
t wo poi nt s are a l ong way from t he cal i brat i on l i ne
formed by t he ot her sampl es). In t hi s case, t he
sampl e(s) i n quest i on may be i ncorrect i n some way
- ei t her t he dat a may have been ent ered i ncorrect l y
i nt o t he dat a fi l e, t he assay for t he sampl e may be
wrong, t he sampl e may have been cont ami nat ed et c.
What ever t he reason, t he cause shoul d be
i nvest i gat ed and correct ed i f possi bl e.
3. Usi ng t he equat i ons wi t h sampl es al ready
el i mi nat ed aut omat i cal l y by and present ed t o t he
user by t he soft ware program. It i s recommended
t hough t hat t he user al so manual l y checks t he form
of t he equat i on and sampl es el i mi nat ed t o ensure
t hat t he best possi bl e equat i on i s chosen.



Fi gur e 6- 1 Exampl e Regr essi on Pl ot

The user can al so reduce t he range of t he observed
assays t o obt ai n bet t er equat i ons i n t he operat i ng
range expect ed.

When al l of t he requi red sampl es have been del et ed, t he
user can re-eval uat e t he regressi on and t hen pri nt a
copy of t he resul t or post t he equat i on chosen t o t he
soft ware confi gurat i on, by sel ect i ng t he Appl y but t on
i n t he regressi on soft ware(RARP), for i mmedi at e on-
l i ne use.

Note:
Normal l y no more t han 10% of t he sampl e poi nt s can be
del et ed wi t hout i nvest i gat i ng furt her i nt o t he reason
why so many sampl es dont fi t t he regressi on l i ne.

6.6.2 General Rules for Choosing the Best Equation
It i s a good i dea t o consul t your pl ant met al l urgi st
regardi ng concent rat i on range and desi red accuracy.
They may al so provi de useful hi nt s about correct i on
t erms based on mi neral ogy and/ or ore bl endi ng and/ or
pl ant operat i ng condi t i on.

Ot her i mport ant rul es whi ch must be observed when
choosi ng t he best cal i brat i on equat i on for a part i cul ar
appl i cat i on are as fol l ows:


1. Al ways make sure t hat t he fundament al form of t he
equat i on i s i ncl uded when runni ng t he program.
The fundament al equat i on rel at es t he assay t o t he
si ngl e most si gni fi cant t erm. For exampl e, t he
si ngl e most si gni fi cant t erm i n a cal i brat i on for
%Cu i s t he copper count -rat e (vi z. CuKa). The
resul t s for t he more compl ex equat i ons can be
compared t o t he resul t s for t he fundament al
equat i on t o see i f t here real l y i s an i mprovement .
Ext ra t erms are oft en needed t o cover di fferent
mi neral ogi cal forms.
2. Al ways l ook at t he pl ot for t he fundament al
equat i on form. If t he pl ot shows one or t wo bad
poi nt s on t hi s graph, i t i s a st rong (but not
concl usi ve) i ndi cat i on t hat t hese dat a poi nt s are i n
error. If t he same poi nt s are bad on t he graphs for
t he more compl ex forms of t he cal i brat i on equat i on
and for ot her assays, t hen you can be much more
cert ai n t hat t here i s an error i n t he dat a for t hese
poi nt s and hence you can el i mi nat e t hem compl et el y
from t he dat a set .
3. Al ways ensure that t he coeffi ci ent of t he
fundament al t erm has t he correct posi t i ve or
negat i ve si gn. In general , t he fundament al met al
count -rat e t erm i n an equat i on wi l l be posi t i ve i n
si gn.
For exampl e, i n a cal i brat i on for %Cu, t he
coeffi ci ent of t he copper count -rat e t erm shoul d
al ways be posi t i ve. In a densi t y cal i brat i on,
however, t he coeffi ci ent of t he scat t er count -rat e
must al ways be negat i ve i n si gn. If t he si gn i s not
correct , l ook at t he dat a fi l e t o see i f t here i s an
error.
4. In general , al l cal i brat i on equat i ons shoul d be based
on at l east 20 i ndi vi dual sampl e poi nt s. An i ni t i al
cal i brat i on can use fewer sampl es as l ong as t he
number of t erms i s l i mi t ed. The fol l owi ng t abl e
shows t he maxi mum number of t erms t hat are
permi t t ed for use i n a cal i brat i on equat i on based on
t he number of sampl e poi nt s i n t he dat a set :

Number of
Samples
Maximum Number of Equation Terms Allowed
Initial Calibration Final Calibration
5 1 -
10 2 1
15 3 2
20 3 3
30 4 4



Note:
In general you shoul d not need t o use more t han 4
i ndependent t erms i n a cal i brat i on equat i on.

5. If t he pl ot of t he resul t s of t he best regressi on
equat i on shows t hat t here are a smal l number of
sampl e poi nt s whi ch do not fi t t he cal i brat i on as
wel l as t he maj ori t y of ot her poi nt s (see Fi gure
6-1), you may want t o del et e t hem from t he dat a set
and re-run t he regressi on. Thi s wi l l normal l y
i mprove t he cal i brat i on equat i on and may even gi ve
a bet t er equat i on wi t h fewer t erms. Somet i mes, one
or t wo poi nt s are so far from t he ot her poi nt s t hat
t here i s l i kel y t o be an error i n t he dat a ent ered i nt o
t he fi l e and i t and shoul d be checked.
6. Before del et i ng each poi nt , fi rst check t hat al l of
t he dat a for t hi s poi nt has been ent ered i nt o t he dat a
fi l e correct l y. If i t i s correct , t hen i nvest i gat e
furt her t o fi nd t he cause of t he probl em. For
exampl e, you may want t o have a coupl e of t he
sampl es i ncl udi ng t hi s one re-assayed. It i s best i f
you can correct t he dat a i n t hi s manner. Aft er
t ryi ng unsuccessful l y t o correct t he dat a, you may
t hen del et e t he poi nt (s).
7. St at i st i cal l y, you may onl y del et e up t o 10% of t he
t ot al number of sampl e poi nt s. If more t han 10%
need del et i ng t o make t he regressi on accept abl e,
t here coul d be a probl em wi t h ei t her t he sampl i ng
met hod or anal yt i cal (chemi cal ) accuracy.
El i mi nat e al l errors of t hi s t ype before proceedi ng
wi t h t he cal i brat i on. Thi s i s very i mport ant t o
ensure t hat t he anal yser i s cal i brat ed wi t h t he best
possi bl e accuracy.
8. Look for a 10% rel at i ve i mprovement i n RMS Error
before deci di ng t o remove one more sampl e poi nt ,
or t o use an equat i on wi t h one more t erm.
9. Ensure t hat St at i st i cal Error i s l ess t han hal f t he
RMS Error.
10. In summary, l ook for:
- l ow RMS Error
- l ow St at s Error (
1
/
2
RMS or l ess)
- Hi gh Correl at i on Coeffi ci ent (>0. 9)
- Fewer t erms (must i ncl ude fundament al )
- Posi t i ve fundament al t erm (except %sol i ds where
fundament al t erm i s negat i ve)


- Look for a 10% rel at i ve i mprovement i n RMS
Error before deci di ng t o remove one more sampl e
poi nt , or t o use an equat ion wi t h one more t erm.
Calibration Checking the Calibration Accuracy


6.7 Checking the Calibration Accuracy
Aft er t he syst em has been cal i brat ed, i t shoul d be checked
peri odi cal l y t o ensure t hat t he cal i brat i ons are produci ng
t he correct resul t s part i cul arl y si nce i ni t i al cal i brat i on
equat i ons are onl y as effect i ve as t he range of ore t ypes
and operat i ng condi t i ons encount ered duri ng t he i ni t i al
cal i brat i on. Thi s wi l l requi re t he bui l di ng-up of dat a from
cal i brat i on sampl es t o cover as ful l a range as possi bl e.
Based on t he resul t s of t he checki ng, i t may be necessary
t o up-dat e t he cal i brat i on (assay equat i on) and t he
procedure gi ven here for checki ng t he cal i brat i on accuracy
shoul d be fol l owed.

Once or t wi ce per week t he on-l i ne assays from t he
anal yser shoul d be compared wi t h assays from t he
l aborat ory t o ensure t hat i t i s gi vi ng t he correct resul t s. It
shoul d be not ed t hat i t i s best t o t ake a cal i brat i on sampl e
as a compari son sampl e over a 5-mi nut e i nt erval i nst ead of
usi ng shi ft composi t es or 2 hourl y grab sampl es. There are
several reasons for t hi s:
1. Shi ft composi t e sampl es average out t he normal
fl uct uat i ons i n t he performance of t he pl ant so t hey
onl y gi ve a fai rl y superfi ci al compari son. The MSA
anal ysi s t anks operat es l argel y i ndependent of fl ow
rat e whereas a shi ft sampl e wi l l be affect ed by fl ow
rat e fl uct uat i ons.
2. Somet i mes t he shi ft composi t e sampl e i s not a t rue
average of t he performance of t he pl ant over t he shi ft .
Thi s can occur i f t here i s a maj or di st urbance i n t he
operat i on i n t he pl ant bet ween t i mes when sub-
sampl es of t he composi t e were t aken.
3. A sampl e t aken over t he measurement peri od from t he
st ream bei ng anal ysed corresponds exact l y wi t h t he
sl urry whi ch t he probe was measuri ng over t he same
t i me peri od.
If you wi sh t o use pl ant shi ft sampl es for t he compari son,
more care shoul d be t aken i n i nt erpret i ng t he compari son
bet ween t he shi ft resul t s and t he correspondi ng resul t s
from t he on-l i ne anal yser such as compari ng %sol i ds, and
moni t ori ng fl ow rat e fl uct uat i ons t hroughout t he shi ft . If
t he anal yser i s consi st ent l y di spl ayi ng assays t hat are
si gni fi cant l y di fferent (out side t he st at i st i cal normal
di st ri but i on, see sect i on 6. 8) t o t he shi ft sampl es t hen
ext ra cal i brat i on sampl es shoul d be t aken and new
equat i ons generat ed t o fi ne-t une t he cal i brat i ons.

Addi t i onal sampl es are t aken and assayed exact l y as per
t he procedures gi ven earl i er i n sect i ons 6. 3 and 6. 4.
Comparing Check Samples with On-line Assays Calibration


6.8 Comparing Check Samples with On-line Assays
The most useful met hod i s as fol l ows:
1. At t he comput er not e t he correspondi ng on-l i ne assays
for each sampl e from t he each anal yser, at t he (fi ni sh)
t i me t he sampl e was t aken. Thi s can be done by
checki ng t he t abul ar assays screen, or usi ng t he
Assay. DBF fi l e l ocat ed i n t he same fol der as t he
Cal i brat i on Dat a. DBF fi l e. Thi s opt i on must be
sel ect ed ei t her duri ng i nst al l at i on of t he Wi nISA
Del phi Cl i ent or set up i n t he Wi nISA Del phi Cl i ent
Opt i ons menu.
2. Record t he l aborat ory and on-l i ne assays and t hei r
di fference.
3. Repeat st eps 1 and 2 unt i l at l east 20 sampl es have
been t aken, and whi l st runni ng t he same cal i brat i on
equat i ons for t he st ream bei ng checked (ot herwi se
your ISA readi ng may vary t oo much).
4. Pl ot t he di fference bet ween t he t wo assays, for each
sampl e as you obt ai n t he dat a, on a graph versus t i me
(see exampl e graphs bel ow). Thi s graph shoul d
cont ai n t he resul t s for al l of t he previ ous sampl es and
so you wi l l bui l d up a graph t hat i ndi cat es t he
performance of t he on-l i ne anal yser over a l ong peri od
of t i me.
5. The pl ot of t he di fference shoul d show a smal l scat t er
about zero such t hat around 67% of your check
sampl es shoul d fal l wi t hi n 1RMS and around 95%
wi t hi n 2RMS as per a st at i st i cal normal di st ri but i on
(see normal di st ri but i on curve). The scat t er for t he
sampl es t aken shoul d be about t he same si ze as t he
RMS error from t he i ni t i al cal i brat i on (see St ream 1
dat a i n Fi gure 6-2). In t hi s case, t he cal i brat i on i s
good and t he anal yser i s operat i ng correct l y.
Devi at i ons from t he i deal graph descri bed above
i ndi cat e a probl em and a descri pt i on of vari ous
sympt oms and remedi es i s gi ven wi t h each graph (see
St ream 2 & 3 dat a i n Fi gure 6-2).

Note:
The error i n t he anal yser assay val ue i s al ways The
Tot al Cal i brat i on Error. A check sampl e t hat i s
anal ysed i n t he l aborat ory has an error The Tot al Lab
Error. Hence, t he di fference bet ween t he t wo assay
readi ngs t hen has a t ot al error of (Tot al Cal i brat i on
Error + Tot al Laborat ory error). In a wel l mai nt ai ned
syst em, t hi s condi t i on i s t rue for 67% of t he sui t e of
check sampl es t aken. 95% wi l l be wi t hi n a mul t i pl e of
2 t i mes t hi s t ot al error. If t he check sampl e i s added t o


t he cal i brat i on, t he t ot al error i s t hen i ncl usi ve of l ab
error.

Calibration Comparing Check Samples with On-line Assays


Stream 1:
An occasional point a long way from
zero, with most points (at least 68%)
within 1RMS. This indicates that the
analyser is working okay but occasionally
something unusual happens that gives
a sample assay difference that is much
larger than usual. Check that the probe
window is clean each time a sample is
taken and that sample collecting,
preparation and analysis is consistent.
Also check that the water sprays are
either consistently off or on depending
on the requirement at the time of calibration,
and that the stirrer is operating correctly.

Stream 2:
Most samples were initially within
1RMS which indicated that the analyser
was working okay but then after a
period of time there is a definite drift away
from the normal operating range.
1) This may indicate that the probe source
has decayed significantly and that source
decay has been removed from the software.
Check software configuration, re-measure
the standard count-rate and up-date files.
A decrease in probe detector efficiency
could also cause this effect and standardising
will overcome this. Also check that the probe
set up parameters (eg. bias, SCAs, gain, etc).
2) Change in one type (i.e. mineralogy or
blending). 3) Stirrer impellor wear.
4) Dirty MEP primary window.

Stream 3:
Most samples were initially within 1RMS
which indicated that the analysis system
was working okay but then after a period
of time there is a definite scattering of the
samples which indicates that there is a
problem with the analysis system. Check
the probe window (for cleanliness) probe
set up, measure the probe resolution, check
the probe spectrum and perform a stability
test over at least 24 hrs. If any of these
checks is abnormal then follow the
procedures given in this manual to locate.
and fix the problem.
Fi gur e 6- 2 Exampl e pl ot s of t he di f f er ence bet ween on-l i ne
and l abor at or y assays
Stream 1 Check Samples
-4
-3
-2
-1
0
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2
3
4
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
Time
D
i
f
f
e
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e
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c
e

(
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M
S
)

-4
-3
-2
-1
0
1
2
3
4
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
Time
D
i
f
f
e
r
e
n
c
e

(
R
M
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)

-5
-4
-3
-2
-1
0
1
2
3
4
5
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
Time
D
i
f
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e
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e

(
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)



An al t ernat i ve met hod i s t o cal cul at e t he RMS Devi at i on
on t he sui t e of check sampl es t hat you have t aken and re-
cal cul at e t hi s each t i me a new check sampl e i s added. To
use t hi s met hod you wi l l need t o t ake at l east 20 check
sampl es.

The RMS devi at i on t hat you cal cul at e on your check
sampl es shoul d be cl ose t o t hat obt ai ned for t he
cal i brat i on, whi ch i s t he assay equat i on t hat i s bei ng used
at t he t i me of t aki ng t he check sampl es. If not t hen t here
is a problem wi t h t he operat ion of t he anal yser and some
furt her checks need t o be done as per t he remedi es gi ven
wi t h t he graphs above.


7
Operation

Thi s sect i on i s wri t t en for t hose personnel who wi l l
oversee t he dai l y operat i on of t he equi pment . It i ncl udes a
descri pt i on of t he component s of t he syst em and more
part i cul arl y t he purpose of t he el ect roni c cards and
modul es.

Thi s sect i on may be used i n conj unct i on wi t h sect i on 5,
Commi ssi oni ng and sect i on 6, Cal i brat i on as most of t he
procedures requi red t o keep t he on-l i ne anal yser operat i ng
effi ci ent l y and rel i abl y are gi ven i n t hose sect i ons.

The on-l i ne sampl i ng and anal ysi s equi pment provi des
measurement of mi neral sl urry for t he det ermi nat i on of
el ement al assays and percent sol i ds.

The anal yser uses a sol i d-st at e Mul t i -El ement Probe
(MEP) t hat can measure up t o ei ght el ement s and percent
sol i ds si mul t aneousl y. The Mul t i pl exi ng part of t he
anal yser enabl es j ust one probe (MEP) t o be used t o cost -
effect i vel y measure more t han one st ream.

The i n-bui l t sampl i ng syst em provi des for represent at i ve
sampl i ng of t he sl urry for anal ysi s as wel l as met al l urgi cal
account i ng sampl es.

The syst em component s are descri bed i n det ai l al ong wi t h
a descri pt i on of funct i on and purpose of each el ect roni cs
modul e and card.

Safety & Environmental Protection Operation


7.1 Safety & Environmental Protection
7.1.1 Safety Mode
In t he event t hat any operat i ng condi t i ons are abnormal
(eg. power, probe wi ndow rupt ure, et c. ) t he probe wi l l be
aut omat i cal l y l i ft ed from t he sl urry by i t s pneumat i c hoi st
t o prevent possi bl e damage t o t he probes det ect or i f a
wi ndow rupt ure occurs. The probe can not be l owered
unt i l such t i me as t he probl em i s rect i fi ed. The MSA uni t
wi l l al so aut omat i cal l y change t o Manual Mode,
prevent i ng i t from movi ng up, down or l at eral l y. Safet y
sensi ng ci rcui t s mean t hat t he probl em must be fi xed
before t he MSA can be put back i nt o aut omat i c operat i on
(i . e. Aut oMode).

Note:
There are t wo t ypes of manual mode:
1) man where anot her event such as WR, ai r fai l or
EMst op occurs. When t he event i s cl eared or repai red,
t he MSA wi l l ret urn t o Aut o Mode.
2) Man where manual mode i s sel ect ed at t he OI. To
ret urn t he MSA t o Aut o Mode i t must be sel ect ed at
t he OI.

A "Mai ns Isol at or" swi t ch i s provi ded on t he MSA uni t
(see phot o l eft ).

An Emergency St op l at chi ng press but t on i s l ocat ed on
t he MSA (see phot o l eft ). Pressi ng and t urni ng t hi s but t on
i nt o i t s l ock posi t i on freezes al l operat i on of t he MSA
uni t , i ncl udi ng st i rrers and sampl ers. The probe wi l l al so
freeze i n what ever posi t i on i t was when t he St op but t on
was pressed, i . e. i t IS NOT homed t o t he rai sed posi t i on.
The MSA uni t cont rol wi l l al so revert t o manual mode
and so operat i on cannot resume unt i l t he St op but t on i s
rel eased.

St i rrer Overl oad Ci rcui t s are provi ded for each st i rrer
mot or i nsi de t he mai n MSA Cont rol l er (see phot o l eft ). If
a st i rrer overl oads and "t ri ps-out " t hen i t must be reset
manual l y. The MSA RLC wi l l recogni se t hi s st at e and
prevent t he probe from measuri ng t hi s st ream (zone) unt i l
t he probl em i s fi xed. Thi s condi t i on i s one of a range of
abnormal operat i ng condi t i ons (MSA st at us' ) whi ch may be
encount ered (see sect i on on MSA st at us and error
messages).
Operation Safety & Environmental Protection


Ai r Pressure Fai l ure. The RLC al so moni t ors t he st at us of
t he ai r pressure and i n t he event t hat t he ai r pressure fai l s
or fl uct uat es si gni fi cant l y (t o bel ow about 400 kPa,
dependi ng on t he set t i ng of t he pressure swi t ch) t he
anal ysi s probe wi l l be aut omat i cal l y l i ft ed from t he sl urry
and a warni ng wi l l be di spl ayed at t he comput er t o i nform
t he operat ors t hat t here i s a probl em. An ai r fai l ure
message wi l l al so be di spl ayed on t he OI panel and t he
MSA wi l l revert t o manual mode.

When ai r pressure i s rest ored and t he next move command
i s sent t hen (i n "Aut oMode") t he MSA wi l l resume normal
operat i on.

Probe Wi ndow Rupt ure. The probe wi ndow st at us i s al so
moni t ored by t he RLC and report ed as ei t her "Wi ndow
OK" or Wi ndow Rupt ure" at t he OI panel . Whi l st
operat i ng i n "Aut oMode" a "Wi ndow Rupt ure" al arm
message wi l l al so be di spl ayed at t he comput er i f a
wi ndow rupt ure i s det ect ed. If a wi ndow rupt ure i s
det ect ed t he probe wi l l be aut omat i cal l y rai sed from t he
sl urry and cont rol wi l l revert t o manual mode. The MSA
wi l l not resume operat i on unt i l such t i me as t he probl em i s
fi xed.

Safet y Guards, wi t h an Int erl ocked Gat e (see phot o l eft ),
are provi ded on t he MSA frame t o prevent i nj ury from t he
movi ng probe. When t he i nt erl ocked gat e i s opened, t he
probe i s rai sed and i t s movement st opped. The MSA
revert s t o manual mode and wi l l not ret urn i nt o
Aut oMode (operat i onal ) unt i l t he gat e i s cl osed. When
t he i nt erl ocked gat e i s opened, t he st i rrers can cont i nue
worki ng t o prevent t he anal ysi s t anks from sandi ng up by
pressi ng t he St i rrer Overri de but t on (shown i n t he phot o
l eft ). When t he gat e i s open a message Gd Open wi l l be
di spl ayed on t he OI panel st at us di spl ay.

7.1.2 Radiation Shielding
The MEP cont ai ni ng t he radi oi sot ope onl y emi t s radi at i on
i n a forward di rect i on from t he probe head when t he
st andard bi scui t has been removed and t he i sot ope i s
exposed. Under normal operat i on (i mmersed i n t he
anal ysi s t ank) t he sl urry and t ank act as a shi el d t hus
shi el di ng any radi at i on from t he probe when t he probe i s
movi ng up, down or l at eral l y, shi el di ng i s provi ded by t he
bui l t -i n met al pl at e and sampl ers. Furt her det ai l s on
radi at i on are provi ded i n chapt er 1, Warni ngs and
Caut i ons.


7.1.3 Environmental Protection
By i t s nat ure most of t he mechani cal part s of t he anal yser
syst em have t o operat e under t he normal l y arduous
envi ronment al condi t i ons t hat prevai l i n a mi neral
processi ng pl ant . The Thermo El ect ron desi gn mi ni mi ses
t he number of movi ng part s t hus exposed and speci fi es
l arge safet y margi ns and wear l i fet i mes on t hose t hat are.
El ect ri cal and el ect roni c cont rol equi pment i s envi ronment
prot ect ed t o AS1939-1990 cl ass IP66. Mat eri al s
Speci f i cat i ons are gi ven i n chapt er 3.

7.1.4 Starting and Stopping
Except i n an emergency, t he MSA shoul d onl y be st opped
and st art ed from t he OI panel at t he uni t i t sel f by sel ect i ng
t he Manual and aut omat i c operat i ng mode. In manual
mode t he MSA uni t WILL NOT respond t o any move
commands from t he ISA comput er. The probe wi l l
however be rai sed from t he sl urry i n t he event of a wi ndow
rupt ure. To re-st art t he MSA uni t t he aut omat i c
operat i ng mode must be sel ect ed at t he OI.

The MSA operat i on can al so be st opped by openi ng t he
i nt erl ocked gat e. The mai ns power can be l ocked out at
t he Mai ns Isol at or swi t ch on t he front panel of t he mai n
MSA cont rol l er (see phot o l eft ).

On poweri ng-up t he MSA, t he MEP wi l l aut omat i cal l y
move t hrough a Posi t i on Test . Thi s aut omat i c procedure
sel f-t est s t hat t he MSA posi t i on sensi ng component s
(proxi mi t y sensors, l i mi t swi t ches), probe movement ,
mot or st at us, et c. , are worki ng. If a fai l ure i s det ect ed an
error message wi l l be di spl ayed on t he OI panel st at us l i ne
menu (see next sect i on and chapt er 9, Troubl e Shoot i ng).

MSA St at us. On power-up t he OI panel wi ll al ways
di spl ay t he st at us of vari ous component s of t he MSA uni t
whi ch are under t he cont rol of t he RLC (eg. st i rrers, probe,
ai r, l i mi t and proxi mi t y swi t ches, et c). The RLC wi l l al so
det ect any such component fai l ure or abnormal i t y duri ng
normal operat i on of t he MSA uni t and report i t t o t he
comput er as wel l as di spl ay i t i n t he st at us message l i ne
on t he OI panel (see phot o l eft ).

If t he MSA does not go i nt o a Posi t i on Test when
powered up t hen t he RLC may have l ost i t s fi rmware
confi gurat i on, i n whi ch case you wi l l need t o fol l ow t hese
st eps;
Operation Safety & Environmental Protection


1. Re-ent er t he RLC Zone Mask (<ZoneMask>) for your
MSA (t hi s i s provi ded on i nst al l at i on by t he Company
or i t can be found i n t he sect i on coveri ng t he OI RLC
menus) i n chapt er 7, Operat i on.
2. If you have met al l urgi cal sampl ers t hen you wi l l al so
need t o ent er t he RLC maski ng for t hese by sel ect i ng
t he menu opt i on (<SMPMask>).
3. Re-ent er t he avai l abl e zones, i . e. t he zones, 1 t o 12 t hat
you want t o measure (<ZneAvai l >, see OI RLC menu
sect i on) i n chapt er 7, Operat i on.
4. Check t he (Servi ce Bay) has been correct l y set , usual l y
t hi s i s t he l ast zone. If you prefer a di fferent zone,
ent er i t here.
5. If you want t he MSA t o resume normal operat i on
aut omat i cal l y aft er a power fai l ure, check now t hat
<Aut oSt art > has been set t o YES.
6. Sel ect <Aut omode>, t he MSA shoul d t hen perform a
Posi t i on Test , i f not t urn off t hen on t he MSA power.
If a Posi t i on Test i s st i l l not possi bl e, t hen check t he
OI panel di spl ay for any error messages. If an error
message i s di spl ayed t hat i ndi cat es t here i s i nformat i on
bei ng down-l oaded t hen t hi s means t he RLC i s
obt ai ni ng i t s embedded code (Appl i cat i on code) from
t he ISA comput er, of course t hi s cant happen i f t he
comput er i s down, or t he dat a l i ne bet ween t he MSA
and comput er (or convert er uni t ) i s faul t y, i n whi ch
case t he RLC wi l l t ry i ndefi ni t el y t o obt ai n t he
Appl i cat i on code i t requi res so check t he ISA comput er
and dat a comms (AIN).

Note:
When appl i cat i on code i s bei ng downl oaded from t he
comput er t he TXEN, RXD and TXD LEDs wi l l fl ash on
t he AM955 convert er uni t (see fi gure 5-6). Al so t he LEDs
on t he AM092 card i n t he si gnal anal yser and on t he
AM777 cont rol l er wi l l fl ash at t he same t i me as t he
AM955 uni t (see Fi gure 5-2 for det ai l s of t he AM092 card
and Fi gure 5-3, modul e A3, for t he l ocat i on of t he
AM777).



7.1.5 Sampler Control
A sampl er sel ect or swi t ch i s avai l abl e for each
Met al l urgi cal Sampl er fi t t ed on t he MSA. These swi t ches
are l ocat ed near t he sampl er cover i t sel f (see phot o l eft ).

7.1.6 Power Failures
On a power fai l ure, t he MSA probe wi l l be rai sed from t he
anal ysi s t ank t hat i t was measuri ng at t he t i me of fai l ure.

On resumpt i on of power, t he MSA uni t wi l l cont i nue
operat i on accordi ng t o t he ISA comput er sequence,
provi ded t he <Aut oSt rt > opt i on at t he OI panel has been
set t o "yes. If t hi s opt i on was set t o "no" t hen t he MSA
uni t wi l l revert t o "manual mode" and t hus not cont i nue i t s
normal operat i on unt i l i t i s reset t o "Aut oMode" at t he OI
panel and t he next "move" command i s recei ved from t he
ISA comput er.

If t he ISA comput er fai l s, whet her i t be a power fai l ure or
shut down of t he server soft ware, t he MSA uni t wi l l st op
operat i ng, and t he probe wi l l hol d i t s current posi t i on
(usual l y down i n t he l ast zone measured). The MSA wi l l
remai n i n Aut omode awai t i ng furt her i nst ruct i on. The
MSA wi l l onl y cont i nue aut omat i c (normal ) operat i on upon
resumpt i on of t he comput er power and server soft ware
program. The cont rol l i ng server soft ware wi l l
aut omat i cal l y re-st art aft er power resumpt i on i f set up at
t he comput er t o st art up on boot as a servi ce.

Operation Multi-Stream Analyser (MSA)


7.2 Multi-Stream Analyser (MSA)
7.2.1 Basic Operation
MEP
The MSA ut i l i ses t he Mul t i -El ement Probe (MEP) for
measuri ng up t o t wel ve (12) st reams on a t i me-shari ng
basi s usi ng a separat e anal ysi s t ank for each st ream t o be
measured (refer t o sect i on 7. 2. 2).

Probe Washi ng
A probe wat er spray i s bui l t -i n t o wash t he probe bet ween
measurement s so t hat st ream cross-cont ami nat i on doesn' t
occur. Thi s wat er spray can be st art ed and st opped by
sel ect i ng t he OI menu opt i on, <PrbSpray>. However, t hi s
spray must al ways be on duri ng normal operat i on of t he
MSA uni t .

Probe Movement
Probe (MEP) movement i s cont rol l ed by t he i n-bui l t RLC,
however t he comput er cont rol l ing soft ware i s confi gured
wi t h t he st ream measurement t i me, sequence and
frequency. Movement of t he probe i s act uat ed by a "move"
command recei ved from t he comput er, provi ded t he MSA
i s i n "Aut oMode" of operat i on. If t he MSA i s i n "manual
mode" t hen movement of t he probe can onl y be done by
manual l y sel ect i ng appropri at e menu opt i ons from t he
Operat or Int erface (OI) panel . The MSA uni t can onl y
resume i t s confi gured movement pat t ern when set t o t he
"Aut oMode".

AutoMode: In t hi s remot e cont rol mode, t he probe
wi l l move accordi ng t o i nst ruct i ons from t he comput er.
i . e. , t he comput er i s confi gured wi t h t he measurement
t i me (i n i nt egral seconds) for each st ream and t he
sequence i n whi ch t he st reams are t o be anal ysed. The
MSA soft ware i s confi gured duri ng commi ssi oni ng of
t he MSA on-si t e. The "Aut oMode" of operat i on i s
sel ect abl e from t he OI panel on t he MSA uni t . For
safet y reasons, swi t chi ng i nt o aut omat i c from manual at
t he remot e comput er i s di sal l owed.
Multi-Stream Analyser (MSA) Operation


Manual Mode: In "manual mode" t he comput er cont rol
i s overri dden and cont rol of t he probe movement i s
sol el y from t he OI panel on t he MSA i t sel f i . e. l ocal
cont rol . In t hi s mode t he probe wi l l not move unt i l
t ol d t o do so from t he OI panel . To move t he probe up
or down or an arbi t rary di st ance l eft or ri ght , use t he
<Move Probe> menu opt i on on t he OI. Not e t hat t hi s
wi l l not al l ow you t o l ower t he probe unl ess i t i s
posi t i oned over a t ank or i n t he servi ce bay (where
fi t t ed). To move t he probe t o a speci fi c zone, choose
Sel Zone and ent er t he zone number. A l i st of t he OI
menu opt i ons i s provi ded i n a l at er sect i on i n t hi s
chapt er.

There are t wo t ypes of manual mode;

1. man made wi t h a l ower case m where anot her
act i on such as Wi ndow Rupt ure, Ai r Pressure
Fai l ure, Emergency St op or Guard Open have
occurred. The RLC revert s from Aut o mode t o
man mode when t he faul t / condi t i on occurs, and
aut omat i cal l y ret urns t o Aut o mode when t he
faul t / condi t i on cl ears. Sel ect i ng Aut o mode at t he
OI wi l l not ret urn t he MSA t o Aut o mode unt i l t he
faul t / condi t i on cl ears.

2. Man mode wi t h an uppercase M where t he user
has sel ect ed Manual Mode at t he Operat or Int erface.

The MSA wi l l remai n i n Manual mode regardl ess of
power bei ng t urned off and on, or any faul t or ot her
condi t i on cl eari ng. It wi l l onl y ret urn t o Aut o
mode i f sel ect ed at t he OI, and i f t here are no ot her
faul t s or condi t i ons t hat mi ght cause t he MSA t o be
i n manual mode.


Park Probe: When fi rst i nst al l i ng t he MSA, a probe
"park" posi t i on (servi ce bay) shoul d be al l ocat ed t o t he
MSA i f a separat e mai nt enance bay i s not at t ached.
Thi s means t he MSA uni t i s confi gured so t hat when t he
Park Probe but t on (see phot o l eft ) i s pressed t he
probe wi l l be aut omat i cal l y rai sed from t he sl urry (i f i t
was measuri ng at t he t i me) and moved t o t he zone t hat
was al l ocat ed as t he servi ce bay. If a mai nt enance bay
i s i ncl uded wi t h t he MSA uni t t hen t he probe wi l l
aut omat i cal l y move i nt o t hi s bay when t he Park Probe
but t on i s pressed. If i t doesn' t t hen you may have t o
t el l i t t hat a mai nt enance bay i s at t ached by al l ocat i ng
t he "park" posi t i on (zone) as t hi s bay. To al l ocat e a
"park" zone (servi ce bay) t he operat or must sel ect t he
<ServcBay> menu opt i on at t he OI panel t hen ent er t he
zone number (eg "6"). Parki ng t he probe i s general l y
used when mai nt enance on t he probe i s requi red. Thi s
may i ncl ude LN
2
fi l l i ng, wi ndow changi ng, et c.

Whenever t he probe i s parked, t he MSA cont rol wi l l
al ways revert t o "manual mode" and t herefore, t he probe
wi l l not move under i nst ruct i ons from t he comput er unt i l
such t i me t he Park Probe but t on i s rel eased. If t he
cont rol does not aut omat i cal l y revert t o t he comput er
(aut omat i c mode) t hen re-sel ect t he "Aut oMode" at t he OI
panel agai n.

Rai se Probe: An addi t i onal Rai se but t on (see phot o
t op l eft ) i s provi ded t o al l ow t he operat or t o rai se t he
probe from t he sl urry aft er parki ng. The probe can t hen
be washed off easi l y and mai nt enance performed,
i ncl udi ng changi ng t he wi ndow assembl y.

Anal ysi s Tanks
Each st ream t o be measured by t he MSA i s di rect ed
t hrough i t s own anal ysi s t ank (zone). St andard MSA
anal ysi s t anks are desi gned t o t ake no more t han 15 m
3
/ hr
sl urry fl ow ei t her as a ful l -fl ow st ream or a sampl ed
st ream. Somet i mes t hese t anks wi l l not t ake t he speci fi ed
maxi mum fl ow i f t here i s excessi ve frot hi ng such as i s t he
case wi t h concent rat e st reams. It i s i mport ant t hat t he
sl urry fl ow-rat es are mai nt ai ned at t he t ank desi gn l evel s
t hroughout t he operat i ng l i fe of t he MSA as si gni fi cant
changes i n t he sl urry present at i on t o t he probe may resul t
i n t he cal i brat i ons becomi ng unrel i abl e, t hus provi di ng
i ncorrect on-l i ne assays. It i s part i cul arl y i mport ant t hat
any pri mary (and secondary) sampl i ng equi pment used t o
provi de t he sampl ed fl ows t o t he anal ysi s t anks be
mai nt ai ned.


Each anal ysi s t ank cont ai ns a st i rrer for whi ch an
i ndependent on/ off i sol at or swi t ch i s provi ded on t he
cont rol l er si de of t he MSA frame (see phot o l eft ). It i s
i mport ant , whi l st sl urry i s fl owi ng, t hat t hese st i rrers are
kept operat i ng ot herwi se t he anal ysi s t ank may sand up. A
fai l ure of a st i rrer wi l l be regi st ered by t he RLC, an error
wi l l resul t and t he probe wi l l not vi si t t hat zone agai n
unt i l t he probl em i s fi xed.

A wat er spray i s al so i ncl uded i n each t ank of t he MSA
uni t . They are manual l y operat ed (on/ off) by a needl e
val ve (one per spray) l ocat ed on t he rear of t he MSA frame
(see phot o l eft ). A mai n wat er i sol at i on val ve i s al so
l ocat ed here whi ch wi l l shut off al l wat er suppl y t o t he
MSA uni t . The purpose of t ank wat er spray i s t o break
down excessi ve frot h, part i cul arl y i n concent rat e st reams.
It i s i mport ant t hat a wat er spray i s kept operat i onal i f t hat
anal ysi s t anks spray was used duri ng cal i brat i on of t hat
st ream.

Metal l urgi cal Sampl ers
Met al l urgi cal Sampl ers, i f fi t t ed t o t he out l et si de of t he
anal ysi s t ank (see phot o l eft ), have bot h aut omat i c cont rol
(confi gured at t he OI panel ) for t he purpose of t aki ng shi ft
composi t e sampl es and cal i brat i on sampl es, or l ocal
manual cont rol (operat or cont rol l ed) for t aki ng spot
sampl es (t hi s i s vi a t he sampl er i sol at or swi t ch mount ed
near each sampl er, see phot o l eft ).

gi ven sampl i ng peri od (t hi s i s confi gured i n t he comput er
soft ware). By sel ect i ng t he <Smp-Mode> OI menu opt i on,
t he user can sel ect one of t he four sampl er operat i ng
modes; "manual ", "cal i brat i on", "st andard shi ft " or
"random shi ft ". The user shoul d al so refer t o t he l at er
sect i on on usi ng t he OI panel .

Manual Cut: The user can sel ect <Cut >at t he sampl er
swi t ch t o act ual l y t ake a sampl e and so can be used t o
t ake a met al l urgi cal spot sampl e from any one of t he
MSA st reams (zones), even i f t he probe i sn' t measuri ng
t hat st ream.


Cal i brati on Mode: In "cal i brat i on" mode a sampl e
wi l l aut omat i cal l y be t aken from t he next st ream (zone)
whi ch i s sel ect ed from t he OI panel and t he
correspondi ng probe count -rat es wi l l t hen be st ored
aut omat i cal l y i n t hat st reams Cal i brat i onDat a. dbf fi l e
at t he comput er. The number of sampl e cut s t aken
whi l st t he probe i s i n t he zone depends on t he "number
of cut s per sampl e" defi ned i n t he comput er soft ware
confi gurat i on and t hi s i s t urn wi l l depend on t he
measurement t i me peri od. Thi s onl y appl i es i f t he MSA
uni t i s i n i t sel f operat i ng i n "Aut oMode".

Shi ft Mode: There are t wo furt her modes for shi ft
sampl es; one i s t he "st andard shi ft " mode whi ch
provi des t he operat or wi t h a composi t e shi ft sampl e t hat
i s col l ect ed over a pl ant shi ft (confi gured i n t he
comput er soft ware) wi t h sampl e cut s bei ng t aken at
regul ar t i me i nt erval s pre-set by sel ect i ng <Smp-Ti me>
at t he OI (t hi s sampl e cut i nt erval need onl y be set
once).

Random Shi ft mode provi des shi ft sampl es composed
of sampl es whi ch are cut randoml y wi t hi n a pre-set
t i me i nt erval . The user i s prompt ed t o pre-set a
mi ni mum t i me requi red bet ween such sampl es so as t o
avoi d t he possi bi l i t y of t wo sampl es bei ng t aken very
cl ose t oget her.

7.2.2 Operation of the MEP
The MEP uses a l ow-energy radi oi sot ope X-ray source and
a Si (Li ) sol i d-st at e X-ray det ect or whose hi gh sel ect i vi t y
and sensi t i vi t y enabl es t he measurement of very l ow
concent rat i ons of el ement s, such as t hose encount ered i n
copper t ai l i ngs st reams. The probe i s capabl e of
measuri ng el ement s down t o cal ci um i n t he t abl e of at omi c
el ement s and can measure up t o ei ght el ement s and
sol ut i on densi t y si mul t aneousl y.


The MEP uses t he radi oi sot ope source t o exci t e fl uorescent
X-rays from el ement s i n a mi neral sl urry or sol ut i on
(det ai l s of t he radi oi sot ope used i n your probe are st amped
on t he radi at i on l abel on t he probe and are al so gi ven i n
t he Dat a Sheet s provi ded i n At t achment 2 i n chapt er 5).
Each el ement i n t he sampl e emi t s fl uorescent X-rays of an
energy and i nt ensi t y whi ch i s charact eri st i c of t hat el ement
and i t s concent rat i on. The fl uorescent and back-scat t ered
X-rays from t he sol ut i ons i mpi nge on t he det ect or t o
produce smal l el ect ri cal pul ses t hat are ampl i fi ed and
t ransmi t t ed t o t he Si gnal Anal yser el ect roni cs uni t for
processi ng. The vol t age of t he el ect ri cal pul se i s
proport i onal t o t he energy of t he i nci dent X-ray. The
number of X-rays i s proport i onal t o t he el ement al
concent rat i ons i n sl urry. The scat t ered X-rays are used t o
provi de measurement s of t he densi t y. Fl uorescent X-ray
energi es for t he most commonl y anal ysed el ement s are
gi ven i n chapt er 5, Commi ssi oni ng. The X-ray energy
spect rums for t he MEP(s) i nst al l ed i n your pl ant are
provi ded i n At t achment 2 i n chapt er 5, Commi ssi oni ng.

Note:
Radioi sotope sources used i n t he probes have a
recommended working li fe (RWL). Usual l y t his i s bet ween
5 and 15 years. The RWL DOES NOT i mpl y t hat t he
isotope cannot be used aft er that peri od. It means t hat t he
local radiat i on authorit y may requi re a wipe t est on t he
source aft er t hat peri od t o check t he sources i nt egri t y so
that i t can cont i nue to be used for i ts appli cati on. Check
wi th your Radiat i on Safet y Offi cer (RSO) or local
radi at ion aut hori t y.



7.2.3 Liquid Nitrogen Requirement of the MEP
The MEP det ect or needs a cont i nuous suppl y of l i qui d
ni t rogen LN
2
(t o keep i t bel ow 100 Kel vi n whi l e i t i s
operat i ng). Refer t o sect i on 2. 8. 3 and Rout i ne
Mai nt enance sect i on 8. 1. 2 for LN
2
fi l l i ng requi rement s.
Thi s l ow t emperat ure i s requi red t o reduce t he t hermal
energy of t he el ect rons i n t he det ect or and FET so t hat
t hei r cont ri but i on t o t he el ect roni c noi se of t he syst em i s
mi ni mal .

Warni ng:
If t he bi as vol t age i s appl i ed t o a det ect or t hat i s not
suffi ci ent l y cool ed, i t may be seri ousl y damaged.
Never use any ot her form of cool i ng ot her t han LN
2
.

There are devi ces i n t he probe whi ch offer some prot ect i on
agai nst warmi ng up; a l i qui d ni t rogen sensor i n t he
dewar whi ch det ect s when t he l evel decreases t o l ess t han
about one l i t re and a resi st ance t hermal sensor (RTD)
whi ch moni t ors t he det ect or' s t emperat ure and
aut omat i cal l y shut s down t he bi as suppl y i f t he
t emperat ure i ncreases above about 140 Kel vi n (-133
o
C).
The bi as suppl y i s aut omat i cal l y rest ored aft er refi l l i ng t he
probe dewar when t he t emperat ure ret urns t o normal .
Safet y i ssues wi t h safe handl i ng of LN
2
are provi ded i n
sect i on 1, Warni ngs and Caut i ons.

Warni ng:
The more t i mes t he MEP det ect or i s al l owed t o run dry of
LN
2
t he ri sk of det ect or fai l ure i ncreases exponent i al l y.

The det ect or' s LN
2
dewar i s encased i n a heavy st ai nl ess
st eel dewar cover (upper shroud). Thi s cover prot ect s t he
det ect or dewar, mi ni mi si ng LN
2
l osses and mi crophoni c
noi se effect s due t o pl ant vi brat i ons. The cl i p-down l i d
for LN
2
fi l l i ng must al ways be cl osed properl y t o ensure
t hat t he ni t rogen gas boi l -off fl ows down t he i nsi de edge
of t he shroud t o keep i t free of moi st ure. The gas exi t s t he
shroud by way of t he el ect ri cal condui t . Do not l eave the
foam pl ug i nserted as thi s i s for transport onl y to
prevent di rt from enteri ng the dewar.

In t he event t hat t he probe compl et el y runs out of LN
2
,
t urn off t he power and al l ow i t t o warm up t o room
t emperat ure. Thi s wi l l t ake about 24 hours.



Do not appl y ext ra heat t o at t empt t o speed up t hi s
process. Several days wi t hout LN
2
cool i ng wi l l usual l y
have no det ri ment al effect (al t hough i t i s best t o mi ni mi se
t he number of warm-ups, t o maxi mi se det ect or l i fe). Aft er
refi l l i ng, t he probe shoul d be l eft for t wo t o four hours
before appl yi ng t he bi as vol t age so t hat t he uni t has t i me
t o cool down and re-est abl i sh a worki ng vacuum.

7.2.4 MSA Controlling Electronics
There are t wo mai n MSA Cont rol l ers i n an MSA uni t , one
of whi ch i ncorporat es t he RLC (see phot o l eft ) as i t s st and
al one embedded l ogi c cont rol element . The RLC i s l i nked
t o t he Operat or Int erface (OI) panel mount ed on t he
out si de panel of t he encl osure. The RLC l ooks aft er al l
t he det ai l s of operat i ng t he MSA such as probe movement ,
st i rrer operat i on and t he Met al l urgi cal Sampl er operat i on.
Under normal operat i on t he MSA i s run i n "Aut oMode"
whi ch means t he probe movement and st ream measurement
t i me and sequence are det ermi ned by t he user defi ned
confi gurat i on i n t he comput er soft ware. "Manual mode"
can onl y be sel ect ed from t he OI panel . The MSA
execut abl e modul e (Appl i cat i on code) i s down-l oaded t o
t he RLC vi a t he RS-485 dat a cabl e from t he comput er on
i ni t i al st art -up. If a modem i s connect ed t o t he comput er,
up-dat es of t hi s modul e can be down-l oaded t o t he Cl i ent ' s
MSA from t he Company head offi ce. Thi s cont rol l er al so
cont ai ns a si ngl e phase AC power out l et for connect i ng a
Mul t i -Channel Anal yser (MCA) duri ng set t i ng up and
t est i ng. The Si gnal Anal yser chassi s i s al so mount ed
i nsi de t hi s cont rol l er cabi net .

The ot her Cont rol l er cont ai ns t he st i rrer overl oads,
mi ni at ure ci rcui t breakers (MCBs), sampl er cards and t he
mai ns suppl y t ermi nal s (see photo l eft ). An AC vari abl e
speed mot or dri ve i s al so mount ed i nsi de t hi s encl osure.
Thi s i s fact ory set and t he set t i ngs used are shown i n Tabl e
7-1.


Allen Bradley AC Drive Parameter Settings Model 160
Parameter
Number
Parameter Name Default Value MSA Setting

30

Accel Time

10.0s

1.2s

31

Decel Time

10.0s

0.4s

35

Base Frequency

60 Hz

50 Hz

36

Base Voltage

460 V

400 V

38

Boost Select

4

8

42

Motor Overload Current

115%

1.1 A

50

Restart Tries

0

2

61

Preset Frequency 0

3 Hz

0 Hz

62

Preset Frequency 1

20 Hz

30 Hz

63

Preset Frequency 2

30 Hz

40 Hz

64

Preset Frequency 3

40 Hz

50 Hz
Note: All other parameter settings are default

Tabl e 7- 1 Var i abl e Speed Dr i ve Fact or y Set t i ngs


7.2.5 Using the Operator Interface Panel
The Operat or Int erface (OI) panel l ocat ed on t he out si de of
t he RLC MSA Cont rol l er has a membrane keypad and a
LCD di spl ay of 2 l i nes and 40 charact ers. It al so has Run
and At t ent i on LED i ndi cat ors (see phot o l eft ). Thi s OI
panel enabl es user i nt eract i on wi t h t he MSA uni t vi a t he
RLC. In bot h "aut omat i c" and "manual " modes of
operat i on t he user has access t o al l t he OI funct i ons
avai l abl e wi t h t hei r pass code l evel of access (see l at er)
whi ch must be ent ered at t he menu <MenuMode>.

The (AM894) OI panel i s shown schemat i cal l y bel ow.

F1 F2 F3 F4
Run Attention
1
6
DESIGNED IN AUSTRALIA
AM894
2
7
3
8
4
9
5
0
ENTER
DEL
Zone _ *23__________Ud Hld Rev Stop 11R0
<AutoMode> <Sel Zone> <MovePrbe> < >

Menu i t ems can be of t wo t ypes, "Di spl ay Onl y" or "Enter
Data". Al l t ypes are sel ect ed vi a t he funct i on keys.
Sel ect i ng a "Di spl ay Onl y" i t em wi l l di spl ay a message
(usual l y a st at us report ) on t he t op l i ne. Sel ect i ng an
"Enter Data" i t em wi l l di spl ay a message whi ch wi l l
general l y cont ai n t he current val ue of a dat a i t em, t he
al l owabl e l i mi t s and a request t o ent er a new val ue.

New val ues t o be ent ered are general l y numeri c. As t he
numeri c keys ( <0> <1> <2> <3> <4> <5> <6> <7> <8>
<9> ) are pressed, t he new val ue i s eval uat ed and
di spl ayed. If i t i s great er t han t he upper l i mi t , t he key i s
i gnored. In some cases, numerat ed val ues are ent ered by
usi ng t he arrow keys. In t hese cases, t he user i s i nformed
of t hi s opt i on.

<DEL> Thi s key wi l l del et e t he l east si gni fi cant di gi t of
t he current val ue. Duri ng t he "Enter Data" sequence,
pressi ng t he <Del > wi t h no dat a ent ered key wi l l abort t he
sequence and ret urn t o t he menu at any t i me. The
di rect i on keys are usual l y i gnored i n t hi s mode.



<ENTER> When t he desi red numeral or arrow has been
t yped, pressi ng t he <Enter> wi l l have t hi s val ue accept ed
and ret urn t o t he mai n menu.

<F1>, <F2>, <F3> and <F4> are t he Funct i on Keys.

Start-Up Menu. Upon st art -up, t he OI panel wi l l di spl ay
a st at us l i ne at t he t op (see phot o l eft ) and a sel ect i on of 4
menu opt i ons di rect l y above t he funct i on keys (<F1> <F2>
<F3> <F4>).

To sel ect a menu opt i on press t he <F. . > key i mmedi at el y
bel ow t he menu i t em you wi sh t o access. The menu woul d
now normal l y break down i nt o a l ower l evel of a furt her 4
menu i t ems (t hese are di scussed furt her bel ow).

The <UP> & <Down> keys are used t o move bet ween t he
vari ous menu l evel s.

There are seven (7) l evel s of OI menu and these are:

<St at sDsp><St i rsDsp><ProxSt at ><Sel Smpl r>
<DebugDsp><ZonesDsp>< ><MenuMode>
<Sel Smpl r><Smp-Mode><Smp-Ti me><Take Cut >
<Aut oMode><Sel Zone><MovePrbe>< >
<PrbSpray><ZneAvai l ><ServcBay><Aut oSt rt >
<Open Rl y><Cl oseRl y><ForceRl y><Free Rl y>
<Reset RLC><ZoneMask><Smp Mask><Rst Dat a>

Note:
Menu l evel s 3 t o 7 are access-rest ri ct ed, and so requi re a
password t o be ent ered upon sel ect i ng <MenuMode> t o
proceed furt her.



7.2.6 OI Panel Menu Options

Menu Level 1

<StatsDsp><StirsDsp><ProxStat><SelSmplr>
<StatsDsp>
will display the main status display on the top line. This display will typically
appear as: Auto RunMde WndOK AirOK Rdy123456789ABC
The fields are as follows:
Man/Auto for manual or automatic operating mode.
GdOpen/RunMde/EMStop to indicate whether the MSA is in Run Mode or if
the "Emergency Stop" button has been pressed, or if the interlocked guard
door is open. The EMStop message has preference.
WndRpt/WndOK indicates the status of the probe window rupture.
AirFl/AirOK indicates the air pressure level.
Before a self test has been performed, the next field (ie. the rest of the line)
will show "PositionTestReq". Once it has begun it will display,
"PositionTesting". Once a self test has been performed the next field shows
which zones are ready (ie. no errors positioning & stirrers going).
If an error occurs, it is displayed in this field. Typical messages are :
ErrRaisingPrb x,RevLsNotFound x,StuckAtLstZne x,
ZoneNotFound x,ZnePositionErrx,FailedToLower x,
InvalidZneRqstx
where "x" is the zone at which the error occurred. It is one of the following
letters "R123456789ABCFP" (R=Reverse Limit Switch, F=Forward Limit
Switch, P=Park limit switch, A=zone10, B=zone11 and C=zone12).
If the Park button has been pressed the message Parked, Latched will be
displayed. Last fields indicate which zones are ready (Rdy), numbered 1 to
C. Any zones that arent ready will be indicated by a blank field. A zone
must be defined in the zone mask, see <ZoneMask> and available, see
<ZneAvail> before it can be ready for analysis. Turning off a stirrer will
render a zone not ready.
<StirsDsp>
is used to display which stirrers are running and which units are in overload
condition. A typical display might be:
Stirrer Run 12345__89ABC O/L_____67_____
The presence of the O/L label does not mean there is an overloaded stirrer
unless the stirrer number is also given.
<ProxStat>
is used to display the state the proximity sensors are reading. A typical
display is: Zone R12*4567__ABCFPuD Dwn Fwd Stop 2340
Zone. An "*" in this field, indicates that the probe is at that zone (ie. in this
case in or above zone 3). The "_" indicates that zone 8 & 9 have not be
found or configured. The lower case "u" indicates that the probe is not "up"
(a "U" would indicate this). The "D" implies the probe is "Down". If the probe
is not positioned at a zone, either an "r or f indicating reverse or forward
carriage drive motor will appear between "Zone" and "R123..." (eg.
ZonerR12*.... implies the probe is to the reverse of position 3).
If the probe carriage-drive motor is in overload condition (and hence the
probe cannot move) the previous display will be replaced with the following
message: Probe MotorOverload
Dwn This second field reflects the vertical position of the probe. It is one of
' Hld' ,' Up ' ,' Dwn' ,' u?d' (ie. "Hld" indicates "Probe Held" (e.g. when the Raise
button is pressed) & "u?d" indicates an error).
Fwd The third field reflects the horizontal movement of the probe. It is one
of 'Stn', 'Fwd', 'Rev', 'r?f' to indicate stationery, moving forward, reversing and
action not know (which implies an error).
Stop The fourth field reflects the current probe motor speed. It is one of
' Stop' ,'Slow' ,' Fast' ,'Trbo' to indicate stationery, slow, fast and top speed. In
last group the state of the sprays are reflected by either an "Spry" (for when
the sprays are on) or the position of the probe. The last zone the probe was
at, the current position and the next position. An internal state (for debug) is
displayed in the last position.
<SelSmplr>
show the current state of a sampler. Each time it is pressed, the next valid
sampler state is displayed. The display is described later.


Menu Level 2

<DebugDsp><ZonesDsp>< ><MenuMode>
<DebugDsp>
displays a bit map of the actual low level RLC input/output states. They are
for factory use only. The first field displays the version number of the
application code (eg M123 implies Moving type code, version 1.23).
<ZonesDsp>
will display the available zones are set by the user (see later). A typical
display is as:
ZneAvl 1234_S789__C AutoStart
ZneAvl is a list of which streams are currently active. In the above example,
zones 5,10 & 11 have been declared (by the user) not to be active. The ' S'
indicates that zone 6 has been declared to be the service zone and it has
been confirmed during a Position Test. A lower case s would indicate that
the zone has been entered as being the service bay (see <SrvcBay> but it
has not been confirmed during position testing. Upon a Park request, the
probe will move to this zone.
NoAutoStart/AutoStart to indicates whether auto-start on power up is
requested.
<MenuMode>
is used to access more secure levels of the menu. The question, ' Enter
"Menu Mode" Pass Code' , is asked. The menu has three levels of access.
By default the PassCodes are 416,417 & 418. At level 1, only first 3
levels (out of a total of 7) are available. Level 2 has 5 lines. At level 3 all
are available.

Note:
The Pass Codes shoul d not be easi l y accessi bl e for use.
Doi ng so may cause unwant ed t amperi ng wi t h t he RLC
set t i ngs.



Menu Level 3

<SelSmplr><Smp-Mode><Smp-Time><Take Cut>
<SelSmplr>
Displays a sampler status and is used to select a metallurgical sampler to
operate on. As it is pressed the sampler number in the following display
"Sampler 1 Mode Off Period 0 mins" is incremented for each valid sampler.
Sampler modes are Off for shift samplers and Cal for Calibration samples.
"RShft" implies random shift mode is selected.

For each sampler installed the mode (Off,Manual,Calibration,Shift) is
displayed. If "Shift" is selected the operator is asked if they want random cuts
for which an answer of "yes" will prompt them to enter the minimum time
between random samples. For a sampler in standard shift mode, only the
number of minutes between cuts is displayed. If random cuts in a time period
has been selected, the minimum time allowed between sample cuts is also
displayed. Further details are given under <Smp-Mode> below.

<Smp-Mode>
is used to change the mode of a sampler. The question asked is ' Smp Mode
(v=Off ^=Man <=Cal >=Shft)' . If Shift mode is selected the question "Take
Random Samples (^=Yes,v=No) is asked. If random cuts are required, a
further question "Min. time between samples (minutes)" is asked.

After a mode change is made, a request to the change the bucket is made.
Its form is ' Change Bucket & Continue (^=Yes,v=No).

For calibration mode, the following messages are displayed depending on the
status: or if a failure occurs Calib Sample Failed ' Waiting Bucket
Change' ,' Ready to take Samples',' Taking Sample Cuts ' ,' Calib Sample
Taken' . They reflect the status of the calibration sample for that zone.

<Smp-Time>
is used to change the sampler cut time when in shift mode. The question
asked is ' Sampler Period (Minutes)' e.g. if you have an 8 hour shift then you
may want to take a cut every 30 mins, then 16 sample cuts will be taken over
the shift period.

<Take Cut>
is used to take a cut with the currently selected sampler.

Note:
<TakeCut > does not need t o be used t o t ake a manual cut ,
i nst ead use t he Sampl er Swi t ch (see phot o l eft ), cut
sel ect or.

Note:
The Sampl er Swi t ch (see phot o l eft ) overri des t he set t i ngs
i n t he Operat or Int erface menus. To i sol at e t he sampl er,
si mpl y swi t ch i t t o off, where i t can al so be l ocked
out .

Note:
The Sampl er Swi t ch must i n Aut o for shi ft and/ or
cal i brat i on sampl i ng.



Menu Level 4

<AutoMode><Sel Zone><MovePrbe>< >

<AutoMode>
is used to put the system into automatic operating mode (i.e. under remote
computer software control). The MSA will only move to streams in "automatic
mode". The question ' Select Mode
(^=Automatic,v=Manual)' is asked.

<Sel Zone>
is used to move the probe to a particular zone to sample. The question asked
is ' Enter Stream to Select (1,2,3,.) ' .

<MovePrbe>
is used to move the probe horizontally & vertically. When selected the
following message is displayed ' <=Rev >=Fwd ^=Up v=Down Del=Stop' .
Pressing the direction keys will send the probe in the direction requested. The
probe will NOT move horizontally if it is not clear of the zones. The <Enter>
key is used to exit this option. The key will function when the MSA is in
ManualMode.

Note:
<Sel Zone> or <MovePrbe> can be done i n ei t her Aut o
Manual mode, however i n Aut o your request may be
overri dden by t he remot e ISA comput er at any t i me.



Menu Level 5

<PrbSpray><ZneAvail><ServcBay><AutoStrt>
<PrbSpray>
is used to operate the probe wash sprays. The question asked is ' Probe
Spray (^=Start,v=Stop)' The probe wash spray will remain on until an
overriding request is made.

<ZneAvail>
is used to select which zones are available for analysing. The question 'Zone
Numbers to change (1..12,0=All)' is asked, upon which the desired zone is
entered. Then the new state is requested via the ' Zone Status (^=Online
v=Offline)' question.

<ServcBay>
is used to select which zone is to be used as a service bay when a park
request is received. The question ' Service Bay (1..12,0=ParkBay)' is
asked

<AutoStrt>
is used to select the auto start on power on. The question asked is (' Auto
Start on PowerUp (^=Yes,v=No)' . If No is selected the MSA will power up in
manual mode. If Yes is selected the MSA will power up in auto mode but
only if it was in auto mode prior to the power failure and/or there were no
problems that cause man mode, such as window rupture.

Warni ng:
The MSA wi l l not aut omat i cal l y anal yse t he zones
(st reams) requi red unl ess i t has been t ol d t hat t he zone i s
avai l abl e usi ng <ZneAvai l >.

Warni ng:
The MSA wi l l not aut omat i cal l y perform a posi t i on t est on
power up nor re-st art anal ysi ng aft er a fai l ure unl ess t he
<Aut oSt rt> opt i on i s set t o yes.



Menu Level 6

Note:
Thi s menu l evel i s not normal l y used out si de t he fact ory.

<Open Rly><CloseRly><ForceRly><Free Rly>
<Open Rly>
is used to open a particular relay. The question asked is ' Relay to Open
(10-17, 20-27, 30-37)' . The relay number is expressed via the number on a
particular board. Some examples are, 10 implies relay 0 on module 1, 31
implies relay 1 on module 3, 48 implies all relays on module 4, 170 implies
high order relay 0 on module 1 (ie. 17 mod 16), 330 implies low order relay 0
on module 1 on the second bus.

<CloseRly>
is used to close a particular relay. The question asked is ' Relay to Close
(10-17, 20-27, 30-37)' .

<ForceRly>
is used to force a relay or input to a particular state. The first question asked
is ' Relay to Force (10-17, 20-27, 30-37)' followed by ' Which way (v=Open,
^=Closed)' .

<Free Rly>
is used to free a relay from being forced. The question asked is ' Relay to
Release from being Forced.



Menu Level 7

<ResetRLC><ZoneMask><Smp Mask><Rst Data>
<ResetRLC>
is reset the RLC. The question asked is ' Reset RLC ? (^=Yes,v=No)' . If three
resets occur without a power off, the application will be aborted and all setup
parameters lost. This menu option is normally only used during factory set-up
and testing. If extra analysis tanks (zones) or metallurgical samplers are
installed on-site then this menu option can be used.

<ZoneMask>
is used to select the number of zones installed. The question asked is ' Zones
Built (octal)' . The top line will display the current setting. A typical message
is ' Zones 123456______ Samplers 123456______' which implies that zones
and samplers 1 to 6 are installed. The new number must be entered as a
base 8 number. Typical zone mask numbers are:
17==> Streams 1,2,3 & 4 are installed
7==> Streams 1,2 & 3 are installed
77==> Streams 1 to 6 are installed
7777==> Streams 1 to 12 are installed
37==> Stream 1,2,3,4 & 5 are installed (see example in Figure 7-1)
The RLC MUST perform a position test if a change is made, usually this
would be initiated by cycling the MSA main power switch.

<SMP Mask>
is used to select the number of metallurgical samplers installed. The
question asked is 'Samplers Installed (octal)'. The answers MUST be entered
as a base 8 number (ie. 17==> Streams 1,2,3 & 4 are installed ; 7==>
Streams 1,2 & 3 are installed). See example in Figure 7-1. The RLC must
perform a position test, usually this would be initiated by cycling the MSA
main power switch.

<RST Data>
is used to reset the RLC data base (eg. samplers installed). The question
asked is ' Reset All Save Data RLC (^=Yes,v=No)' . This is currently only
available for Unix ISA Software Systems.

Warni ng:
The MSA wi l l not operat e i f t he zone mask has been wi ped
out of RLC memory. In t hi s case re-ent er t he zone mask
usi ng t hi s menu opt i on <ZoneMask> at t he OI panel . You
wi l l t hen need t o t el l t he RLC whi ch zones (st reams) are
act ual l y avai l abl e by sel ect i ng <ZneAvai l > opt i on at menu
l evel 5.

Warni ng:
The met al l urgi cal sampl ers wi l l not operat e i f t he sampl er
mask has been wi ped out of RLC memory. In t hi s case re-
ent er t he sampl er mask usi ng t hi s menu opt i on
<SmpMask>at t he OI panel .



Note:
Aft er re-ent eri ng RLC dat a, t he MSA wi l l need t o be put
back t o Aut oMode at menu l evel 4 and rest art ed by
cycl i ng t he MSA mai n power swi t ch so t hat i t performs a
new Posi t i onTest ot herwi se i t wi l l st ay i n
Manual Mode and not re-st art under comput er cont rol .

Z
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1

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n
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Z
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2

Z
o
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e

3

Z
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4

Z
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5

n
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Z
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6

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electronics enclosure electronics enclosure & OI
1 2 3 4 5 6 R F
Reverse Limit
Switch
Forward Limit
Switch
Top View Layout of MSA

Forward direction when standing at
the OI side of the MSA
Reverse direction when standing at
the OI (operator interface) or sample outlet side of the MSA

Zone Mask:
Prox sensors corresponding to zones built: F 6 5 4 3 2 1 R
0 if not built, 1 if built for zone mask : 1 1 1 1 1 1
In this example probe sensors exist for position 1, ------- -------
5 and 6 even though there are no tanks 7 7

Sampler Mask:
0 if not built (ie no tank and /or no sampler), 1 if built: 0 0 1 1 1 0
In this example there are only samples for zones ------- -------
2, 3 and 6. 1 6

Converting masks to Octal (base 8):

000 0
001 1
010 2
011 3
100 4
101 5
110 6
111 7
Prox Sensors:

Fi gur e 7- 1 An Exampl e of How t o Cal cul at e a MSA Zone and
Sampl er Mask


7.2.7 Signal Processing Electronics (Signal Analyser)
Si gnal pul ses from t he det ect or i n t he anal ysi s probe
(MEP) are ampl i fi ed i n t hat probe and pass vi a a screened
anaconda cabl e t o t he Si gnal Anal yser (see phot o l eft ).
Here t hey are shaped, ampl i fi ed, sort ed and count ed before
t ransmi ssi on t o t he Wi nISA comput er over t he AIN bus
(RS-485) or TCP/ IP net work. The Si gnal Anal yser i s
mount ed i nsi de t he l arger MSA cont rol encl osure (see
phot o bot t om l eft ).

The basi c funct i ons of t he Si gnal Anal yser el ect roni cs are:
MEP t ermi nat i on.
Pul se hei ght shapi ng and sort i ng i nt o channel s. Each
channel represent i ng an energy range i n t he X-ray
spect rum. The Si gnal Anal yser out put s up t o 8
el ement al and 1 backscat t er si gnal channel from t he
anal ysi s probe.
Suppl y of st abl e fi l t ered DC l ow vol t age power and
bi as t o t he probe.
Support t he al arm ci rcui t s (eg. wi ndow rupt ure, l ow
LN
2
, det ect or t emperat ure (RTD) al arm ci rcui t fai l ure).
Test faci l i t i es (eg. Mul ti -Channel Anal yser (MCA)
connect i on for set t i ng t he channel s on t he Si ngl e-
Channel Anal yser' s (SCAs) i n t he Si gnal Anal yser).
A net work i nt erface t o an RS-485 mul t i -drop bus (AIN)
cont rol l ed and moni t ored by a remot el y l ocat ed
comput er runni ng one t he Wi nISA soft ware package.
Al t ernat i vel y t he net work may be i mpl ement ed i n
Et hernet (TCP/ IP), shared wi t h ot her pl ant -wi de
appl i cat i ons, but ul t i mat el y connect ed t o such a
comput er.

Sampling System Operation


7.3 Sampling System
7.3.1 Sampling System Function
To ensure t hat t he anal yser syst em provi des t he best
possi bl e accuracy, i t i s very i mport ant t hat t he probe
measures a t rul y represent at i ve sampl e of t he whol e sl urry
st ream and t hat most of t he ent rai ned ai r has been removed
from t he sl urry. These condi t i ons are sat i sfi ed by t he
speci al l y desi gned st ruct ure cal l ed an Anal ysi s Zone.

7.3.2 Slurry Effects
The anal yser probe ' sees' and measures a rel at i vel y l arge
proport i on of t he sl urry st ream whi ch i s passi ng t hrough
t he Anal ysi s Zone and t hi s ensures t hat t he assays
provi ded by t he ISA syst em are represent at i ve of t he whol e
sl urry st ream. The vol ume of sl urry ' seen' by a probe
depends on t he vol ume t hat t he probe ' sees' at any one t i me
and t he vel oci t y of t he sl urry (or how qui ckl y t hat vol ume
of sl urry i s repl aced).

The sampl e seen by t he anal ysi s probe i s about 5mm
deep (X-ray penet rat i on) by 20mm di amet er. Al t hough t he
proport i on of t he st ream act ual l y measured by t he probe
seems smal l i n absol ut e t erms, i t i s a much hi gher
proport i on of t he t ot al st ream t han i s t aken for manual
process cont rol sampl es and i t i s a more represent at i ve
sampl e because t he sl urry i s homogeneousl y mi xed i n t he
speci al l y desi gned Sampl i ng Syst em.

A st i rrer i s normal l y al ways requi red i n t he anal ysi s t ank
t o ensure t hat a wel l mi xed represent at i ve sampl e i s
present ed t o t he anal ysi s probe. The MSA i s suppl i ed
compl et e wi t h a st i rrer (where requi red) and t he st i rrer' s
operat i on i s cont rol l ed from t he front panel of t he MSA
Cont rol l er.



7.3.3 Metallurgical Sampler
If t he Company suppl i ed cross-cut Met al l urgi cal Sampl er
has been fi t t ed at t he overfl ow of t he anal ysi s t ank (see
phot o l eft and Figure 7-2, Figure 7-3) t hen i t needs t o be set -
up and t est ed for t he 3 modes of operat i on before
Cal i brat i on begi ns:
Aut o (for shi ft sampl i ng)
Cal i brat i on (comput er cont rol l ed)
Manual Cut

The fi rst t wo sampl er modes are confi gured at t he OI panel
(see phot o mi ddl e l eft ).

Cal i brati on-Mode
The manual cut i s user sel ect abl e at t he sampl er swi t ch
(see phot o l eft ). Set t he Sampl er Swi t ch t o Aut o.

gi ven sampl i ng peri od (t hi s i s defi ned i n t he soft ware on
t he cont rol l i ng comput er, refer t o t he Soft ware Manual ).
By sel ect i ng t he Smp-Mode OI menu opt i on, t he user can
sel ect t he "cal i brat i on" mode (see phot o l eft ). The user
shoul d al so refer t o t he sect i on on usi ng t he OI panel , i n
sect i on 7. 2. 6.

In "cal i brat i on" mode a sampl e wi l l aut omat i cal l y be t aken
from t he next st ream (zone) whi ch i s sel ect ed from t he OI
panel and t he correspondi ng probe count -rat es wi l l t hen be
st ored aut omat i cal l y i n a fi l e for t hat st ream name cal l ed
Cal i brat i onDat a. dbf. The number of sampl e cut s t aken
whi l st t he probe i s i n t he zone depends on t he "number of
cut s per sampl e" defi ned i n t he comput er confi gurat i on
soft ware and t hi s i s t urn wi l l depend on t he measurement
t i me peri od whi ch i s usual l y 5-mi nut es. Check t hat t he
cal i brat i on mode works for al l MSA st reams and make
adj ust ment s t o t he sampl er cut t er speed and number of
sampl e cut s t aken where necessary t o cont rol t he vol ume
of sampl e col l ect ed (refer t o sect i on 5. 11. 3).

Operation Sampling System


Shi ft Sampl ers
Set t he sampl er swi t ch t o Aut o. Sel ect t he sampl er
number and mode at t he OI panel and t hen sel ect shi ft .
There are t wo furt her modes for shi ft sampl es; one i s t he
"st andard shi ft " mode whi ch provi des t he operat or wi t h a
composi t e shi ft sampl e t hat i s col l ect ed over a pl ant shi ft
(confi gured i n t he comput er) wi t h sampl e cut s bei ng t aken
at regul ar t i me i nt erval s pre-set by sel ect i ng <Smp-Ti me>
at t he OI (t hi s sampl e cut i nt erval need onl y be set once
per st ream). The ot her mode provi des shi ft sampl es
composed of sampl es whi ch are cut randoml y wi t hi n a pre-
set t i me i nt erval i n case cycl i c pl ant behavi our i s
suspect ed. The user i s prompt ed t o pre-set a mi ni mum
t i me requi red bet ween such sampl es so as t o avoi d t he
possi bi l i t y of t wo sampl es bei ng t aken very cl ose t oget her.

Ask t he pl ant supervi sor what sampl e i nt erval s are
requi red over t hei r shi ft and set t he sampl er t i me
accordi ngl y. Make sure t he shi ft set up i n t he comput er
soft ware. Test t hat al l st reams work i n shi ft mode.
Adj ust t he number of sampl es t aken by changi ng t he
sampl er t i me i n order t o cont rol t he vol ume of sampl e i n
t he bucket at t he end of a shi ft .

Note:
A (whi t e) reset but t on i s provi ded on t he AM987 Sampl er
Reversi ng Modul e i nsi de t he Sampl er Cont rol l er. In t he
event t hat t he sampl er "t ri ps out ", t ry pressi ng t hi s reset
but t on (see phot o l eft ).



Fi gur e 7-2 Met al l ur gi cal Sampl er Assembl y- Fr ont El evat i on
Operation Sampling System


Fi gur e 7- 3 Met al l ur gi cal Sampl er Assembl y- Si de El evat i on

WinISA Computer Operation


7.4 WinISA Computer
The Thermo El ect ron anal yser syst em uses a Personal
Comput er (PC) wi t h ei t her a Wi ndows NT4 Server or
Wi ndows 2000 Professi onal operat i ng syst em. These PCs
are usual l y mai nt ai nabl e by l ocal speci al i st s. Indust ri al -
grade comput ers are usual l y provi ded for harsh dust y
operat i ng condi t i ons.

The comput er i nt errogat es t he anal yser at fi xed i nt erval s
usual l y of 60 seconds. The WinISA soft ware l ogs count -
rat es and cal cul at es el ement al assays and densi t y from t he
cal i brat i on equat i ons generat ed as per t he procedure gi ven
i n sect i on 6, Cal i brat i on. In conj unct i on wi t h 1-sampl e
(usual l y 1 mi nut e) assays, sampl e average (usual l y rol l i ng
5 = 5 mi nut es), hourl y, shi ft and dai l y assay averages are
al so cal cul at ed and al l assay i nformat i on i s present ed t o
t he operat ors as col our t rend graphs and t abl es on t he
comput ers col our moni t or and any net worked Cl i ent
comput ers t hat may be set up i n t he pl ant or offi ces by t he
pl ant net work admi ni st rat or.

The Wi nISA comput er can al so cal cul at e recoveri es of
mi neral concent rat e based on t he on-l i ne measurement of
concent rat i on of mi neral i n t he feed, concent rat e and t ai l s
st reams of each process ci rcui t . Al l of t he assays are
st ored on t he hard di sk i n t he comput er as hi st ori cal dat a
fi l es for l at er ret ri eval for pl ant t rendi ng purposes. An
opt i onal A4 col our pri nt er provi des (aut omat i c) hard-copy
pri nt -out s of assay dat a at preset t i mes each day.

The Sof t ware Manual provi des much det ai l about t he
Wi nISA comput er and soft ware.

Operation MSA Software Program


7.5 MSA Software Program
The MSA obj ect i ncorporat ed i nt o t he Wi nISA soft ware i s
capabl e of performi ng sophi st i cat ed st ream mul t i pl exi ng
by cont rol l i ng a st ream-swi t chi ng devi ce. The st ream-
swi t chi ng devi ce cont rol l ers, cal l ed RLCs (Remot e Logi c
Cont rol l er) used i n t he MSA uni t i s a t ype M (Movi ng).
Movi ng t ype RLCs act ual l y move a probe bet ween several
anal ysi s-zones (or st reams): The probe i s rai sed, carri ed
hori zont al l y t o t he new posi t i on, t hen l owered i nt o t he
next st ream. St ream-swi t ch sequenci ng i s cont rol l ed by
t he soft ware comput er but l ow l evel MSA cont rol (such as
rai si ng and movi ng t he probe) i s cont rol l ed by t he RLC.

The Wi nISA soft ware communi cat es wi t h bot h t he RLC(s)
and t he Si gnal Anal yser(s) t hat are connect ed t o t he MSA
uni t . The RLC(s) and t he Si gnal Anal yser(s) may ei t her be
connect ed t o t he same RS-485 net work (AIN) or vi a t wo
separat e seri al l i nes (normal l y onl y one AIN seri al l i ne i s
at t ached t o t he MSA uni t and any ot her Thermo El ect ron
i n-pl ant i nst rument at i on i s "hung" on t hi s l i ne. The
comput er soft ware cont rol s t he st ream-swi t chi ng and
col l ect s count -rat e dat a from t he Si gnal Anal yser(s) onl y
over t he t i me when t he probe i s posi t i oned, t hen swi t ches
t o t he next st ream, and so on. The count -rat es, assays,
except i ons, such as wi ndow rupt ures, et c. and not i ces of
met al l urgi cal sampl es for each st ream are al so present ed t o
t he comput er soft ware. Whi ch st reams are t o be anal ysed,
t he sampl i ng sequence and measurement t i me are al l
confi gured i n t he Wi nISA Soft ware MSA obj ect s.

The Sof t ware Manual provi des det ai l s of how t o confi gure
t he soft ware for an MSA.

7.5.1 Error Messages
Each RLC has 12 st at us-words, whi ch can be accessed by
t he comput er soft ware. The cl i ent programs i nt erpret t he
st at us bi t mapped words and di spl ay t he appropri at e error,
however, t hey are di scussed her i n ful l . The fol l owi ng
operat i onal st at us-words are sent :

1. The probes posi t i on. The range i s 1-12. If a probe i s
bet ween posi t i ons (anal ysi s t anks or st reams), t he
l at est t raversed posi t i on i s recorded.
2. For t he probes vert i cal posi t i on:
0 = bot t om, 1 = mi ddl e, 2 = t op.
3. Request ed posi t i on, i f i n t ransi t , 0 ot herwi se.
4. Bi t -map of posi t i ons t hat are OK, so posi t i on 1 = 1,
posi t i on 2 = 2, posi t i on 3 = 4, posi t i on 4 = 8, . . ,
MSA Software Program Operation


posi t i on 12 = 2048. If, for exampl e, posi t i ons 1, 2, 3
and 5 are OK, t he resul t i s 1 + 2 + 4 + 16 = 23.
5. Bi t -map of posi t i ons (zones) wi t h hori zont al -
posi t i oni ng fai l ure. If t he MSA st i l l at t empt s t o
recover, t he posi t i on wi l l be OK, but aft er 3
posi t i oni ng at t empt s, t he posi t i on wi l l cease bei ng
OK.
6. Bi t -map of posi t i ons (zones) wi t h vert i cal -posi t i oni ng
fai l ure.
7. Bi t -map of posi t i ons (zones) wi t h vert i cal -posi t i oni ng
fai l ure due t o ai r-pressure fl uct uat i on.
8. Bi t -map of posi t i ons (zones) whi ch are t emporari l y
i nact i ve (due t o a st ream bei ng deact i vat ed.
9. Bi t -map of posi t i ons (zones) whi ch are ski pped
because t he at t ached condi t i on i s not sat i sfi ed.
10. Bi t -map of posi t i ons (zones) whi ch are not OK due t o
a probl em i n t he RLC (such as a faul t y proxi mi t y
sensor or st i rrer).
Seri ous probl ems i nhi bi ti ng the MSAs normal operati on
i ncl ude the fol l owi ng 10 status. A val ue of 0 means t hat
t he RLC (and hence MSA) i s funct i onal . The fol l owi ng
are added up:
1 - Power fai l ure
2 - Ai r pressure fai l ure
4 - Li mi t -swi t ch fai l ure
8 - Posi t i oni ng (proxi mi t y) sensor fai l ure
16 - Probe fai l ed t o rai se, st i l l i n sl urry
32 - Probe wi ndow-rupt ure (WR)
64 - RLC does not respond or i s di sconnect ed
128 - RLC i n manual mode
256 - The Emergency-St op swi t ch i s pressed
2048- Door i s open (i nt erl ocked safet y guard door)

The fol l owi ng probl ems, though requi ri ng attenti on, do
not i nhi bi t the RLC operati on:

512 - Dri ve Mot or i n Overl oad Condi t i on
- One or more of t he st i rrers i s i n overl oad condi t i on

Any changes wi l l not t ake effect unt i l t he end of t he
measurement peri od unl ess pri ori t y i s gi ven t o t ake effect
i mmedi at el y or aft er t he end of t he sequence cycl e. Thi s i s
soft ware confi gurabl e. Refer t o t he Wi ndows ISA
Soft ware User Manual for error and st at us messages and
confi guri ng det ai l s.

Operation Data Communication & Interfacing


7.6 Data Communication & Interfacing
Here we are concerned wi t h dat a fl ow i nt o t he Wi nISA
comput er from t he fi el d devi ces over t he AIN bus and al so
dat a t ransfer from Wi nISA t o ot her comput ers or syst ems
out si de of t he ISA syst em.

7.6.1 Data Communication Between Analyser and Computer
Thi s sect i on descri bes t he most common met hod of
communi cat i on used i n current pract i ce. Ot her met hods
i ncl udi ng Et hernet and fi bre opt i c segment s may opt i onal l y
al so be used, however t he AIN prot ocol st i l l appl i es and a
conversi on t o a seri al format i s st i l l requi red at one or
bot h ends.

Dat a from t he probes Si gnal Anal yser i s capt ured by t he
Wi nISA comput er over t he AIN fi el dbus usi ng RS-485
si gnal s. Si mi l arl y, commands t o cont rol t he si gnal
anal yser and t he remot e sampl i ng are pl aced on t hi s
fi el dbus. The RS-485 si gnal s from t he anal ysi s probe
el ect roni cs i n t he pl ant are usual l y (except i on i s CoBox)
i nt erfaced t o a seri al port on t he Wi nISA comput er usi ng
an RS-232 t o RS-485 Convert er (AM955 modul e pi ct ured
l eft ).

The AIN prot ocol i s mast er/ sl ave usi ng vari abl e l engt h
ASCII dat a packet s wi t h a check-sum. The Wi nISA
comput er al ways ret ai ns t he rol e of bus mast er t o el i mi nat e
any possi bi l i t y of a bus confl i ct (t wo devi ces
si mul t aneousl y on t he bus). The comput er wi l l onl y ever
rel i nqui sh Mast ershi p t o a second i dent i cal comput er (i f
present ) runni ng as a hot backup when for some reason i t
i s deemed necessary t o do so. Packet s of dat a represent i ng
count -rat es at sel ect ed energi es t oget her wi t h ot her
i nformat i on, such as st ream i dent i fi cat i on, st at us and
al arms, are read i n by t he Wi nISA comput er at t he end of
each anal ysi s peri od and convert ed t o assays by
cal i brat i on-deri ved equat i ons. Thi s end user i nformat i on i s
present ed numeri cal l y or graphi cal l y by t he Wi nISA
comput er and i s avai l abl e for t ransfer t o ot her devi ces.

At t he physi cal l i nk (hardware) l ayer t he AIN consi st s of a
t hree wi re unbi ased EIA RS-232 bus (a si ngl e screened
t wi st ed pai r cabl e (pl us one spare)) l i nki ng up t o 32 AIN
devi ces over a maxi mum cabl e l engt h of 1200 met res. For
l arge syst ems up t o ei ght AIN busses can be support ed by
t he Wi nISA soft ware wi t h up t o 32 devi ces on each. Each
bus wi l l requi re a seri al port and a RS-232 Seri al Li ne.
chapt er 4, Inst al l at i on provi des det ai l about t hi s t ype of
dat a communi cat i on.
Data Communication & Interfacing Operation


7.6.2 Data Transfer to Plant Process Control Systems
Int erfaci ng t o a pl ant Process Cont rol Syst em (PCS), t o
provi de assay and al arm t ransfer, can be provi ded by t he
fol l owi ng t hree (3) ways:

1. Ethernet
TCP/ IP Et hernet Net work. The Thermo El ect ron Wi nISA
comput er i s provi ded wi t h a net work card and TCP/ IP
prot ocol as st andard suppl y. The onus i s on t he cl i ent t o
provi de t he pl ant net work and associ at ed securi t y. A
Company suppl i ed Wi nISA comput er wi l l be fact ory
confi gured for TCP/ IP net worki ng usi ng ei t her Modbus
TCP or OPC (Obj ect Li nki ng and Embeddi ng for
Process Cont rol ). Ot herwi se consul t wi t h t he Company.

2. Seri al
RS-232 (or RS-422 or RS-485, t hough i t s best t o speci fy
t hi s at t he t i me of orderi ng) seri al l i nk. The Thermo
El ect ron Wi nISA Soft ware provi des for i nt erfaci ng t o
vari ous process cont rol syst ems usi ng t he Modbus prot ocol
(Modi con PLC). Det ai l s for confi guri ng t he Wi nISA
soft ware for t hi s dat a communi cat i on can be found i n t he
dedi cat ed sect i on i n t he Sof t ware Manual . The Thermo
El ect ron Wi nISA soft ware can emul at e a Modi con
Programmabl e Logi c Cont rol l er (PLC) and i t responds t o
or i ni t i at es a subset of commands from/ t o anot her Modi con
PLC i n a Mast er/ Sl ave rel at i onshi p.

Note:
Wi nISA Modbus funct i onal i t y i s l i mi t ed t o conformance
cl ass (funct i on codes 3 & 16) of Open Modbus/ TCP
Speci fi cat i on-Schnei der El ect ri c.

Wi t h t he Wi nISA comput er as a sl ave, al l Wi nISA assays,
fl ag-assays and i nput -devi ce al arms/ warni ngs are avai l abl e
on request from t he Mast er Modi con PLC. The Wi nISA
comput er wi l l abi de by t he Modbus Prot ocol respondi ng t o
READ HOLDING REGISTERS (03). The Wi nISA
comput er wi l l repl y t o al l ot her funct i on codes wi t h t he
uni mpl ement ed error code. It i s i mport ant t hat t he PLC
pol l i ng frequency and response t imeout s be set t o no fast er
t han 1 second i nt erval s. Thi s i s because Wi nISA under
Wi ndows NT/ 2000 i s not a "Real Ti me" operat i ng syst em
and cannot guarant ee a fi xed response-t i me as some
responses may be l ost at hi gher pol l i ng frequenci es.
Remember Assay Updat es are usual l y onl y once per mi nut e
anyway.
Operation Data Communication & Interfacing


As t he mast er, al l Wi nISA assays and hardware
al arms/ warni ngs and st at us are sent t o a desi gnat ed sl ave
hol di ng-regi st er. The t ransfer occurs over an RS-232 (or
RS-422 or RS-485 wi t h opt i onal dri vers) seri al l i ne usi ng
t he Modbus Prot ocol wi t h ei t her Remot e Termi nal Uni t
(RTU) or ASCII frami ng, or over TCP/ IP port 502 usi ng
t he Open Modbus/ TCP prot ocol . The Wi nISA comput er
wi l l send i t s dat a vi a t he PRESET MULTIPLE
REGISTERS (16) funct i on code.

For seri al l i ne connect i ons t he Baud-rat e i s user
confi gurabl e and may be any one of 110, 300, 600, 1200,
2400, 4800, 9600 and 19200.

Transmi ssi on mode i s ei t her, Remot e Termi nal Uni t
(RTU), ASCII or TCP. Wi t h RTU frami ng t he charact er
format i s 8 dat a bi t s pl us 1 st op bi t . Wi t h ASCII frami ng
t he charact er format i s 7 dat a bi t s, pl us 1 pari t y bi t (ei t her
even, odd or no pari t y), pl us 1 st op bi t .

Each hol di ng regi st er represent s ei t her an assay val ue, or
up t o 16 packed fl ags of i nput devi ce al arms/ warni ngs.
The user may choose whi ch dat a i s t o be t ransferred and t o
whi ch hol di ng regi st er i t i s assi gned.

Dat a t ype for assay val ues i s user sel ect abl e (refer t o t he
Soft ware Manual for det ai l s).

The base address where assays begi n i s 1. Thi s i s
normal l y referred t o as Regi st er 40001; however, a fi xed
offset can be appl i ed t o t he base address (eg. Offset = 100,
fi rst regi st er = 40101). The devi ce i dent i fi er for t he
Wi nISA comput er i s confi gurabl e and can be set t o any
address i n t he range 1 - 99.

ISA-devi ce al arms/ warni ngs and st at us si gnal s from i n
pl ant ISA hardware can al so be sent t o t he PLC/ DCS. The
Sof t ware Manual det ai l s t he error/ warni ng and st at us
words used i n Wi nISA. Any combi nat i on of st at us and
error bi t s can be read by t he DCS/ PLC.

3. Anal ogue
4-20mA si gnal s. The Company can suppl y ADAM modul es
t o provi de 4-20mA out put for each assay of i nt erest . If
more t han ei ght assays are t o be t ransmi t t ed, i t i s normal l y
more economi cal t o use a seri al l i nk.

Signal Analyser Circuits Operation


Note:
ADAMs are common posi t i ve, not ful l y i sol at ed.

7.7 Signal Analyser Circuits
The probe Si gnal Anal yser el ect roni cs i s mount ed i n t he
ri ght hand si de of t he ri ght hand si de cont rol l er of t he
MSA (see phot o l eft ).

In t he descri pt i on of t he Si gnal Anal yser el ect roni cs t hat
fol l ows, every pri nt ed ci rcui t board (PCB) or modul e i s
i nt roduced, wi t h emphasi s on i t s rel at i onshi p t o ot her
modul es and t he syst em as a whol e.

7.7.1 Chassis Layout
The Si gnal Anal yser chassi s l ayout i s shown i n Fi gure 7-4
and phot o l eft , so t he user can i dent i fy t he posi t i on of
t hese modul es or cards. The ai m of t hi s sect i on i s t o gi ve
t he user a general underst andi ng of t he funct i ons of t he
component s and so al ong wi t h sect i on 9, Troubl e Shoot i ng,
be abl e t o di agnose faul t s and wrong adj ust ment s. It i s not
i nt ended t hat faul t s are t raced t o t he el ect roni c component
l evel , but i t shoul d be possi bl e t o l ocat e t he offendi ng
modul e and t hen repl ace i t wi t h one from your spare part s.

Operation Signal Analyser Circuits




Si gnal Anal yser cards and t hei r funct i on are as fol l ows:

Function Slot Part
No.
Description
LV Supply for Cards & MEP U4 AM056 24V Supply/Ref. Card
Low Voltage Supply for logic U5 AM059 Low Volt Supply Card
LV Supply for SCA Cards U6 AM351 12V Supply Clock
HV Supply to Probe U9 AM062/02 Bias Supply Card
Pulse amplifier & shaping U1 AM001/91 Linear Amplifier Card
Analogue Signal Processing U2 AM002/91 Pulse Validation Card
Gate clock of when busy U3 AM091/03 Live-Time Clock Card
Pulse Sorting U11-U19 AM990/10 SCA Module
Squaring pulse for SCA,MCA & test functions U10 AM994/01 MCA Access Module
Bias Supply Controller U20 AM963/20 Bias Control Module
RS-485 Output/WR Alarms + 24V Hoist Supply Control U7 AM093/11 Comms Adaptor
Plant network (AIN) comms + LN
2
Sensor Control/Alarm U8 AM092/10

Network Interface Card
Tabl e 7-2 Si gnal Anal yser Car d Funct i on

Note:
U1, U2 et c refer t o t he Si gnal Anal yser PCBs by t hei r
posi t i on i n t he chassi s i n Figure 7-4. U1 i s at t op l eft , i n
connect or (sl ot ) J1, progressi ng l eft t o ri ght and down t o
U20 i n sl ot J20 at bot t om ri ght .

7.7.2 Signal Flow
A "posi t i ve st ai rcase waveform" si gnal from t he probe
ent ers t he Si gnal Anal yser and i s rout ed t hrough t o t he
AM001/ 91 Li near Ampl i fi er, i n chassi s posi t i on U1, and
t he AM002/ 91 Pul se Val i dat i on Card, i n posi t i on U2. Thi s
pai r of cards i s referred t o as t he Anal ogue Si gnal
Processor (ASP). Fi gure 7-5 shows schemat i cal l y t he fl ow
of si gnal .

Each st ep i n t he waveform i s produced by an X-ray or
gamma-ray i nt eract i on wi t h t he Si (Li ) cryst al i n t he probe
and wi l l have a hei ght of t he order of a few mi l l i vol t s.
The hei ght of each st ep i s proport i onal t o t he energy
deposi t ed i n t he cryst al by t he correspondi ng X-rays.
Several t i mes each second t he si gnal exhi bi t s a l arge
negat i ve t ransi t i on as t he det ect or' s fi el d-effect t ransi st or
(FET) gat e i s di scharged by fl ashi ng i t wi t h l i ght . Thi s
t ransi t i on i s cal l ed t he opt i cal reset and i s sensed by t he
Si gnal Anal yser whi ch i s designed t o i gnore any fol l owi ng
out put from t he probe for t hat bri ef peri od unt i l t he probe
and i t s ampl i fi ers recover t o st abl e operat i on. The si gnal
t hen cont i nues from t hi s pai r of cards t o t he AM994/ 01
MCA Access Modul e from where i t i s sent i n paral l el t o
t he AM990/ 10 SCAs (Si ngl e-Channel Anal ysers). Up t o
Operation Signal Analyser Circuits


ni ne (9) SCAs are fi t t ed t o t he chassi s. Refer t o Fi gure
7-4.

mepsaflow

Fi gur e 7- 5 Si gnal Fl ow Thr ough t he Si gnal Anal yser

7.7.3 Auxiliary Cards
Auxi l i ary cards and modul es i n t he Si gnal Anal yser are:
AM062/ 02 Bi as Suppl y Card (U9) whi ch suppl i es t he
Hi gh Vol t age for t he probe.
AM963/ 20 Bi as Cont rol Modul e whi ch safeguards t he
det ect or and FET agai nst sudden i ncreases i n Hi gh
Vol t age.
AM091/ 03 Li ve Ti me Cl ock Card whi ch provi des a
correct i on for t he l oss of count s due t o t he fi ni t e si gnal
processi ng t i me of t he ASP ci rcui t .
AM092/ 10 Net work Int erface Card (U8) cont ai ns a
mi croprocessor and forms t he mai n communi cat i on
pat hway ont o t he RS-485 Net work (AIN). It al so
moni t ors t he l i qui d ni t rogen l evel and cryost at
t emperat ure, si gnal s al arms, sends warni ngs for any
abnormal swi t ch set t i ngs and cont rol s t he bi as
shut down.
AM093/ 11 Comms Adapt or Card (U7) moni t ors t he
wi ndow sensor for moi st ure l eakage and l oss of ci rcui t
cont i nui t y. It al so convert s dat a generat ed by t he
AM092/ 10 card t o RS-485 compat i bl e si gnal s for


t ransmi ssi on t o t he Wi nISA comput er. Thi s dat a
cont ai ns count -rat es, l i ve-t i me and al arm/ warni ngs.
Signal Analyser Card Functionality Operation


7.8 Signal Analyser Card Functionality
7.8.1 AM001/91 Linear Amplifier
The probe si gnal ent ers t he Si gnal Anal yser vi a a BNC
(coaxi al ) connect or at t he bot t om l eft of t he chassi s and i s
rout ed t o t he AM001/ 91
1
Li near Ampl i fi er Card i n posi t i on
U1 (t op l eft edge connect or). The AM001/ 91 i s
responsi bl e for convert i ng t he posi t i ve goi ng st eps on t he
probe waveform t o pul ses and ampl i fyi ng and shapi ng
t hem t o a near Gaussi an format . One very i mport ant
funct i on of t hi s card i s t o det ect t he very begi nni ng of t he
posi t i ve st ep i n t he so-cal l ed fast ampl i fi er t o enabl e
pi l e up det ect i on. It al so mai nt ai ns a zero vol t basel i ne i n
conj unct i on wi t h t he AM002/ 91 card.

7.8.2 AM002/91 Pulse Validation
Operat i ng i n conj unct i on wi t h U2 (AM002/ 91
2
Pul se
Val i dat i on Card), t he AM001/ 91 ampl i fi es and shapes t he
i ncomi ng probe si gnal and compensat es for spuri ous
effect s such as pi l e-up, overl oads and reset s. Thi s pai r of
cards i s oft en referred t o j oi nt l y as t he Anal og Si gnal
Processor or ASP.

The out put si gnal from t he ASP consi st s of posi t i ve
pseudo-Gaussi an pul ses (referred t o ground). The
ampl i t ude of t hese pul ses i s proport i onal t o X-ray energy
and may have a maxi mum of 10 vol t s. Ot her i mport ant
si gnal s from t he ASP are a st robe pul se t o i ndi cat e whi ch
si gnal pul ses are val i d and when (i n t he t i me domai n) t o
sampl e t hei r ampl i t ude and al so a l i ve-t i me cl ock si gnal t o
enabl e so-cal l ed dead t i me correct i on. Not e t hat t he
OVERLOAD LED on AM001/ 91 may be seen t o fl i cker
fai nt red under normal condi t i ons because a smal l
percent age of pul ses i n any spect rum wi l l exceed t he
operat i onal l i mi t of t he ASP (wi t hout harm, of course).

Not e t hat t he AM001/ 91 and AM002/ 91 pai r t oget her shape
t he pul se wi t h a 9s t i me const ant . Whi l st t hi s produces
excel l ent resol ut i on, somet i mes t hey cannot handl e t he
hi gh count -rat e requi red for cert ai n source/ sl urry
combi nat i ons al t hough resol ut i on i s t raded off i n t hese
cases. In such cases a short er t i me const ant may be
chosen, for exampl e AM001/ 91-4 (4 s) or AM001/ 91-2
(2 s).

1
Later versions of cards are identified by incrementing the second digit in the suffix of the AM number, eg. AM001/91.
Such units are fully backwards compatible and will generally conform to this description, with identical or improved
specifications.

2
As already noted, AM002/90 may be replaced by AM002/91 etc.


The correspondi ng AM002 card must al ways be used, i . e.
AM002/ 91-4 goes wi t h AM001/ 91-4 et c. Do not mi x and
mat ch t hese cards!

7.8.3 AM994/01 MCA Access Module
The Gaussi an si gnal pul se and i t s st robe are passed t o t he
AM994 MCA Access Modul e. Thi s modul e i s named t hus
because i t carri es most of t he ci rcui t s necessary t o connect
i n an MCA (Mul t i -Channel Anal yser) and vi ew t he
spect rum and SCA set t i ngs. As far as t he si gnal i s
concerned i t more-or-l ess rout es st rai ght t hrough t o t he
SCAs.

It does pass t hrough a sampl e-and-hol d and a l i near gat e
ci rcui t , however. These ci rcui t s ensure t hat t he si gnal i s
present ed t o bot h t he SCAs and MCA i n a st andardi sed
manner (essent i al l y square pul ses) whi ch al l ows operat i on
wi t h vari ous brands of MCA wi t h l i t t l e, or no, dependence
on t hei r vari ous i nput ci rcui t s.

The AM994 MCA Access Modul e performs a moni t or
funct i on over t he SCAs and i nt eract s wi t h t hem t o ai d i n
set t i ng up. Thi s onl y appl i es as l ong as t he TEST/ RUN
swi t ch i s set t o TEST. None of t he cont rol s on t he SCAs
(excl udi ng screwdri ver adj ustment s) or t hose of t he
AM994 i t sel f, are funct i onal i f t hi s swi t ch i s on RUN. The
AM994 has an INJECT mode whi ch may be used t o sel ect a
dummy i nput si gnal i n l i eu of t he probe deri ved pul se. The
ampl i t ude of t he i nj ect ed pul se i s vari abl e over t he ful l
range of t he SCAs (0-10 V) usi ng t he 10-t urn
pot ent i omet er l abel l ed REF VOLTS. It has a rat e of
preci sel y 5 kHz, but unl i ke t he probe si gnal i s essent i al l y
non-random i n ampl i t ude or t i me. (A more det ai l ed
di scussi on of t he AM994 i s gi ven i n t he sect i on 5,
Commi ssi oni ng).

7.8.4 AM990 Single-Channel Analyser (SCA)
The si gnal from t he AM994 (whi ch goes t o al l SCA i nput s
i n paral l el ) agai n consi st s of an anal og pul se (0-10 V) and
a separat e st robe pul se (TTL). Now, however, t he si gnal
pul se has a guarant eed fl at t op, due t o t he
sampl e-and-hol d. The st robe t ransi t i on occurs i n t he cent re
of t hi s fl at regi on, wel l away from ri ngi ng and ot her si gnal
di st ort i ons. The t ask of t he SCA i s t hus great l y si mpl i fi ed
(most desi rabl e because i t s circui t has t o be dupl i cat ed
ni ne t i mes).

Two t ri m-pot s on each of t he AM990 SCA modul es
det ermi ne t he vol t age (i n t he range of 0-10 V) of t he l ower
l evel LL and upper l evel UL of t he SCA channel .
Operation Signal Analyser Card Functionality


These t ri m-pot s are accessi bl e onl y t hrough hol es i n t he
front panel of t he SCA modul es. These hol es are
i nt ent i onal l y smal l t o di scourage unaut hori sed t amperi ng.

When a st robe pul se arri ves wi t h an ampl i t ude bet ween t he
LL and UL vol t ages and a st robe t ransi t i on al so occurs,
t he SCA wi l l sampl e t he pul se' s fl at t op and recogni se i t as
bei ng i n channel . It wi l l t hen cause a count t o be sent t o
t he AM092/ 10 card for st orage. The resul t i ng count -rat e
dat a i s t hen t ransmi t t ed vi a t he AM093/ 11 card ont o t he
AIN RS-485 l i ne.
Set t i ng t he UL and LL di scri mi nat ors (vol t ages) i s
di scussed i n sect i on 5, Commi ssi oning.

7.8.5 AM092/10 Network Interface Card
The AM092/ 10 card has a 16 bi t embedded mi croprocessor
whi ch forms t he mai n communi cat i on pat hway ont o t he
Mul t i -drop RS-485 net work (AIN). There are al so ni ne 16
bi t hi gh speed (hardware) count ers, vari ous memory and
l ogi c devi ces and provi si on t o read t he chassi s seri al
number for devi ce i dent i fi cati on purposes (t hi s devi ce
i dent i fi cat i on i s used by t he Wi nISA soft ware and i s
referred t o as t he devi ce number). The count ers accept
condi t i oned nucl ear pul ses ori gi nat i ng i n t he MEP
connect ed t o t he si gnal anal yser. The mi croprocessor
reads t hese count ers peri odi cal l y on t he fl y and when
i nt errogat ed by t he Wi nISA comput er (net work mast er)
wi l l repl y by i ssui ng a packet of seri al ASCII charact ers t o
t he AIN. Thi s packet conforms t o a prot ocol l ai d down by
t he Company and cont ai ns count -rat e, al arm and st at us
i nformat i on as wel l as a check-sum.

A maj or feat ure of t he AM092/ 10 i s t hat i t i s capabl e of
rel oadi ng i t s own execut abl e appl i cat i on code from t he
AIN, and st ori ng i t i n capaci t or backed CMOS memory
(whi ch l ast s approxi mat el y one mont h i f t he Si gnal
Anal yser power i s off). Worki ng i n conj unct i on wi t h t he
soft ware program (Wi nISA) t he Net work Int erface card
wi l l aut omat i cal l y l oad or rel oad t he l at est versi on of
appl i cat i on program resi dent on t he cent ral hard di sk,
whi ch means t hat updat i ng and di st ri but i on of new
appl i cat i on code i s made very si mpl e. If re-l oad i s
requi red t he four red LEDs on t he AM092/ 10 card fl ash i n
uni son, t hen duri ng l oadi ng i ndi cat e fi l l i ng of t he cards
CMOS memory. The AM092/ 10 card al so moni t ors t he
l i qui d ni t rogen l evel and t he cryost at t emperat ure, si gnal s
al arms, sends warni ngs for any abnormal swi t ch set t i ngs
and cont rol s bi as shut down.


Note:
The appl i cat i on code must resi de i n t he AM092/ 10 cards
memory before t he si gnal analyser funct i ons work. Refer
t o t he Soft ware Manual for det ai l s of t he AIN code.

7.8.6 AM093/11 COMMS Adaptor
The COMMS Adapt or Card (AM093/ 11) moni t ors t he
wi ndow sensor for moi st ure l eakage and l oss of ci rcui t
cont i nui t y. It convert s dat a generat ed by t he AM092/ 10
card t o RS-485 or RS-232 compat i bl e si gnal s for
t ransmi ssi on over t he AIN t o t he Wi nISA comput er. Thi s
dat a cont ai ns count -rat es, l i ve-t i me and al arm i nformat i on.

A j umper l i nk on t hi s card (see Fi gure 7-6) must be i n t he
posi t i on SAMPLER for use i n MSA syst ems.

AM093/11 Card

Fi gur e 7- 6 Showi ng j umper l i nk on AM093/ 11

7.8.7 Functionality of Signal Analyser Support Cards
The remai ni ng ci rcui t s of t he Si gnal Anal yser perform t he
vari ous support i ng funct i ons of del i veri ng power t o t he
probe and prot ect i ng i t from damage i n abnormal
ci rcumst ances. These are very i mport ant funct i ons
because t he safet y, rel i abi l i t y and l ong-t erm performance
of t he probe are very much dependent on t hem.

The fol l owi ng sect i ons descri be t he funct i onal i t y of t hese
cards.

Link m ust inpo s ition "SAM PLER A M0 93 /11 Car d
Link must in po sition " SAM PLER A M 0 93 /11 Car d
Link set to
SAMPLER


7.8.8 AM062/02 Bias Supply
It i s necessary t o suppl y a bi as vol t age t o t he
semi conduct or det ect or i n t he probe. Thi s vol t age must be
negat i ve (rel at ed t o ground), moderat el y st abl e and al most
t ot al l y free from ri ppl e and sudden changes. The current
drai n i s mi nuscul e and so RC fi l t ers wi t h l arge R-val ues
are adequat e. Thi s means, however, t hat hi gh qual i t y
i nsul at i on i s needed for al l cabl es and connect ors carryi ng
bi as vol t age and t hat t hi s i nsul at i on must be kept dry.

The bi as vol t age i s generat ed by t he AM062/ 02 Bi as
Suppl y Card t hat pl ugs i nt o t he ri ght most sl ot of t he t op
row (U9) of t he si gnal anal yser chassi s. Thi s i s a
swi t chi ng suppl y whi ch deri ves i t s i nput power from t he
+15 V suppl y and runs at approxi mat el y 25 kHz. The
funct i on of t he AM062/ 02 i s t o devel op a pot ent i al
bet ween 0 V and -1000 V i n proport i on t o an i nput
reference vol t age whi ch may be bet ween 0 V and +5. 00 V.
Thi s reference vol t age i s set by a 10-t urn pot ent i omet er
on t he AM963/ 20 Bi as Cont rol l er modul e.

Cauti on:
Take care not t o come i n cont act wi t h t he Hi gh Vol tage
t hat exi st s on t hi s card. Al l ow two mi nutes aft er
swi t chi ng off for t he charge on t he fi l t er capaci t ors t o drop
t o a safe l evel , before t ouchi ng or unpl uggi ng t he card.

7.8.9 AM963/20 Bias Controller
The AM963/ 20 Bi as Cont rol l er i s desi gned t o safeguard
t he expensi ve semi -conduct or det ect or and i t s associ at ed
expensi ve FET. It i s i mport ant t hat t he bi as vol t age i s not
i ncreased t oo fast on i ni t i al swi t ch on because a sudden
i ncrease i n bi as can permanent l y damage t he FET. Al so a
fai l ure of t he opt i cal reset syst em wi l l al l ow t he FET gat e
vol t age t o ri se t o aval anche poi nt and possi bl y dest roy t he
FET. Thi s si t uat i on can come about by fai l ure of t he 24
vol t suppl y, for exampl e, as wel l as numerous ot her t hi ngs.
The AM963/ 20 i s desi gned t o reduce t he bi as t o a safe 30
vol t s i f t he normal reset rat e i s i nt errupt ed for any reason.

Aft er any i nt errupt i on t o t he bi as vol t age such as due t o a
power fai l ure t he AM963/ 20 wi l l rest ore t he bi as t o i t s
preset l evel (on t he 10-t urn di al ), provi di ng t he normal
peri odi c reset si gnal i s recei ved from t he probe. It does
t hi s by set t i ng t he bi as t o 30 vol t s when t he LN2 l evel
sensi ng ci rcui t si gnal s OK, and wai t i ng for reset s t o
commence.


Provi di ng t he reset rat e i s great er t han one every 5 seconds
and l ess t han 500 per second, t he bi as i s ramped up t oward
t he sel ect ed val ue at approxi mat el y 10 vol t s per second. It
i s normal for t he reset rat e t o i ncrease dramat i cal l y as t he
bi as i ncreases. The act ual reset rat e i s moni t ored by t he
AM963/ 20. Thi s modul e wi l l t emporari l y pause t he bi as
rampi ng process i f t he reset rat e exceeds 500 per second
and resume rampi ng when i t drops sl i ght l y bel ow t hi s rat e.

If t he rat e cl i mbs t o 1000 per second and exceeds i t for
more t han one second t he bi as i s reduced i nst ant l y t o t he
safe 30 vol t poi nt . A bi col our LED i ndi cat es t he exact
st at us of t he bi as suppl y as fol l ows:

1. The LED i s off when, and onl y when, t he bi as suppl y i s
compl et el y shut down. Thi s means t hat zero bi as energy
i s bei ng del i vered al t hough some resi dual charge on t he
bi as cabl e may be present and t hi s wi l l t ake a mi nut e or
more t o bl eed away. Thi s si t uat i on exi st s when t he
BIAS swi t ch i s off or t he LN
2
l evel sense ci rcui t i s
i ndi cat i ng t he LN FAIL st at us.

2. When t he LED fi rst l i ght s i t wi l l be red as t he 30 vol t
bi as l evel i s est abl i shed as a feel er t o see i f t he det ect or
responds wi t h reset s.

3. If reset s do not appear t he AM963/ 20 wi l l remai n
i ndefi ni t el y at 30 vol t s wi t h t he red LED on. Thi s
condi t i on may i ndi cat e t hat t here i s moi st ure on t he
pre-amp and HV el ect roni cs i n t he probe i t sel f. Thi s
wi l l requi re Dryi ng out of t he Probe, and t hi s
procedure i s gi ven i n sect i on 8, Mai nt enance.

4. As reset s are regi st ered i n t he range 1. . 500 per sec. , t he
LED wi l l be seen t o fl ash (st i l l red) about once every
second as t he bi as i s sl owl y i ncreased.

5. If a pause i s necessary (because t he reset rat e i s t oo
hi gh), t he LED wi l l resume a st eady red for t he
durat i on of t he pause and conti nue fl ashi ng as t he ramp
recommences.

6. When t he end poi nt vol t age i s reached (i . e. as set on
di al ) t he LED wi l l change t o a st eady green. At t hi s
poi nt t he warni ng si gnal t o t he cent ral Wi nISA
comput er i s t urned off and t he l i ve t i me cl ock i s
enabl ed.


7. Now t he bi as i s hel d st eady but t he AM963/ 20
cont i nues t o moni t or reset rat e. It wi l l ret urn i t t o t he
rest art val ue (30 vol t s) i f reset rat e goes out si de t he
range 0. 2 t o 1000 per second. Thi s si t uat i on wi l l be
i ndi cat ed by a warni ng si gnal at t he Wi nISA comput er
accompani ed wi t h zero l i ve-t i me, and t he BIAS LED
wi l l be red. Unl ess act i on i s t aken t o power down t he
probe t he AM963/ 20 wi l l resume rest art as soon as
accept abl e reset rat e i s rest ored.

8. A second bi col our LED l abel l ed OPTICAL RESET i s
mount ed above t he 10-t urn di al . Thi s LED normal l y
fl ashes green al most cont i nuousl y (l ess frequent l y i f t he
radi oi sot ope source i s absent or shut t ered, or t he probe
i s out of t he st ream). Thi s LED i ndi cat es t wo di fferent
t hi ngs about t he i ncomi ng probe si gnal :
COLOUR
The col our green i ndi cat es t hat t he gross count -rat e
i s wi t hi n t he maxi mum al l owabl e rat e for t he ASP
fi t t ed. If t he count -rat e i s t oo hi gh i t goes red.
FLASH
It fl ashes once for each reset t ransi t i on det ect ed i n
t he probe si gnal . The col our of t he fl ash may be red
or green dependi ng on 1 above. At hi gh reset rat es
t he fl ashes wi l l merge i nt o an unst eady gl ow.

Because each reset al so regi st ers one or more count s,
al bei t out si de t he spect rum, i t i s possi bl e t hat t he
OPTICAL RESET wi l l t urn red moment ari l y duri ng t he
bi as ramp-up st age but t hi s i s of no consequence.
Shoul d i t t urn red duri ng normal operat i on i t may
i ndi cat e one of t he fol l owi ng probl ems:
The radi at i on l evel (X-ray fl ux) i s t oo hi gh, or
An excess of el ect ri cal noi se i s bei ng generat ed
i n t he probe. Thi s may be due t o t he l oss of LN2
cool i ng or a degraded vacuum or agei ng Si (Li )
det ect or or FET and wi l l show some effect on t he
spect ral performance of t he probe.
One of t he t wo cards AM001/ . . or AM002/ . . i s
defect i ve.
El ect romagnet i c Int erference (EMI or RFI). Thi s
can be checked by ensuri ng t he fi l t er under t he
dewar i s present and OK. Al so l ook for possi bl e
sources of EMI nearby eg. vari abl e speed mot or
dri ves, et c.


The OPTICAL RESET LED i s act ual l y dri ven by t he
ASP and has no el ect ri cal connect i vi t y wi t h t he bi as
generat i ng or cont rol l i ng ci rcui t s. It i s l ocat ed on
t hi s panel onl y so t hat i t wi l l be observed more
easi l y.

7.8.10 AM091/03 Live-Time Clock
Al ong wi t h t he SCA count -rat es and ot her dat a, Li ve-Ti me
i nformat i on i s sent t o t he Wi nISA Comput er. The reason
and need for t hi s si gnal i s t o provi de a correct i on for t he
l oss of count s i n t he ASP duri ng t he peri ods of t i me t hat i t
i s busy processi ng an earl i er recei ved pul se or i s ot herwi se
engaged. The ASP del i vers a l ogi cal st at us si gnal t o t he
AM091/ 03 Li ve-Ti me Cl ock Card (U4). Thi s card carri es
a st abl e quart z cryst al osci l l at or whi ch, i n t he event of
zero i ncomi ng count s (Li ve-t i me = 100%), generat es a
regul ar si gnal of one cycl e i n approxi mat el y 8. 4 seconds.
As t he i ncomi ng count -rat e i ncreases t hi s cl ock si gnal
sl ows down. For exampl e, i f t he ASP i s spendi ng 30% of
i t s t i me busy or dead t hen t he l i ve-t i me i s 70% and t he
out goi ng l i ve-t i me cl ock wi l l be one cycl e i n 8. 4/ 0. 7 =
12. 0 sec. The cent ral comput er i s programmed t o
normal i se al l 9 (max) count -rat e channel s from t he same
si gnal anal yser agai nst t hi s cl ock before furt her
processi ng. In t hi s way t he effect s of changi ng count -rat es
i n one part of t he spect rum do not i nfl uence t he apparent
count -rat e i n ot her part s.

7.8.11 Power Supply Cards
Several regul at ed l ow vol t ages are requi red by t he vari ous
modul es and t he probe. The PCBs whi ch regul at e t hese
vol t ages are recogni sabl e by t hei r heat si nks. The hi gh
current +5 vol t s regul at or i s mount ed di rect l y ont o t he
t ransformer panel al ong wi t h i t s fi l t er capaci t or.

Cleaning and Replacing the Probe Window Operation


7.9 Cleaning and Replacing the Probe Window
Normal l y, t he probe wi ndows do not need regul ar cl eani ng
because t he fl ow of t he sl urry past t he probe keeps t he
probe surfaces cl ean and pol i shed. However, i n some
st reams, part i cul arl y where t he pH i s hi gh (>10) a
preci pi t at i on may occur whi ch t hen requi res regul ar
cl eani ng t o remove t he scal e.

Note:
Scal i ng or preci pi t at i on on t he probe wi ndow wil l change
t he count -rat e measurement so i t i s i mport ant t hat regul ar
wi ndow cl eani ng be i mpl ement ed for such si t uat i ons. The
frequency of cl eani ng wi l l depend on t he ext ent of t he
scal i ng probl em and wi l l vary from one pl ant and one
st ream t o anot her.

When a severe preci pi t at i on probl em occurs on t he wi ndow
of t he probes such t hat cl eani ng i s requi red on a shi ft
basi s, a sol ut i on t o t he probl em may be t o repl ace t he
wi ndow mat eri al t ype wi t h one t hat i s more resi st ant t o a
preci pi t at i on bui l d-up. Such mat eri al s may be PTFE
(Tefl on), Kapt on or PEEK. Consul t t he Company for
furt her i nformat i on. If changi ng t he wi ndow t ype doesnt
provi de a sol ut i on t hen t hey must be cl eaned more
regul arl y.

Note:
Al ways re-st andardi se t he probe i f t he wi ndow mat eri al
t ype i s changed.

Even t hough t he sl urry wi l l normal l y keep t he wi ndows
cl ean, t here i s no oft en need t o worry about t he wi ndows
bei ng worn away - t he probe wi ndows are very t ough 50
mi cron Myl ar (pol yet hyl ene pl ast i c) and wi l l oft en l ast for
at l east 3 and perhaps 6 mont hs, i n even t he most abrasi ve
sl urri es.

Scrat ches can harbour cont ami nant s whi ch may affect t he
probes readi ngs and can compromi se t he wi ndows
i nt egri t y. Therefore t he pri mary (sl urry cont act ) wi ndow
shoul d be repl aced i f i t shows si gns of cont ami nat i on
and/ or scrat ches t hat cannot be easi l y cl eaned off.


If t he wi ndow i s physi cal l y rupt ured or t orn t hen t he
backup wi ndow may be rupt ured al so. In t hi s case, sl urry
may have ent ered t he probe. The i nsi des of t he probe and
t he det ect or t hen need t o be t horoughl y cl eaned. Thi s t ype
of rupt ure i s very uncommon and can normal l y be
compl et el y avoi ded by usi ng screens t o remove t ramp
mat eri al from t he process st reams.

7.9.1 Cleaning the Probe Window
The frequency of wi ndow cleani ng vari es enormousl y
dependi ng on t he rat e of bui l d-up. In rare cases, t he
wi ndows have t o be cl eaned once every shi ft whi l e i n ot her
cases, t hey onl y need t o be cl eaned once per week or even
l ess. Cl eani ng t he wi ndow i s a si mpl e t ask and shoul d
t ake about t wo mi nut es t o perform. The best way t o fi nd
out how oft en t he wi ndow must be cl eaned i s t o spot check
t he wi ndow over a peri od of a few days.

The procedure fol l owi ng i s st ep by st ep i nst ruct i ons of
how t o cl ean t he probe wi ndow.

It ems requi red t o cl ean t he wi ndow are:

Bucket of wat er or wat er hose.

Di l ut e aci d (eg. hydrochl ori c). A concent rat i on of 5%
aci d i s usual l y best . Choose t he aci d t hat removes t he
preci pi t at i on easi est . Not e t hat aci d i s onl y requi red i f
wat er al one doesn' t remove t he bui l d-up.

Cl ot h or paper t i ssue for wi pi ng t he wi ndow.

Tongs t o hol d t he cl ot h wi t h (t hese are suppl i ed i n t he
Tool Box).

Smal l mi rror or pi ece of pol i shed st eel so t hat you can
vi ew t he wi ndow. A t el escopi c mi rror i s suppl i ed i n t he
Tool Box.

Warni ng:
If usi ng HCl aci d, do not use more t han 5% concent rat i on,
ot herwi se damage may occur t o t he 316 grade st ai nl ess
st eel probe part s and wi ndow wear wi l l i ncrease t oo.

Operation Cleaning and Replacing the Probe Window


The procedure for cl eani ng t he probe wi ndow i s as
fol l ows:

1. Remove t he probe from t he sl urry (anal ysi s t ank) by
pressi ng t he Park but t on t hen t he Rai se but t on
(see phot o l eft ) t o secure t he probe for mai nt enance.

2. Wash t he wi ndow by pouri ng wat er over i t and t he
probe head and wi pe wi t h t i ssue or soft cl ot h usi ng
t he l ong handl ed t ongs provi ded.

3. Use t he mi rror t o i nspect t he wi ndow for any si gns
of a bui l d-up of preci pi t at i on - t he wi ndow shoul d be
perfect l y t ransparent t o l i ght i f i t i snt t hen i t may
be scrat ched and must be repl aced (see repl aci ng t he
wi ndow i n sect i on 7. 8. 2). If i t i s st i l l di rt y t hen use
t he di l ut e aci d.

4. When t he wi ndow i s cl ean, put t he probe back i nt o
operat i on by rel easi ng t he Park but t on. It may
t ake a mi nut e or so for t he probe t o move.

Cauti on:
To avoi d exposure t o t he l ow l evel radi at i on, you shoul d
be careful t o ensure t hat no part of your body can be ' seen'
by t he radi oact i ve source. Remember, i f you can see t he
source, t he source can see you!

7.9.2 Replacing the Probe Window
The fol l owi ng procedure i s a st ep by st ep i nst ruct i on of
how t o change out t he wi ndow of t he probe. When you
have had some pract i ce at changi ng t he wi ndows, you
shoul d be abl e t o perform t he whol e procedure i n about 5
mi nut es.

If a WR has occurred t hen an al arm message wi l l be
di spl ayed on t he Wi nISA comput er. The probe wi l l al so be
rai sed from t he sl urry and you wi l l have l ost your on-l i ne
assay readi ngs.

Before st art i ng t he procedure, t he fol l owi ng t ool s and
i t ems shoul d be col l ect ed:
The socket dri ver for removi ng t he wi ndow assembl y
(vi a square head bol t s).
A bucket of wat er or hose for washi ng t he probe head i f
necessary before removi ng t he wi ndow assembl y.


Some mat eri al (t i ssue or soft cl ot h) for dryi ng t he probe
head and wi ndow assembl y aft er washi ng.
A cont ai ner of pet rol eum j el l y or equi val ent for l i ght l y
l ubri cat i ng t he wi ndow assembl y O-ri ng.
A smal l mi rror i s al so useful. The wi ndow of t he probe
can be i nspect ed usi ng t he mi rror wi t hout exposi ng you
t o any radi at i on.
A set of l aborat ory t ongs i s useful for hol di ng i t ems i n
front of t he probe t o avoi d exposi ng your hands t o t he
radi at i on.
Spare wi ndow assembl y (pi ct ured).

Al l t he above i t ems are i n t he Tool box suppl i ed wi t h t he
equi pment (refer t o At t achment 1 i n Chapt er 5).

The procedure for changi ng t he wi ndow i s as fol l ows:

1. Go t o t he anal yser t hat i ndi cat ed a wi ndow rupt ure
(t here i s no need t o t urn off t he power, nor t he bi as
vol t age). The probe wi l l al ready be rai sed on i t s
hoi st . The MSA wi l l be i n manual mode so move
t he probe t o an accessi bl e end of t he MSA by usi ng
t he <ProbeMove> command on t he OI panel .

2. Wash al l of t he st ai nl ess st eel of t he probe head and
t he wi ndow. Thi s can be done wi t hout exposi ng any
part of you t o t he radi at i on.

Note:
Whi l st t he MSA i s i n manual mode i t wi l l not respond t o
any move commands from t he cont rol l i ng comput er.
Openi ng t he guard door al so put s t he MSA i n manual mode
and st ops any aut omat i c movement . Remember t o press
t he st i rrer overri de but t on so t hat t he t anks dont sand up.

Cauti on:
Do not expose yoursel f, or anyone el se, t o t he X-ray
radi at i on emi t t i ng from t he probe.

3. Dry t he probe head and wi ndow assembl y usi ng a
soft cl ot h or paper t i ssue and t he t ongs.

4. Remove t he Wi ndow Assembl y by t urni ng t he t wo
square head capt i ve bol t s wi t h t he spi got t ool . The
bol t s wi l l dri ve t he fl ow cel l out ward from t he front .

Operation Cleaning and Replacing the Probe Window


5. Swap t he spare Wi ndow Assembl y di rect l y i nt o pl ace
whi l st t he ol d one i s t aken t o a cl ean work area for
wi ndow refi t t i ng. The O-ri ng i n t he spare wi ndow
assembl y may need a l i ght greasi ng wi t h pet rol eum
j el l y.

6. Ti ght en t he t wo square head bol t s t o secure t he
wi ndow assembl y so t hat i t i s fl ush wi t h t he head.

7. The MSA may now be put back i nt o aut omat i c
cont rol . To do t hi s, cl ose t he guard door, t he
Guard Open message at t he OI panel wi l l
di sappear, t hen sel ect <Aut o Mode> at t he OI and
wai t a mi nut e or so and t he MSA shoul d st art under
Aut omat i c Cont rol from t he comput er.

8. Repl ace t he mai n (broken) pri mary wi ndow i n t he
wi ndow assembl y i mmedi at el y, i n a cl ean and dry
room, so t hat i t i s ready for t he next t i me a wi ndow
change i s requi red. Al so repl ace t he al armed
(backup) wi ndow t oo i f i t i s broken or cri nkl ed. The
procedure fol l ows:

7.9.3 Replacing the Primary Window
The procedure for repl aci ng t he pl ast i c sl urry cont ent
wi ndow i s si mpl y a mat t er of unscrewi ng t he
ei ght count ersunk screws (see phot o l eft ) of t he backup
wi ndow ri ng (AM233/ 20) and fi t t i ng a new 58. 8 mm
di amet er di sc of 50 mi cron t hi ck cl ear Myl ar wi ndow, i n
pl ace of t he ol d one. These wi ndows are suppl i ed i n t he
Tool Box and can be re-ordered from t he Company when
your st ock i s l ow. Fi gure 7-7 shows an expl oded vi ew of
t he Wi ndow Assembl y.

Al so remove any di rt or ot her debri s or corrosi on duri ng
t hi s process. The O-ri ng shoul d be very l i ght l y greased
wi t h pet rol eum j el l y. The rot at i onal ori ent at i on of t hi s
ri ng i s uni mport ant i n t hi s product .



AM232 - ALARMED WINDOW ASSEMBLY
BRASS SCREWS (8)
TE-91 - BACKUP WINDOW
ASSEMBLY
STAINLESS STEEL WINDOW
SEALING RING
MYLAR PRIMARY WINDOW
O-RING*
* Apply petroleum jelly
TGM part no. 55035 to o-
ring.
O-RING*
* Apply a very thin smear of
petroleum jelly (TGM part no. 55035
to o-ring prior to assembly).
44844.dwg

Fi gur e 7- 7 Expl oded Vi ew of t he MEP Wi ndow Assembl y

Backing Up Data Operation


7.10 Backing Up Data
In case of soft ware fi l e corrupt i on or compl et e comput er
hardware fai l ure i t i s most i mport ant t hat regul ar back-ups
are done so t hat dat a and fi l es can be rest ored i f such
event s occur. It i s part i cul arl y i mport ant t o do a backup
each t i me changes are made t o t he anal yser soft ware
confi gurat i on and i n part i cul ar when changes are made t o
t he assay equat i ons aft er addi ng cal i brat i on dat a.

Copi es of cri t i cal fi l es can be done t o anot her fol der i n t he
di rect ory t ree on t he comput er or across t he pl ant net work
t o anot her comput er. More i mport ant l y t hough, a
ret ri evabl e copy t o 3. 5Di skett e, t ape dri ve or CD, shoul d
be done.

It i s recommended t hat ful l backup of t he GM Mi neral s
fol der be done at l east once per mont h (t hi s wi l l back up
bot h dat a and confi gurat i on). The user shoul d refer t o t he
Sof t ware Manual for furt her det ai l s on backi ng up,
i ncl udi ng l i ve aut omat i c backups of dat a and/ or
confi gurat i on of t he Wi nISA Soft ware.


8
Maintenance

The Thermo Electron on-l i ne syst em has been desi gned t o
mi ni mi se rout i ne mai nt enance. Al l beari ngs, dri ve and
st i rrer gear mot ors are grease l ubri cat ed for l i fe and t hus
are mai nt enance free. Ai r equi pment , i ncl udi ng cyl i nders
and sol enoi d val ves are l ubri cat ed for l i fe and requi re no
rout i ne mai nt enance. The ai r l i ne fi l t ers are fi t t ed wi t h
aut omat i c drai ns t o rel ease any wat er t rapped i n t hem.

To mai nt ai n t he syst em i n good worki ng order, a
Prevent at i ve Mai nt enance Schedul e i s recommended
herei n. However, as pl ant condi t i ons can vary
consi derabl y, t hi s pl an shoul d be t aken as a gui de onl y.
The commi ssi oni ng report may cont ai n addi t i onal
mai nt enance recommendat i ons. In addi t i on, t he Company
recommends each si t e records al l mai nt enance performed
on t hei r anal yser syst em and devel ops a program t o sui t
t hei r part i cul ar appl i cat i on.

At t achment 1 provi des a l i st of recommended st art -up
spares.

At t achment 2 provi des a l i st of recommended one (1)
years operat i onal spares.

The Part s Li st Manual provi des a compl et e l i st of al l part s
and assembl i es used i n t he anal yser syst em.

Preventative Maintenance Schedule Maintenance


8.1 Preventive Maintenance Schedule
8.1.1 Daily Maintenance
(Usual l y performed by pl ant operators, approx. durati on i s 5-10 mi nutes
per anal ysi s stream)

Inspect t he anal ysi s t anks t o ensure t hat t hey are
funct i oni ng correct l y and sl urry i s fl owi ng freel y (i . e. ,
no sandi ng or bl ocki ng) l ook for sl urry fl owi ng over t he
overfl ow wei r i n t he t ank. Check/ unbl ock pri mary
sampl er/ sampl e del i very l i nes i f necessary. Report
excessi ve sl urry fl ow or surgi ng.

Check t hat st i rrers and wat er sprays, i f used, are
worki ng correct l y. If a st i rrer appears t o be under-
agi t at i ng, check for wear/ damage or t rash mat eri al .

Check t hat t he met al l urgi cal sampl ers are worki ng and
change shi ft sampl e bucket s at t he end of each shi ft .

Check t hat on-l i ne assay dat a i s bei ng di spl ayed
correct l y on t he comput er screen. If not , t hen check for
al arm/ warni ng messages and i nvest i gat e why. If a
Wi ndow Rupt ure al arm i s di spl ayed t hen check t hat t he
probe i s rai sed out of t he sl urry and repl ace t he probe
wi ndow as soon as i s pract i cal l y possi bl e (refer t o t he
operat i onal procedure i n chapt er 7, Operat i on).

8.1.2 Weekly Maintenance
(Approx. durati on i s 40 mi nutes per MSA)

Fi l l t he probe dewar wi t h Li qui d Ni t rogen (LN
2
). Thi s
must be done rout i nel y and preferabl y t he same day of
t he week each week. Mondays and Thursdays are good
days for pl ant s operat i ng wit h regul ar 5/ 2 weekends.
Keep a l og-book of fi l l ing t i mes and approxi mat e
amount used each t i me. Moni t ori ng t he LN
2
usage wi l l
i ndi cat e t he condi t i on of t he probe det ect or over t he
l ong t erm and hence i ndi cat e when probe evacuat i on i s
requi red.

Take one or t wo cal i brat i on st yl e check sampl es per
st ream. These shoul d be compared t o t he MSA readi ngs
at t he same end t i me, t hen added t o t he sui t es of
cal i brat i on dat a.
Maintenance Preventative Maintenance Schedule


Check t he operat i on of t he probe wat er spray ri ng and
t he frot h depressant wat er spray i n each anal ysi s t ank
where t hey are bei ng used. Fai l ure of any of t he probe
wat er sprays may cause cross-cont ami nat i on or
i ncorrect readi ngs i f i t s a frot h spray t hat has fai l ed,
cl ean or repl ace as necessary.

Wash t he anal yser wi t h a l ow pressure cl ean wat er hose
t o prevent sl urry bui l d-up. Part i cul ar at t ent i on shoul d
be made t o cl eani ng movi ng part s, i ncl udi ng t he gui de
wheel s on t he movi ng carri age, met al l urgi cal sampl er
cut t er and nozzl e, st i rrer mot or/ gearbox, shaft and
i mpel l or.

Check t he cl eanl i ness and condi t i on of t he probe
wi ndow. Cl ean and repl ace as necessary (procedures are
provi ded i n chapt er 7, Operat i on).

Check t he condi t i on of t he Proxi mi t y Sensors. Cl ean i f
covered heavi l y i n sl urry.

Note:
The MEP wi l l use 0. 6-1. 2 l i t res of l i qui d ni t rogen per day
as l ong as t here i s a good vacuum i nsi de t he det ect or
chamber. Thi s vol ume does not account for LN st orage
and handl i ng l osses. As t i me passes, t he vacuum i nsi de t he
det ect or chamber may det eri orat e and t he l i qui d ni t rogen
usage wi l l consequent l y i ncrease due t o gas-conduct ed
heat l osses. Aft er several years, t hi s l oss of vacuum may
begi n t o affect t he performance of t he probe by degradi ng
t he resol ut i on of t he det ect or and t hus changi ng t he
st andard count -rat es. At t hi s st age, t he probe must be
re-evacuat ed. t he Company wi l l provi de assi st ance wi t h
re-evacuat i on.



8.1.3 Monthly Maintenance
(Usual l y performed by pl ant mai ntenance personnel , approx. durati on of
each task i s 5-10 mi nutes per uni t)

Ensure t he hoi st ai r cyl i nder (ram) i s operat i ng
correct l y. Check t he prot ect i ve boot and repl ace as
necessary.

Check t he operat i on of t he safet y l at ch on t he hoi st . To
check t hi s rai se t he hoi st , cl ose off t he ai r suppl y and
open t he ai r bl eed val ve on t he ai r reservoi r. If t he
hoi st l owers ful l y t hen t he l at ch i s not worki ng. Al so
t he l at ch can be heard cl unki ng when rai si ng and
l oweri ng t he probe.

Check t he condi t i on of t he probe carri age gui de rol l ers,
i f worn repl ace. The probe carri age shoul d move bot h
vert i cal l y and hori zont al l y i n a smoot h operat i on.

Appl y general purpose grease t o movi ng part s as per
l ubri cat i on schedul e i n sect i on 8. 2.

Check t he operat i on of t he l i mi t swi t ch act i vat or arms
(These are fi t t ed on t he met al l urgi cal sampl ers). If
t hey are st i cki ng, ei t her repl ace or l ubri cat e wi t h l i ght
oi l (see l ubri cat i on schedul e i n sect i on 8. 2).

Check t he operat i on of al l Met al l urgi cal Sampl ers by
request i ng a manual cut . If a sampl er i s st i cki ng,
remove t he cover, cl ean t he sl i de rai l s and appl y ant i -
sei ze grease (Refer t o l ubri cat i on schedul e i n sect i on
8. 2). Do not use general purpose grease i n pl ace of
ant i -sei ze grease. Al so check t he condi t i on of t he
sampl e out l et hose and repl ace i f necessary.


Ini t i at e a Wi nISA di rect ory back up. Use t he DAT t ape
or CD-R or i n a sui t abl e net work l ocat i on as
appropri at e. Inst ruct i ons are provi ded i n t he Wi nISA
manual (Thi s t ask woul d normal l y be performed by t he
si t e net work/ comput er admi ni st rat or).

8.1.4 3-Monthly Maintenance
(Usual l y performed by the metal l urgi cal techni ci an, approx. durati on of
each task i s 20-30 mi nutes)

Re-st andardi se t he anal yser. The St andard Bi scui t i s t o
be at t ached t o t he probe head for t hi s (shown l eft i n
phot o). The procedure shoul d be carri ed out by t he
met al l urgi cal t echni ci an who i s responsi bl e for
cal i brat i ng t he anal yser. The procedure i s gi ven i n
chapt er 5, Commi ssi oni ng.

From t he st andard measurement s, check t he probe Li ve-
Ti me rat i o (LTR) agai nst t he l ast measurement . Thi s
number i s di spl ayed on t he comput er count -rat es t abl e
as t he fi rst channel val ue for each probe.


The Li ve Ti me Rat i o (LTR) of t he MEP gi ves an
i ndi cat i on of some el ect roni c probl ems whi ch may be
devel opi ng i n t he det ect or. In normal operat i on t he
LTR wi l l remai n fai rl y const ant and wi l l usual l y have a
val ue great er t han 0. 5. It wi l l never exceed 1. 0 (100%)
of course and wi l l onl y approach t hat val ue when t he
probe i s out of t he pul p. The operat i ng l i ve t i me may
possi bl y change by up t o 5% as t he count -rat es i n t he
det ect or vary duri ng normal probe operat i on. If t he
LTR begi ns t o decrease markedl y, i t may i ndi cat e t hat
t here i s an i ncrease i n mi crophoni c noi se or t hat t he
vacuum i n t he det ect or chamber i s det eri orat i ng.

Note:
By keepi ng a record of t he st andard count -rat es, LTR and
t he rat e of LN2 usage, i t i s possi bl e t o ant i ci pat e when t he
probe wi l l requi re mai nt enance. For exampl e, i f t he probe
i s begi nni ng t o use more l i qui d ni t rogen, t hen t he Company
shoul d be not i fi ed and arrangement s made t o re-evacuat e
(pump down) t he probe. If t he count -rat es are begi nni ng
t o change as wel l , t hen t he probe shoul d be servi ced as
soon as possi bl e.

Warni ng:
If LN
2
usage suddenl y i ncreases t o 3 or more l i t res per day
i t can be assumed t hat a maj or vacuum l eak does exi st or
has t emporari l y exi st ed at some earl i er t i me. The most
l i kel y cause of t hi s i s LN
2
comi ng i n cont act wi t h t he
l ower part of t he det ect or uni t from carel essness duri ng
fi l l i ng wi t h LN
2
whi ch can freeze and harden t he O-ri ngs,
whi ch may l eak unt i l warm agai n, or cause maj or physi cal
damage t o t he probe. It i s undesi rabl e t o al l ow t he probe
t o operat e at t hi s hi gh rat e of LN
2
consumpt i on and i t wi l l
have t o be al l owed t o warm up and be re-evacuat ed as a
mat t er of some urgency. During warm-up t here i s a sl i ght
ri sk of a pressure bui l d-up i n t he dewar as gas t rapped i n
t he act i vat ed carbon cryosorbant i s rel eased. Thi s may
expel t he pl ug from t he pump-out port . There must be no
obst ruct i on t o t he pl ug bei ng ej ect ed because t hi s wi l l
prevent possi bl e damage t o t he dewar by over-pressure.



8.1.5 6-Monthly Maintenance
(Usual l y performed by pl ant mai ntenance personnel , approx durati on of
each tank i s 15-20 mi nutes per i tem)

Remove (i f necessary) st i rrer shaft s from t he mot or and
check t he condi t i on of t he i mpel l ers. If repl aci ng an
i mpel l er, ensure i t i s t he same di amet er as t he ori gi nal
and cut t o si ze i f necessary. When re-i nst al l i ng a
st i rrer, make sure i t does not foul t he movi ng carri age
when l oweri ng t he probe before re-appl yi ng power.
The i mpel l er must al so cl ear t he bot t om of t he t ank and
t he probe. An i mpel l er t oo cl ose (<10mm) t o t he
bot t om of t he t ank may wear a hol e i n t he t ank over
t i me. If t he i mpel l or i s t oo cl ose t o t he probe i t wi l l
cause i ncreased wear rat e of t he i mpel l or and t he probe,
and i s l i kel y t o resul t i n mi crophoni cs whi ch wi l l cause
t he probe t o read erroneousl y.

A grease ni ppl e i s fi t t ed on t he i dl er pul l ey shaft
l ocat ed on t he l eft hand si de underneat h each
met al l urgi cal sampl er (phot o l eft ). Appl y one shot of
general purpose grease (do not over grease). See
l ubri cat i on schedul e i n sect i on 8. 2.

Drai n and cl ean out , or repl ace t he ai r fi l t er (l ocat ed
wi t h t he ai r i sol at or val ve).

Check t he condi t i on of t he probe wi ndow and repl ace i f
i t i s di scol oured, scrat ched or cri nkl ed. The l evel of
wi ndow cl eani ng requi red may be reduced or i ncreased
dependi ng on t he sl urry t ype and condi t i on, t hi s wi l l be
det ermi ned duri ng t he commi ssi oni ng of t he ISA
syst em. If t he wi ndow becomes t oo st ai ned t he
t ransmi ssi on may be reduced whi ch wi l l consequent l y
change t he count -rat es used for assay cal cul at i on. If
t he wi ndow becomes t oo scrat ched pi n hol es may
devel oped i n t he wi ndow whi ch wi l l al l ow moi st ure t o
i ngress t he probe. Therefore, a wi ndow shoul d be
repl aced as soon as i t shows signs of severe st ai ni ng or
wear. Under normal operat i ng condi t i ons a wi ndow
wi l l l ast 3 t o 6 mont hs (Thi s t ask woul d normal l y be
performed by pl ant personnel who are l i censed t o work
wi t h radi at i on gauges).



8.1.6 12-Monthly Maintenance or Plant Shutdown
(Usual l y performed by Pl ant Mai ntenance personnel , mi ni mum durati on
of each task i s 20 mi nutes)

Drai n t he anal ysi s zones and wash out any accumul at ed
rubbi sh. Check for wear on t he rubber l i ni ng i f used,
and rel i ne or repai r i f requi red.

Check for wear on t he sampl e cut t ers, repl ace i f worn.

Check Met al l urgi cal Sampl er cut t er carri age bushes and
bel t for wear. Repl ace i f requi red, or t i ght en bel t
where necessary (see phot o l eft ).

Inspect t he anal ysi s t ank and associ at ed pi pe work,
sampl e cut t ers, et c. for si gns of wear and t ear and
repl ace any worn part s. If repl aci ng an i mpel l er, ensure
i t i s t he same di amet er and t ype as t he ori gi nal and cut
t o si ze i f necessary.

Check t hat t he st i rrer i s worki ng and t hat t he i mpel l er
has not been worn away. The sl urry shoul d be wel l
mi xed t o avoi d segregat i on of t he sl urry. However, t he
mi xi ng shoul d not be so t urbul ent t hat ai r i s ent rai ned.
Segregat i on of t he sl urry may cause erroneous assay
dat a. Al so check t hat t he st i rrer i mpel l er or shaft i s not
hi t t i ng t he probe nor t he bot t om of t he t ank, ot herwi se a
hol e may appear i n t he bot t om of t he anal ysi s t ank
t hrough wear.

Remove t he act uat or on t he wat er sol enoi d val ve,
(green suppl y l i ne) and check i t s rubber di aphragm for
wear. Repl ace as necessary (see phot o l eft ).

If t he probe hoi st ai r cyl i nder (pneumat i c ram) i s
st i cki ng, st ri p i t down, cl ean and appl y pneumat i c
grease before re-assembl i ng.

Check t he neoprene gasket i n t he t op of t he dewar cover
i s abl e t o make a good seal . Oft en i f t he t urnbuckl e i s
t oo t i ght when cl osed, t he l i p of t he dewar cover can
deform t he neoprene beyond t he poi nt of el ast i ci t y, and
a groove wi l l remai n.

Cleaning the Probe after Slurry Penetration Maintenance


8.2 Lubrication Schedule
Al l beari ngs and st i rrer gear mot ors are grease l ubri cat ed
for l i fe and t hus requi re no rout i ne mai nt enance. Ai r
equi pment , i ncl udi ng t he hoi st cyl i nder and sol enoi d val ve
are l ubri cat ed for l i fe and requi re no rout i ne mai nt enance.

Ot her l ubri cat i on/ greasing requi rement s are:

Appl y general purpose grease t o any movi ng part s as
requi red.

A grease ni ppl e (see phot o l eft ) i s fi t t ed on t he i dl er
pul l ey shaft l ocat ed on t he l eft hand si de underneat h
each met al l urgi cal sampl er (i f fi t t ed). Appl y one shot of
general purpose grease (do not over grease).

Check t he operat i on of t he l i mi t swi t ch act i vat or arms
on t he met al l urgi cal sampl ers (i f fi t t ed). If t hey are
st i cki ng, ei t her repl ace or l ubri cat e wi t h l i ght oi l (eg
CRC, WD-40, Shel l DWF).

Check t he operat i on of al l Met al l urgi cal Sampl ers. If a
sampl er i s st i cki ng, remove t he cover, cl ean t he gui de
rods and appl y t he recommended l ubri cant .

The recommended lubricant is Rocol MHT available at outlets in most
industrial regions. In some countries it is identified as Molybond GA-50
Anti-Seize Compound. It can be ordered from Thermo Gamma-Metrics in a
125 gm tube as part number 55038.

Shoul d an oi l seal fai l on a st i rrer mot or/ gearbox,
repl ace t he seal and t op up t he oi l . Seal and oi l t ype
wi l l depend on t he t ype of st i rrer, and i s i ndi cat ed i n
t he i dent i fi cat i on pl at e on t he st i rrer.

Note:
Vi scous Organi c grease i s not recommended.

Lubricant and Brush
Maintenance Drying Out The Probe Preamplifier


8.3 Cleaning the Probe after Slurry Penetration
In t he event of a wi ndow rupt ure where sl urry has
penet rat ed t hrough t he back-up wi ndow and i nt o t he
i nsi des of t he l ower probe, i t i s necessary t o cl ean out t he
sl urry and wash t he component s, i ncl udi ng t he source, i n
pure al cohol (eg. et hanol or met hanol ), fl ush wi t h di st i l l ed
wat er t hen dry t horoughl y wi t h warm ai r. A separat e
procedure for dryi ng t he preampl i fi er ci rcui t s on t he
det ect or i s gi ven i n sect i on 8. 5 as t hi s procedure may need
t o be done from t i me t o t i me even i f sl urry hasnt ent ered
t he probe.

Note:
Inbui l t safet y devi ces wi l l have regi st ered a faul t i f sl urry
has penet rat ed t he probe, and t he MSA wi l l revert t o
Manual cont rol so t hat i t cannot cont i nue t o l ower i nt o
anal ysi s zones.

Warni ng:
Permanent damage may resul t i f very hot ai r i s used on t he
el ect roni c component s i n t he l ower probe.

Thi s cl eani ng and i nspect i on must onl y be carri ed out by
an aut hori sed pl ant offi cer (i . e. a person aut hori sed t o use
and handl e radi oi sot opes and radi at i on gauges, an RSO)
who shoul d i nspect t he probe and remove any si gns of
sl urry (or wat er).

Once t he component s are cl ean and dry, repl ace t he
wi ndow assembl y. A det ai l ed descri pt i on of how t o
repl ace a broken probe wi ndow i s gi ven i n chapt er 7,
Operat i on.

It i s t hen i mport ant t o regul arl y (every 3 t o 6 mont hs)
i nspect t he beryl l i um wi ndow on t he front surface of t he
radi oi sot ope source for si gns of corrosi on. Corrosi on of
t he beryl l i um wi ndow appears as a whi t e powder on t he
dark grey beryl l i um.

If sl urry has ent ered t he probe and i s known t o be of a
corrosi ve nat ure t hen t he i sot ope shoul d be i nspect ed more
oft en for si gns of whi t e cryst al l i ne bui l d-up on i t s casi ng
as many i sot opes used al so have a Beryl l i um wi ndow. If
corrosi on of t he source i s evi dent , t he head shoul d be
seal ed i mmedi at el y i n a pl ast i c bag unt i l a wi pe t est can be
IN-LINE FILTER
BERYLLIUM WINDOW
SOURCE HOLDER
WINDOW ASSEMBLY
CABLE ASSEMBLY
LN2 DEWAR
X-RAY DETECTOR
LN2 SENSOR CABLE
MEP UPPER SHROUD
ASEMBLY
(DEWAR COVER)
LN SENSOR
LN FILTER CAP


performed on t he source by t he appropri at e aut hori t y. In
most cases t he appropri at e aut hori t y wi l l be t he
government regul at i ng radi at i on aut hori t y.

Cauti on:
Use a mi rror t o i nspect t he radi oi sot ope source t o avoi d
exposure t o t he X-rays from t he source duri ng t hi s
procedure.

Maintenance Dismantling and Reassembling the Probe


8.4 Dismantling and Reassembling the Probe
The fol l owi ng procedures for di smant l i ng and assembl i ng
t he Mul t i -El ement Probe (Fi gure 8-1) rarel y need t o be
performed. Loadi ng and unl oadi ng t he radi oi sot ope i s a
speci al i sed t ask and must onl y be carri ed out by t rai ned
and l i censed personnel (eg. t he si t e RSO or t he Company
engi neer).

Cauti on:
Before proceedi ng, make sure t he Si gnal Anal yser i s
t urned OFF (see phot o l eft ) and t he probe i s rai sed on i t s
hoi st and parked at one accessi bl e end of t he MSA frame.
Opt i onal l y, t urn off t he mai ns power at t he MSA cont rol l er
swi t ch on t he out si de panel (see phot o l eft ).

WINDOW ASSY
SOLID STATE DETECTOR
LN SENSOR
SOURCE
PREAMPLIFIER
WINDOW RUPTURE
END PLUG
LOCATING BLOCK
LOCATING SPRING
LOWER SHROUD ASSY
SIGNAL BNC
PREAMP POWER
IN-LINE FILTER
RETAINING
BOLT
WINDOW
BIAS
SPIGOT TOOL
LN DEWAR
LN FILLER
COLLAR
LN SENSOR
DEWAR PLUG
DEWAR COVER
WINDOW
ALIGNMENT TOOL

Fi gur e 8- 1 Expl oded Vi ew of t he Component s of an MEP
Dismantling and Reassembling the Probe Maintenance


8.4.1 Dismantling the Probe

1. Ensure t hat t he probe power and bi as vol t age swi t ches
are bot h swi t ched off i n t he Si gnal Anal yser.

2. Remove t he Wi ndow Assembl y by rot at i ng t he t wo
square head capt i ve bol t s at t he rear. Act i on shoul d be
t aken t o avoi d radi at i on exposure before and aft er t he
wi ndow i s removed.

Cauti on:
Handl e t he wi ndow from underneat h and work from t he
back of t he probe t o prevent unnecessary l ow-l evel
radi at i on exposure.

3. Bef ore removi ng t he det ect or from i t s casi ng t he source
shi el d (Insert i on Guard) (shown l eft ) must be fi xed i n
pl ace over t he radi oi sot ope usi ng t wo M3 screws (refer
t o Fi gure 8-2). Thi s serves t o prot ect t he prot rudi ng
spri ng wi ndow cont act s from damage when t he
det ect or/ dewar assembl y i s bei ng l i ft ed out of t he
shroud. It al so act s as a bi ol ogi cal radi at i on shi el d.

Multi-Element Probe
Beryllium
Window
Shield
43403 M3x12
Csk Screw
57565 (2)
Source
(3 possible
positions)
Window Contact
Fingers

Fi gur e 8- 2 Fi t t i ng t he MEP Sour ce Hol der and Shi el d

4. Remove t he dewar cover aft er removi ng t he ei ght hex
dome nut s around t he fl ange. Li ft t he cover st rai ght off.
Maintenance Dismantling and Reassembling the Probe


5. Remove t he BNC pl ug from t he LN sensor at t he t op of
t he dewar.

6. Loosen t he curved met al cl amp on t he bl ack pl ast i c
base (see phot o l eft ) and rot at e t o free t he det ect or.

7. Di sconnect t he t hree cabl es from t he pl ugs under t he
dewar and t he dat a cabl e from t he fi l t er uni t . Take not e
of how t he cabl es are fi xed and dressed so t hey may be
rest ored l at er (see phot o l eft ).

8. Now t he handl e may be used t o l i ft t he compl et e
det ect or/ dewar assembl y and wi t hdraw i t from t he
shroud. It may be easi er i f t wo persons perform t hi s
t ask. The det ect or may become st uck i f i t i s not
wi t hdrawn vert i cal l y. If t hi s occurs, t wi st t he det ect or
sl i ght l y unt i l i t comes out smoot hl y.

9. If t he probe i s t o be removed for l onger t han a few
mi nut es, repl ace t he dewar cover and t he wi ndow t o
ensure t he i nsi de of t he housi ng remai ns cl ean.

8.4.2 Reassembling the Probe
Reassembl y i s essent i al l y t he reverse of above. Det ai l ed
assembl y procedures are gi ven i n t he Inst al l at i on chapt er
of t hi s manual .

Pay part i cul ar at t ent i on t o t he cabl es. They must pass
t hrough t he gap i n t he pi vot fl ange, and wrap under t he
dewar such t hat t hey do not become t rapped under t he
fl ange. When t he det ect or assembl y i s properl y posi t i oned
i t s cent re shoul d coi nci de wi t h t he wi ndow assembl y
cent re
+/ -2. 0mm. Al so check t hat t he bot t om of det ect or can be
pressed back agai nst i t s spri ng and wi l l ret urn about
10mm.

When t he probe i s compl et el y reassembl ed, t he Si gnal
Anal yser power may be t urned back on. Check t hat t he
probe Bi as Ramps up and t hat t he Bi as and Opt i cal Reset
LEDs t urn green, i f so t hen al l i s now okay and t he MSA
may be put back i nt o Aut oMode, under comput er
cont rol .

If t he Bi as suppl y and/ or Opt i cal reset LEDs are not
normal , and you are sure t hat cl eani ng and dryi ng (see
sect i on 8. 5) has been done properl y, t hen consul t wi t h t he
Company i mmedi at el y.
Dismantling and Reassembling the Probe Maintenance


Drying Out The Probe Preamplifier Maintenance


8.5 Drying Out The Probe Preamplifier
On rare occasi ons moi st ure may have accumul at ed on t he
feed-t hrough ci rcui t s and el ect roni cs (pre-amp and HV
fi l t er) mount ed on t he probe det ect or. If so, t hen t he
sympt oms di scussed i n t he Troubl e Shoot i ng sect i on 9 wi l l
be evi dent and t he fol l owi ng mai nt enance procedure i s
requi red t o dry-out t he det ect or component s.

Thi s procedure must al so be fol l owed i f cl eani ng i s
requi red aft er sl urry has ent ered t he probe t hrough a
broken wi ndow.

Before commenci ng t hi s procedure check t he fol l owi ng:
Probe i s near ful l of l i qui d ni t rogen.
Al l cabl es connect ors are cl ean and correct l y
connect ed.
The radi oi sot ope X-ray source has not been di st urbed.
The l i qui d ni t rogen consumpt i on rat e has not changed
great l y. A l arge i ncrease i n l i qui d ni t rogen
consumpt i on i ndi cat es t hat t he vacuum has fai l ed and
t he det ect or uni t needs t o be pumped down. In t hi s
ci rcumst ance cont act t he Company i mmedi at el y.

Thi s procedure shoul d be at t empt ed i n t he order as
present ed as t he st eps progress from easy t o hardest
dependi ng on how severe t he case.

1. If possi bl e, l eave t he probe, wi t h t he dewar ful l , seal ed
for one or t wo days i n i t s shroud, wi t hout t he f oam
pl ug, j ust shut t he st ai nl ess st eel dewar cover. In cases
where onl y a smal l amount of condensat i on has
occurred, ci rcul at i on of t he t ot al l y dry l i qui d ni t rogen
gas around t he det ect or wi l l usual l y dry out t he
preampl i fi er very effect i vel y (see schemat i c l eft ).
Al l ow 1 t o 2 days (of course t hi s means t he MSA wi l l
be off-l i ne duri ng t hi s t i me). Ot herwi se,

2. If t he probe i s l ocat ed i n a conveni ent l ocat i on, remove
t he wi ndow assembl y and shi el d t he radi oi sot ope usi ng
t he shi el d provi ded as i n sect i on 8. 4. Usi ng a domest i c
hai r dryer (or warm ai r gun), gent l y warm t he det ect or
uni t by bl owi ng heat ed ai r upwards t hrough t he openi ng
l eft where t he wi ndow assembl y was removed. Cont i nue
t hi s for about 30 mi nut es maki ng sure t hat t he det ect or
does exceed 50 C. If you can hol d your hand on t he
met al t hen t he t emperat ure i s okay. Remove t he shi el d,
repl ace t he wi ndow assembl y and ret est t he probe.
Drying Out The Probe Preamplifier Maintenance


Warni ng:
Permanent damage may resul t i f very hot ai r i s used on t he
el ect roni c component s i n t he l ower probe.

If t he probe bi as st i l l wi l l not ramp up t hen,

3. For severe cases where procedure 2 doesn' t work, or
sl urry/ wat er has i ngressed past t he wi ndow i nt o t he
shroud, remove t he probe det ect or from i t s shroud,
usi ng t he procedure gi ven i n sect i on 8. 4. Shi el d t he
radi oi sot ope and t he t ake t he det ect or t o a cl ean work
area t hen fol l ow t hese st eps:

a) If t he dewar cont ai ns l i qui d ni t rogen (t hi s i s usual l y t he
case) mount and secure t he det ect or uni t vert i cal l y (use
t he met al st and t hat t he det ect or was shi pped i n, see
phot o l eft ).

b) Locat e t he preampl i fi er. Thi s i s t he area where t he
probe cabl e connect ors at t ach. Undo t he t wo smal l
cross head screws t hat secure t he pre-ampl i fi er cover
(see phot o bel ow l eft ).

Warni ng:
Do not remove any furt her screws or bol t s as most of t hem
secure vacuum seal s. If any of t hese are di st urbed severe
damage t o t he det ect or uni t wi l l occur.

c) Sl i de t he cover t ube up t o expose t he preampl i fi er.

d) Usi ng a domest i c hai r dryer or si mi l ar warm heat
source, bl ow warm ai r i nt o and around t he vari ous part s
of t he preampl i fi er for t hree mi nut es or so. If t here i s
sl urry present , wash t he preampl i fi er i n pure al cohol
(et hanol or met hanol onl y) t hen di st i l l ed wat er before
dryi ng.

e) Repl ace t he pre-ampl i fi er cover and rei nst al l t he
det ect or i nt o i t s probe shroud. In a moi st cl i mat e t hi s
shoul d be done qui ckl y before new moi st ure condenses.

Note:
If aft er t est i ng, t he probe bi as wi l l st i l l not ramp up t hen
cont act t he Company i mmedi at el y.

Storage of Equipment for Extended Plant Shutdown Maintenance


8.6 Storage of Equipment for Extended Plant Shutdown
If t he pl ant i s t o be shut down for a l ong peri od of t i me
t hen i t may be deci ded by t he owners t o remove t he
radi oi sot ope from t he MEP for safe st orage. Thi s i s not a
requi rement by t he Company. Si mi l arl y i t may be deci ded
t o move t he det ect or wi t h shi el ded source t o a st orage
l ocat i on whi ch i s more conveni ent for regul ar LN
2
fi l l i ng.
Agai n, t hi s i s t he owners deci si on.

To remove t he det ect or wi t h i t s (shi el ded) source i n pl ace,
fol l ow t he procedure i n sect i on 8. 4. Thi s provi des for
put t i ng a radi at i on shi el d on t he source hol der. The
det ect or shoul d t hen be put i nt o i t s met al st and t hat i t was
ori gi nal l y suppl i ed wi t h, st ored i n a safe cl ean and dry
pl ace and be kept fi l l ed at l east once per week wi t h LN
2
.
The foam dewar pl ug must be i nsert ed i nt o t he det ect or t o
keep di rt and moi st ure out .

The pl ace of st orage may be on si t e near t o t he l ocat i on of
t he FLE or ot her Li qui d Ni t rogen suppl y, or off si t e wi t h a
t hi rd part y. It may be necessary t o remove t he
radi oi sot ope. Consul t your Radi at i on Safet y Offi ce for
advi ce.

If t he source (wi t h shi el d at t ached) must be removed from
t he det ect or t hen unscrew t he t hree M3 screws t hat fi x t he
source hol der i nt o t he det ect or. Thi s shi el ded source
hol der t hen needs t o be st ored i n a safe pl ace t hat i s
cl assi fi ed as t he si t e radi at i on st ore wi t h cont rol l ed access.
The si t e RSO i s responsi bl e for carryi ng out t hi s t ask and
ensuri ng t hat t he radi oi sot ope i s properl y st ored.

Note:
Repl ace t he upper dewar cover and wi ndow aft er removi ng
t he det ect or t o ensure t he i nsi de of t he housi ng remai ns
cl ean.

Warni ng:
Fai l ure t o keep t he MEP al ways cool ed wi t h LN
2
even
when not i n use, may permanent l y damage i t .

Storage of Equipment for Extended Plant Shutdown Maintenance


Warni ng:
If t he radi oi sot ope source i s t o be removed, i t must be
st ored safel y and t he l ocal radi at i on aut hori t y not i fi ed of
i t s st orage met hod and l ocat i on.

The remai ni ng component s of t he anal yser syst em, i . e.
el ect roni cs, comput er equi pment , et c shoul d j ust be shut
down wi t h mai ns power t agged out (see phot o l eft ) t o al l
i n-pl ant equi pment .

Drai n t he anal ysi s zones and wash down t he anal yser. In
some si t uat i ons i t may be desi rabl e t o cover t he equi pment
wi t h t arpaul i ns or si mi l ar and/ or t ake measures t o prevent
condensat i on or ot her wat er damage.

It i s recommended t hat an i nvent ory of t he st ored
equi pment be mai nt ai ned.

8.7 Replacing the Sample Hose
When t he sampl e hose (part number 34890) requi res
repl acement t ake care t o i sol at e t he Sampl er cont rol l er t o
prevent t he cut t er from movi ng. Remove t he four hex nut s
ret ai ni ng t he fl ange cl ampi ng ri ng. Undo t he hose cl amp
at t he t op end of t he hose. Remove and di scard t he ol d
hose.

Maintenance Storage of Equipment for Extended Plant Shutdown


Convex side to
face upwards
Remove 4 nuts
and SS flange

Fi gur e 8- 3 The Sampl e Hose

Now i nsert a new hose from t he out si de. Make cert ai n t hat
t he convex profi l e on t he hose fl ange i s faci ng up and
i nwards (i . e. t oward t he cut t er) as shown i n Fi gure 8. Sl i p
t he hose cl amp over t he t op of t he hose and sl i de t he hose
over t he cut t er spi got t ube. You wi l l need t o push i t ful l y
on unt i l i t t ouches t he cut t er pl at e at t he bot t om as i n
Fi gure 8-4.

Fi t t he cl amp ri ng and repl ace t he four hex nut s. Posi t i on
and t i ght en t he hose cl amp. Make sure t he hose has no
maj or ki nk and i s not overst ret ched.

Swi t ch t he Sampl er cont rol l er back on and perform several
manual cut s. Check t he hose runs smoot hl y wi t hout
ki nki ng or st rai ni ng.

Fi gur e 8- 4 The sampl e hose cor r ect l y at t ached t o cut t er


Section 8 - Maintenance
Attachment 1Recommended Start Up
Spares


Section 8 - Maintenance
Attachment 2One Year Operational
Spares


9
Trouble Shooting

Thi s sect i on i s wri t t en for t hose personnel who wi l l
oversee di agnosi ng el ect roni c faul t s wi t h t he anal yser
syst em. It i s i nt ended t o provi de a gui de t o di agnosi ng
where t he faul t may be. A descri pt i on of t he el ect roni c
cards and modul es and t hei r funct i on i n t he anal yser i s
provi ded i n chapt er 7, Operat i on, so t hese chapt ers may be
used i n conj unct i on t o l ocat e and repai r a faul t .

The on-l i ne anal yser syst em i s desi gned i n a hi ghl y
modul ar form so t hat faul t s can qui ckl y be i sol at ed t o a
part i cul ar ci rcui t board or sub-assembl y. The board or
sub-assembl y can t hen be repl aced wi t h a spare from t he
spare part s ki t so t hat down t i me for t he syst em i s
mi ni mi sed.

Thi s chapt er provi des a descri pt i on of di agnost i c LEDs
used on t he el ect roni c cards.

Procedures i n t he fol l owi ng sect i ons shoul d hel p t o
qui ckl y i sol at e t he probl em t o one or t wo ci rcui t boards or
sub-assembl i es. At t hat st age, we recommend t hat you
i nt erchange spare boards from t he spare part s ki t t o fi x t he
probl em. The faul t y component shoul d t hen be sent back
t o t he Company for repai r or repl acement (refer t o chapt er
10, Servi ce and Warrant y).

Some Basic System Mechanical Checks Before Proceeding Troubleshooting


9.1 Some Basic System Mechanical Checks Before Proceeding
Because somet i mes a l oss of on-l i ne assays can be
at t ri but ed t o a mechani cal fai l ure, i t i s i mport ant t o carry
out t hese basi c syst em checks before proceedi ng wi t h
i dent i fyi ng any el ect roni c probl ems i n t he syst em. Go and
i nspect t he MSA i n t he pl ant and check t he fol l owi ng:

1. The st at us di spl ay (<St at sDsp>) on t he OI panel some
t ypi cal error messages t hat wi l l st op t he MSA operat i on
(hence st op produci ng assays) are gi ven i n Tabl e 9-2.
MSA Operator Interface Panel Error Messages
(refer t o Fi gure 9-1)
Field/Error Message
(x is the zone
or stream number)
Description/Cause/Remedy
PositionTest Req A self (positioning) test must be performed. Check that
the MSA is in Auto RunMde and select the <AutoStrt>
option in menu level 5 so that a position test will start on
power up and after fixing a failure, the MSA will restart.
Check the <ZoneMask> (at menu level 7) has been
entered and the Zones Available have been configured
(at menu level 5).
ErrRaisingPrb x
Check the probe carriage hoist. If the Hoist Ram is
sticking it may not be able to raise the probe properly.
Clean the Ram as required, see maintenance. Check for
jamming of rollers and other mechanical parts. Check
that the Up/Down sensor switches on the hoist are
working. Replace if failed.
May be seen in conjunction with AirFl message in
<StatsDsp>??

RevLsNotFound x
The message implies the Reverse Limit Switch (ie. The
prox. Sensor) has not registered the probe moving past it.
This can be caused by a very dirty prox. Sensor face,
dirty metal plate on the back of the probe carriage,
mechanical failure of the probe carriage to move past this
sensor so check the movement of the probe and remove
dirt from the guide rail. Otherwise, put the MSA into
manual mode and try manually moving the probe to that
sensor by turning the fly-wheel on the drive assembly). If
all fails check for 24V supply to the prox. Sensor itself,
or check the RLC input card in the MSA controller and
change out as necessary.
StuckAtLstZne x
The probe is not responding to commands to move to
another zone or it does not have programmed any other
zones. Check..

ZoneNotFound x
Either the prox. Sensor for that zone has failed (check 24
v) or it just did not register the probe carriage because the
metal plate on the back of the cartage is either very dirty
or the face of the senor is dirty. Clean as necessary.
Also check that you have defined your available (online)
zones under the menu option <ZneAvail> at menu level
5.
ZnePositionErr x During the Position Test, the probe could not position
Troubleshooting Some Basic System Mechanical Checks Before Proceeding


itself at the zone indicated. This may indicate a prox.
Sensor failure..

FailedToLower x
Ram problem, air failure or lower limit switch failure???

InvalidZneRqst x
The zone number doesnt exist. If it is supposed to then
enter it at <ZneAvail> at menu level 5.
Parked,Latched
The Park button has been pressed and the probe will be
sitting in that zone defined as the service bay.

WndRpt
This message under <StatsDsp> indicates a window
rupture. The probe will also be raised on the hoist. Park
(??, is it possible to do this?) the probe and change out
the window assembly.
AirFl
This message under <StatsDsp> indicates the air pressure
supply has dropped below the supply requirement or has
ceased altogether. Check supply, if okay then check
pressure valves and switches on the probe carriage. Also
check blue supply lines on the MSA.
Stirrer Run---------O/L x
Any zones shown in x, indicate that the stirrer for that
zone has failed through overload. Check.

Probe MotorOverload
The probe carriage drive assembly motor is in overload.
Check.
CalibSampleFailed
This may be caused by;
a. Too many sample cuts requested for the available
time (of the calibration sample).
b. Sampler problem, refer Table 9-5.
Sampler Not Installed
When selecting samplers, is there a message that
indicates that samplers have not been configured, in
which case a manual sample must betaken.
AirFl indicating the air pressure has dropped too low.
ManMode something has caused the MSA to drop out of
AutoMode and into Manual Control (try putting it
back to Auto by selecting the option <MenuMode>
then entering your pass code and then select
<AutoMode>. If it works and the probe starts
operation, then you have fixed the problem. If the
MSA doesnt start operation then check for other
indicative errors on the OI panel, such as AirF1 or
the following;
a. GuardOpen interlocked gate has not been shut
properly, or may even be wide open, shut the
gate.
b. WndRpt indicate you have a broken window in
the probe which needs to be changed out. Follow
the procedure given under the chapter Operation.
c. EMStop someone has pressed the Stop
button. Do not release until you check why this
has been pushed.
d. Park the probe has been parked for assumingly
probe maintenance. Check why before
proceeding to release the Park button
e. Position TestReq the MSA has been reset,
Some Basic System Mechanical Check Before Proceeding Troubleshooting


possibly through power failures or misappropriate
menu entries. Try powering off then on the
MSA. On power up it should do a position test, if
not, then check that the zones are actually
available. If not, then the zone mask may have
been destroyed and needs to be re-entered (see
section 7.2.6, using the OI panel menus). Also
observe any other message lines that appear on
the OI panel. For example, the next one.
f. RevLSNotFound this means the probe missed
seeing its end proximity sensor. Manually
move the probe passed this sensor by turning the
fly-wheel on the drive assembly.
Tabl e 9- 1 MSA Oper at or I nt er f ace Panel Er r or Messages

Once t he probe i s i n front of t he suspect sensor, cl ose t he
guard and put t he MSA i nt o Aut oMode. It shoul d t hen
cont i nue movi ng, i f not check t he ZoneMask,
ZoneAvai l abl e set t i ngs.

If al l t hi s fai l s t o get t he MSA operat i onal t hen proceed t o
checki ng t he el ect roni cs.

Troubleshooting Some Basic System Mechanical Checks Before Proceeding


Z
o
n
e

6

n
o

t
a
n
k
Z
o
n
e

5

n
o

t
a
n
k
Z
o
n
e

4
Z
o
n
e

3
Z
o
n
e

2
Z
o
n
e

1

n
o

t
a
n
k
F 6 5 4 3 2 1 R
Forward Limit
Switch
Remove Limit
Switch
Electronics Enclosure Electronics Enclosure & OI
Forward direction when standing at the OI side
of the MSA
Reverse direction when standing at the OI or
sample outlet side of the MSA
Zone Mask:
Sampler Mask:
Proximity sensors corresponding to zones built: F 6 5 4 3 2 1R
0 if not built, 1 if built for zone mask: 1 1 1 1 1 1
In this example proximity sensors exist for position 1: ------ -------
5 and 6 even though there are no tanks 7 7
0 is not built (ie no tank and/or no sampler), 1 if built: 0 0 1 1 1 0
In this example there are only samples for zones ------ ------
2, 3 and 6. 1 6
Converting masks to Octal (base 8):
000 0
001 1
010 2
011 3
100 4
101 5
110 6
111 7
TOP VIEW LAYOUT OF MSA

Fi gur e 9-1 An Exampl e of how t o Cal cul at e a MSA Zone and
Sampl er mask
ISA Assays Differing from Shift/Check Samples Troubleshooting


9.2 ISA Assays Differing from Shift/Check Samples
For probl ems wi t h t he on-l i ne assays consi st ent l y readi ng
di fferent t o t he shi ft or check sampl e assays and assumi ng
you are st i l l get t i ng assay readi ngs from t he anal yser,
check t he fol l owi ng bef ore proceedi ng wi t h el ect roni cs
di agnosi s;

Check t he cl eanl i ness of t he probe wi ndow. A di rt y
wi ndow wi l l change t he count -rat e measurement s and
hence t he on-l i ne assay readi ng.
Put t he st andard bi scui t on t he probe (refer t o
St andardi si ng i n chapt er 5, Commi ssi oni ng) and
measure t he st andard for 2 or 3 fi ve-mi nut e peri ods.
The st andard measurement s obt ai ned shoul d not be t oo
di fferent t o t hose bei ng used i n t he cal i brat i on equat i on
and shoul d be st abl e.
If t he st andards are very di fferent and unst abl e t hen
measure for a f ew hours and check t he t i me peri od si nce
t hey were l ast measured. If i t i s up t o a year or more
si nce l ast measured t hen ent er t he new st andards val ues
i nt o t he soft ware dat a base and t hen re-check t he on-
l i ne assays readi ngs t o see i f t hey are more accept abl e.

If t he st andard count -rat es were measured more recent l y
and are now very di fferent dont appl y t hem. There
may be an el ect roni c probl em and you wi l l need t o
proceed furt her i n t hi s chapt er t o fi nd t he faul t .

Troubleshooting Diagnostic LEDs


9.3 Diagnostic LEDs
To al l ow rapi d faul t fi ndi ng, many of t he ci rcui t boards
cont ai n di agnost i c Li ght Emit t i ng Di odes (LEDs) l i ke
t hose shown i n t he phot o l eft . The general messages gi ven
by t he LEDs are:

Colour Status Message

Green Lit or Flashing All is Running Normally*
Amber Lit or flashing All is Running Normally*
Red Flashing or flickering Usually a non-fatal problem
Investigate when convenient
Red Permanently &
Brightly Lit
Fatal Problem Investigate
Immediately

Tabl e 9-2 Di agnost i c LED Col our s

Observi ng t he LEDs at vari ous poi nt s i n t he syst em al l ows
you t o very qui ckl y fi nd t he general area of t he probl em.

There are some except i ons t o t hese general messages. For
i nst ance, t he red overl oad LED on t he AM001/ 91 Li near
Ampl i fi er card wi l l general l y fl ash fai nt l y most of t he
t i me. Thi s i s qui t e normal . Al so a number of red LEDs
wi l l i l l umi nat e for a few mi nut es aft er power i s fi rst
appl i ed t o t he uni t .

Fi gure 9-2 shows a schemat i c l ayout of cards and modul es
i n t he MEP Si gnal Anal yser chassi s. A descri pt i on of each
of t he numbered LEDs fol l ows i n Table 9-4.

* The absence of illumination of a green or amber LED or lamp may itself be an indication of a fault in some cases. Often
these colours are used for data or state indicators and hence may go on, off or flicker as a result of some activity or data traffic.

Diagnostic LEDs Troubleshooting




Card No.

Card
Description
LED
No.
LED
Description
Normal
Operating Status
Fault Status
AM001/91 Linear Amplifier Card 1 Overload Flickers Red Solid Red indicates
too many counts
and/or high energy
noise
AM002/91 Pulse Validation Card 2
3

4
5
6
Count High
Count

Too Busy
Busy
Live
Off
Flickers Green

Off
Orange
Green
L2&L3 monitor
incoming pulse rate
(Red if too high).
L4&L5 monitor
outgoing validated
pulses (L4 Red if
high, L5 off).
AM091/03 Live-Time Clock Card 7 T Off Not used
AM056 24V Supply/Ref. Card -
AM059 Low Volt Supply Card -
AM351 12V Supply Clock -
AM093/11 Comms Adaptor 8

9
10

11
12
WR Self Test Fail

TXD (transmit)
RXD (receive)

CTRL(control)
RXEN(rec enable)
Off

Flickers Green
Flickers Green

Flickers Green
Orange
Red if break or short
in Window Rupture
(WR) circuit.
Off for >60 seconds
if no data comms to
PC
Off if no comms
Off if no comms
AM092/10 Network Interface Card 13

14
Self Test Fail

LN Low
Off

Off
Red if fault with LN
level circuit
Red if LN less than 1
litre (and LN test
lamp ON)
AM062/02

Bias Supply Card

15

16
S/C LN Sensor

O/C LN Sensor
Off

Off
Red is a short circuit
in LN sensor circuit
Red is an open
circuit in LN sensor
AM994/01 MCA Access Module 17
18
Acquire Spectrum
Test Mode
Off
Off
No fault condition
No fault condition
AM990/10 SCA Module (slots 11-19) 19-27 SCA Counts Flickers Green Off indicates no
signal
AM963/20 Bias Control Module 28

Optical Reset

Flickers Green

Red indicates too
many resets. Off may
mean fault with
detector or cabling.
29 Bias Green
(Blinking Red on
Ramp Up)
Solid Red indicates
moisture on the
preamp. Off means
Bias switch off or
may indicate fatal
problem with Bias
supply or detector or
cabling.
Tabl e 9- 3 Si gnal Anal yser LEDs - Funct i onal i t y

Troubleshooting Locating a Fault with the Analyser


9.4 Locating a Fault with the Analyser
Thi s procedure assumes t hat no on-l i ne assays are bei ng
di spl ayed, or t hat t hey are very di fferent t o expect ed
val ues. If i ncorrect val ues are bei ng di spl ayed t hen check
t he probe wi ndow condi t i on and t he st andard count -rat es
before proceedi ng any furt her.

1. Check i f t he Wi nISA Server comput er i s act ual l y
runni ng (green ISA i con on t askbar) and i f so open
t he Wi nISA Cl i ent Cont rol Panel and check t hat t he
soft ware i s connect ed t o t he probe i n quest i on and
measuri ng (refer t o t he Sof t ware Manual for furt her
det ai l s). If t he comput er i s not runni ng or t he
measurement cycl e has been st opped, rest art ei t her
or bot h, open t he t abul ar count -rat e di spl ay screen
and wai t a few mi nut es for dat a t o appear. Ot her
di agnost i c warni ngs/ al arms may be vi ewed on t he
Cl i ent wi ndow, ot herwi se i f t here i snt any dat a
proceed t o 2.
2. The LEDs on t he AM093/ 11 Net work Int erface card
(phot o l eft ) i n t he Si gnal Anal yser are part i cul arl y
useful for i ndi cat i ng t he st at e of t he communi cat i on
l i nk bet ween t he Si gnal Anal yser and Wi nISA
comput er. Every mi nut e t he Wi nISA comput er wi l l
i nt errogat e t he Si gnal Anal ysers and i n doi ng so t he
green and orange LEDs on t he AM093/ 11 wi l l fl ash
moment ari l y. Thi s effect i ndi cat es t hat al l
communi cat i on i s proceedi ng normal l y. The LEDs
on t he AM955 convert er (near t he comput er, phot o
l eft ) wi l l fl ash as t he same t i me. If any of t hese
LEDs are not fl ashi ng t hen proceed t o 3. If t hey are
fl ashi ng t hen proceed t o 6.
3. Check t hat t he cabl e bet ween t he AM955 convert er
uni t (and t he ISA comput er) i s connect ed properl y.
4. Check t he cont i nui t y of t he RS-485 dat a cabl e
bet ween t he AM955 and t he Si gnal Anal yser and
check t he t ermi nat i ons on each end.
5. If al l t ermi nat i ons and cont i nui t y are okay t hen ful l y
shut down t he comput er t hen re-boot . Thi s wi l l reset
t he seri al communi cat i on port s. If t hi s fai l s fol l ow
t he procedure i n 9. 4. 1 t o check t hat t here i s act ual l y
dat a comi ng out of t he Si gnal Anal yser.


6. Al arms and Warni ngs on the Wi nISA Computer
can be vi ewed usi ng:
1. Aut ocl i ent
2. Wi nISA Cl i ent , Cont rol Panel
3. Server Moni t or

A Wi ndow Rupt ure al arm i ndi cat es t hat t he wi ndow
i s broken or t here i s moi st ure i nsi de t he wi ndow
assembl y (refer sect i on 9. 4. 2). The probe wi l l
act ual l y be rai sed on t he hoi st and t he OI panel wi l l
i ndi cat e t hat t he MSA has dropped i nt o Manual
Mode (go and check). Remove and repl ace t he
probe wi ndow i mmedi at el y (see sect i on 7. 9. 2)
An Al arm Ci rcui t Fai l ure i ndi cat es a faul t wi t h t he
WR t est ci rcui t (refer sect i on 9. 4. 3) and agai n t he
probe wi l l be rai sed from t he sl urry and so count -
rat es wi l l cease.
A Low Li qui d Ni t rogen warni ng fol l owed l at er by a
Bi as Fai l al arm i ndi cat es t he probe has run out of
LN
2
and must be fi l l ed i mmedi at el y (refer t o sect i on
9. 4. 4). Al l ow a few hours for t he probe t o cool
down before i t ret urns t o normal operat i on.
A LN Sel f Test Fai l ure i ndi cat es a faul t wi t h t he
LN t est ci rcui t (refer t o sect i on 9. 4. 5).
If t here are no apparent al arms t hen proceed t o 7.
7. Check t he st at us of LEDs i n t he Si gnal Anal yser
(refer t o Table 9-4). An abnormal st at us wi l l hel p
i ndi cat e where a probl em i s. If t here are no
abnormal LED st at us t hen proceed t o st ep 8. If
t here i s a faul t st at us i ndi cat ed t hen use t he LED and
card/ modul e descri pt i ons provi ded herei n and i n
chapt er 7, Operat i on t o hel p di agnose t he cause of
t he probl em. Some LED faul t st at us may i ndi cat e a
faul t wi t h t he MEP det ect or and i f so t hen proceed
t o st ep 9.
8. Check t he set t i ngs i n t he Si gnal Anal yser el ect roni cs
(refer sect i on 9. 4. 6). If any of t he SCA set t i ngs or
t he Gai n set t i ng have been adj ust ed i ncorrect l y t hen
count -rat e i nformat i on wi l l be i ncorrect and hence
t he assay readi ngs t oo. You wi l l need t o have kept a
l og book of any real changes t o set t i ngs made i n t he
past . If a servi ce has been done by t he Company t hen
any changes t oo set t i ngs wi l l be recorded i n t he
servi ce report . If al l set t i ngs are okay and no
abnormal LED st at us are evi dent from st ep 7 t hen i t
i s most l i kel y t hat you do not have any el ect roni c


probl em but i nst ead a di rt y wi ndow or cal i brat i on
range probl em.


9. Check t he MEP det ect or operat i on and t hat t he X-ray
spect rum and probe resol ut i on are okay. Refer t o
sect i on 9. 4. 7. You wi l l need an MCA for t hi s. If
you do not have one on-si t e t hen cont act t he
Company.

9.4.1 Checking the Signal Analyser Data Communication
To det ermi ne i f t here i s a probl em wi t h t he dat a
communi cat i ons out of t he Si gnal Anal yser set t he
fol l owi ng swi t ch i n t he Si gnal Anal yser box.

PROBE/ INJECT to INJECT

And vary t he REFERENCE pot ent i omet er on t he MCA
Access modul e so t hat pul ses are i nj ect ed i nt o one of t he
channel s. The pul se frequency i s exact l y 5kHz (5000
count s/ second).

The comput er shoul d di spl ay a number whi ch i s 5000
di vi ded by t he Li ve Ti me Rat io (LTR). The ot her channel s
can be checked i n t he same manner. Thi s procedure not
onl y checks t he Si gnal Anal yser but can al so be used t o
di agnose probl ems i n t he comput er component s.

Open t he Raw Count s t abul ar screen and check whet her t he
numbers are di spl ayed correct l y on t he comput er. If not ,
t hen check t he fol l owi ng:

1. No count s at al l , see sect i on 9. 4, st eps 1-5
2. Incorrect count -rat e; swap AM092, t hen AM091,
t hen AM994, t hen SCA cards.
3. Then swap AM093 card, t hen AM955, t hen check
comput er soft ware (Wi nISA confi gurat i on).

9.4.2 Window Rupture Alarm
The sensor for Wi ndow Rupt ure (WR) i s a ci rcul ar
el ect rode bet ween t he mai n (pri mary) wi ndow and i t s
backup wi ndow (bot h wi ndows are made of t hi n pol yest er
(Myl ar) fi l m). Fi gure 9-3 shows t he component s of t he
Wi ndow Assembl y. A conduct i vi t y measuri ng ci rcui t i n
t he Si gnal Anal yser cont i nual l y moni t ors t hi s el ect rode for
l eakage current and wi l l t ri gger t he al arm condi t i on, whi ch
i s report ed t o t he Wi nISA soft ware, i f t hi s exceeds a
pre-defi ned l i mi t . Furt hermore, because t he el ect rode and
i t ' s connect i ng wi ri ng are i nt ent i onal l y exposed (not
i nsul at ed on al l si des) i n t he bot t om part of t he probe any
moi st ure t hat ent ers t he probe t hrough a l eak, ot her t han at
t he wi ndow, wi l l al so regi st er an al arm.



The WR al arm condi t i on causes t he probe t o be
aut omat i cal l y rai sed from t he sl urry and so count -rat es t o
t he comput er wi l l cease (t he soft ware report s t he hoi st up
st at us as fat al ). An al arm i s sent t o t he Wi nISA comput er
whi ch di spl ays an al arm message.

The AM093/ 11 Comms Adapt or Card moni t ors t he wi ndow
rupt ure ci rcui t ry. The conduct i vi t y sensi ng vol t age i s
al t ernat i ng (i . e. AC) t o prevent de-pl at i ng and unnecessary
corrosi on of t he el ect rode.

AM232 - ALARMED WINDOW ASSEMBLY
BRASS SCREWS (8)
TE-91 - BACKUP WINDOW
ASSEMBLY
STAINLESS STEEL WINDOW
SEALING RING
MYLAR PRIMARY WINDOW
O-RING*
* Apply petroleum jelly
TGM part no. 55035 to
o-ring.
O-RING*
* Apply a very thin smear of
petroleum jelly (TGM part no.
55035 to o-ring prior to
assembly).
44844.dwg

Fi gur e 9- 3 Component s of t he Wi ndow Assembl y

Note:
If t he Myl ar fi l m i n t he TE-91 Backup wi ndow i s
damaged, do not at t empt t o repai r i t . Repl ace wi t h one
from t he spares ki t or t ool box.



Causes of moi st ure i nsi de t he probe whi ch may t ri gger a
Wi ndow Rupt ure Al arm i ncl ude:

Broken pri mary (front ) wi ndow. Repl ace i mmedi at el y.
Leaki ng Wi ndow Assembl y. Remove Wi ndow Assembl y
and repl ace O-ri ng and re-seat backup wi ndow ri ng i f
necessary.
Leaki ng square head bol t s. Remove t he square head
bol t assembl y on t he back of t he probe head. Cl ean,
check, l ubri cat e and repl ace t he O-ri ngs i f necessary.
Condensat i on. Poor ci rcul at i on of dry Ni t rogen gas or
vacuum det eri orat i on i nsi de t he det ect or resul t i ng i n
excessi ve boi l -of f . Check t hat t he f oam pl ug i s not
i nsert ed i n t he dewar and moni t or t he LN
2
usage.
Check t he four smal l breat her hol es are cl ear i n t he
AM249/ 10 (see phot o l eft ). Ref er t o chapt er 8,
Mai nt enance f or f urt her det ai l s.

9.4.3 Window Rupture Circuit Self Test
The Wi ndow Rupt ure or moi st ure sensi ng syst em i s
cont i nual l y t est ed for ci rcui t fai l ure. The wi ndow ci rcui t
on t he AM093/ 11 card does not di fferent i at e bet ween
genui ne Wi ndow Rupt ure and short ci rcui t .

Wi ndow St at us W/ R Test Lamp Hoi st Reset
(1) Lamp
AM093/ 11
STF LED
Heal t hy Of f Of f Of f
Wi ndow Rupt ur e On On On
Wi ndow Ci rcui t Shor t
Ci r cui t
On On On
Wi ndow Ci rcui t Open
Ci r cui t
Of f & st ays Of f
when pr essed*
On On
* not e an S220 appl i cat i on code bug means t hi s but t on wi l l never
l i ght when pr essed.
( 1) Hoi st Reset l amp not appl i cabl e t o MSA, hoi st f unct i on i s
cont r ol l ed by RLC.
Tabl e 9- 4 Wi ndow Rupt ur e Ci r cui t St at us LEDs
Not e t hat t he sel f t est wi l l det ect t he wi ndow assembl y
bei ng removed and wi l l rai se t he probe, i f not al ready up,
except i f t he probe i s parked and/ or i f t he guard door i s
open and/ or i f t he Emergency St op i s pressed. The MEP
wi l l not resume normal operat i on unt i l t he wi ndow
assembl y i s properl y re-fi t t ed.

The sel f-t est i s very t horough i n-as-much as i t veri fi es t he
proper operat i on of t he compl et e ci rcui t from t he act ual
conduct i vi t y el ect rode (a pai r of concent ri c met al ri ngs
around t he wi ndow peri met er) t hrough t he i nt erconnect i ng
conduct ors, pl ugs and socket s t o t he act ual dat a regi st er
whi ch si gnal s t he al arm t o t he out si de worl d.



The key t o t hi s i s t he pai r of si l i con di odes are mount ed i n
t he backup wi ndow i t sel f and connect ed el ect ri cal l y i n
paral l el wi t h t he conduct i vi t y el ect rode.
These di odes have no effect on t he normal operat i on of t he
el ect rode but al l ow t he syst em t o confi rm t hat t he WR
ci rcui t i s compl et e and funct i onal down t o t he el ect rode
i t sel f.

To t est t he di odes use a mul t i met er (DVM) havi ng a di ode
t est capabi l i t y. Thi s shoul d i ndi cat e approxi mat el y 1. 2V
across t hem i n one di rect i on.

If t he WR STF LED i s on and t here i s no apparent wi ndow
rupt ure t hen check t he cont i nui t y of t he whol e WR ci rcui t .
The whi t e wi re under t he upper dewar cover (on t he bl ack
base pl at e) i s part of t hi s ci rcui t so check connect i on t here
and back t o t he Si gnal Anal yser vi a pi n 3 on t he 9-pi n
Det ect or connect or at t he bot t om of t he Si gnal Anal yser
chassi s. The compl et e ci rcui t i ncl udi ng ret urn eart h can
be checked by measuri ng bet ween pi ns 1 and 3 on t he D9
pl ug wi t h a di gi t al vol t met er on di ode t est .

Ot herwi se, repl ace t he AM093/ 11 card wi t h one from your
spares. Remember t o check t he j umper l i nk. A j umper l i nk
on t hi s card (see Fi gure 9-4) must be i n t he posi t i on
SAMPLER for anal ysers fi t t ed wi t h an i n-bui l t
Met al l urgi cal Sampl er and i t must be set t o BUTTON for
anal ysers usi ng t he AM101 cal i brat i on but t on.

AM093/11 Card

Fi gur e 9- 4 Showi ng j umper l i nk on AM093/ 11

Link must in po sition " SAM PLER A M 0 93 /11 Car d
Link set to
SAMPLER if
system has a
Met Sampler,
otherwise set to
BUTTON


9.4.4 LN
2
Monitor
The l i qui d ni t rogen (LN
2
) moni t or consi st s of a Zener
di ode whi ch i s suspended i n t he LN
2
dewar. It i s
posi t i oned such t hat a WARNING wi l l be sent t o t he
Wi nISA Comput er when t here i s l ess t han one l i t re of LN
2

l eft . The LN TEST push-but t on near t he power swi t ch i n
t he Si gnal Anal yser chassi s wi l l al so be i l l umi nat ed, red.

If t he LN
2
suppl y i s not repl eni shed wi t hi n a few hours of
a LN Low warni ng occurri ng t hen t he probe dewar wi l l
event ual l y run dry. Thi s wi l l i n t urn al l ow t he cryost at
(det ect or) el ect roni cs t o heat up. A second sensor, a
Resi st ance Temperat ure Devi ce (RTD) act ual l y i nsi de t he
cryost at wi l l det ect t hi s t emperat ure ri se and shut down t he
bi as suppl y t o t he det ect or once t he t emperat ure has ri sen
above -140
o
C (133 Kel vi n) resul t i ng i n a BIAS FAIL
al arm. Thi s means t hat no count -rat e dat a wi l l t hen be
t ransmi t t ed t o t he Wi nISA comput er and so t he assays
cal cul at ed for t hat st ream wi l l suddenl y change t o unusual
val ues, or cease al t oget her. The Li ve Ti me Rat i o (LTR)
wi l l drop t o zero (check t hi s i n t he Cl i ent Tabul ar
Screens).

The AM092/ 10 Net work Int erface Card moni t ors t he l ow
l i qui d ni t rogen and t emperat ure sensors and i nforms t he
Wi nISA comput er i f one or ot her of t he t est s fai l s. The
AM092/ 10 card has fi ve LEDs (refer t o sect i on 9. 2) whi ch
t oget her wi t h t he l amp i n t he LN TEST but t on al l ow
di agnosi s of several abnormal condi t i ons (see t abl es 9-2
and 9-3).

The RTD i s connect ed t o t he si gnal anal yser vi a pi n 5 of
t he 9-pi n det ect or connect i on at t he bot t om of t he chassi s.

9.4.5 LN
2
Circuit Self Test
The LN
2
Moni t or syst em i s vi rt ual l y fai l -safe and
sel f-t est i ng. The AM092 card aut omat i cal l y checks t he
LN
2
l evel sensor every 20 mi nut es. If t he LN
2
sensor fai l s
or becomes di sconnect ed a warni ng i s si gnal l ed. Manual
checki ng, whi ch i s not necessary on a regul ar basi s,
i nvol ves pressi ng t he LN TEST but t on (for up t o 30
seconds). It wi l l l i ght up i f t hi s ci rcui t i s OK, t hen shoul d
ext i ngui sh wi t hi n 20 seconds of bei ng rel eased.

If not al ready l i t , a moment ary press of t he LN TEST
but t on wi l l i ni t i at e a new measurement and i f t he sensor i s
act ual l y ful l y out of t he l i qui d t he LN TEST l amp shoul d
l i ght i n l ess t han one mi nut e, t hus i ndi cat i ng t hat t he
ci rcui t (i ncl udi ng t he sensor i t sel f) i s okay.


Cal i brat i ng t he LN
2
sensor i s onl y requi red when t he
sensor or AM092/ 10 card i s changed or power has been off
t o t he Si gnal Anal yser for a l ong peri od of t i me. The
procedure i s det ai l ed i n t he chapt er 5, Commi ssi oni ng.

The LN
2
sensor ci rcui t i ncorporat es t he brown Tefl on
coat ed BNC cabl e t hat connect s t o t he LN
2
Sensor at t he
t op of t he det ect or dewar and at t he ot her end i nt o t he
det ect or preamp assembl y. The sensor si gnal i s t hen
out put vi a t he 9-pi n cabl e at pi n 8 t o t he Si gnal Anal yser.
A break i n t hi s l oop, i ncl udi ng a broken di ode at t he end
of t he sensor wi re, wi l l cause t he open ci rcui t LED on t he
AM092/ 10 card t o l i ght Red. A short ci rcui t of t he LN t est
ci rcui t i s when t he vol t age t hat t he AM092 card reads
across t he LN l evel sensor i s si gni fi cant l y l ess (more t han
one vol t l ower) t han t he programmed val ue. Refer al so LN
l evel sensor cal i brat i on procedure i n chapt er 5,
Commi ssi oni ng.

9.4.6 Checking the Signal Analyser Settings
Count -rat es and hence t he on-l i ne assays wi l l change
si gni fi cant l y i f t he SCA set t i ngs or t he AM001 Gai n card
set t i ng are al t ered.

Checki ng the AM001 Gai n Setti ng
The Gai n once set must not be al t ered unl ess a new
det ect or or AM001 card i s i nst al l ed. Check t he current
set t i ng agai nst t he l ast known set t i ng from your
commi ssi oni ng or l ast servi ce vi si t . If i t i s now di fferent
and you have no record of why t hen t ry set t i ng t he Gai n
back t o t he l ast recorded val ue t hen measure t he st andard
(refer chapt er 5, Commi ssi oni ng) and check t he on-l i ne
assays.

Checki ng the SCA Reference Vol t Setti ngs
If t he Gai n set t i ng appears t o be okay t hen check t he SCA
reference vol t set t i ngs agai nst your l ast known val ues. Set
t he di al on t he AM994 MCA access modul e t o 0 vol t s.
Then set t he fol l owi ng swi t ches on t he AM994 MCA
Access Modul e:

RUN/ TEST t o TEST

Sl owl y t urn t he pot ent i omet er cl ockwi se on t he AM994
MCA access modul e and record t he vol t ages each t i me a
SCA LED (green) j ust comes on and t hen j ust goes off.


Thi s i s t he vol t age range or reference vol t set t i ng for t he
SCA.

Repeat t hi s for each SCA and t hen compare t he current
set t i ngs agai nst t he l ast known and recorded val ues.

If one or more of t he vol t age set t i ngs has changed t hen
check fi rst i f t hat part i cul ar SCA (count -rat e channel ) i s
bei ng used i n an assay equat i on t hat i s now di spl ayi ng
wrong assay val ues. If i t i s t hen reset t he vol t age set t i ng
t o what i s shoul d have been and check t he assay val ues
now di spl ayed. St andardi sat i on i s recommended aft er a
change such as t hi s.

To reset t he reference vol t set t i ng t urn t he di al sl owl y t o
t he val ue t hat i t shoul d have been t hen i nsert a smal l
screwdri ver i nt o whi chever of t he UL or LL di scri mi nat or
needs t o be moved and sl owl y t urn t he appropri at e t ri m-pot
unt i l t he green LED j ust l i ght s. Turni ng t he t ri m-pot
cl ockwi se wi l l i ncrease t he vol t age set t i ng and
ant i cl ockwi se wi l l decrease t he vol t age.

Adjusti ng the AM001 Gai n to Real i gn the Spectrum
If t he AM001 card, det ect or or det ect or preamp i s repl aced
t hen t he Gai n needs adj ust ment t o al i gn t he X-ray
spect rum wi t hi n t he SCA set t i ngs. Thi s requi res t he use of
an MCA and i f t here i s not one avai l abl e on-si t e cont act
t he Company t o arrange one t o be sent t o si t e or arrange a
si t e servi ce vi si t .

If you do have an MCA t hen fol l ow t hese st eps t o t une t he
Gai n (refer t o chapt er 5, Commi ssi oni ng i f you do not
know how t o use t he MCA):

1. Check whi ch part s of t he spect rum fal l wi t hi n t he SCA
channel s by set t i ng t he swi t ch on t he AM994 modul e:
RUN/ TEST t o TEST

Then press t he ACQUIRE but t on t o l i ght t he red LED.

2. Then press t he MARK but t on on each SCA bri efl y and
rel ease i t t hen press and rel ease agai n. You shoul d see
spi kes appeari ng at t he LL and UL di scri mi nat or
set t i ngs of each SCA. The fi rst press i nj ect s a marker
pul se at t he LL set t i ng and t he second press i nj ect s a
marker pul se at t he UL set t i ng. Al t ernat e presses i nj ect
pul ses at t he LL t hen UL marker posi t i ons.


3. The GAIN of t he AM001 card i s correct l y set by
adj ust i ng t he GAIN t ri m-pot by a smal l amount t o
ensure t hat t he spect rum peaks fal l i n t he cent re of t he
channel markers (spi kes). Thi s i s best done by
compari ng al i gnment wi t h t wo l arger peaks at t he
bot t om and t op of t he spect rum. As you fi ne-t une t he
gai n, cl ear t he spect rum on t he MCA, st art col l ect i ng
agai n and re-press t he SCA marker but t ons. If a smal l
adj ust ment i s st i l l needed t o t he SCA i t sel f t hen fol l ow
t he procedure i n chapt er 5, Commi ssi oni ng or bel ow.
Thi s may be requi red due t o non-l i neari t i es i n gai n
across t he spect rum bet ween probes.

Note:
It i s possi bl e t o set t he GAIN cont rol wi t hout t he ai d of
an MCA, provi ded t he probe and si gnal anal yser are
ot herwi se okay. To do t hi s, use a met al pl at e (eg Fe) or
a sampl e havi ng a hi gh concent rat i on of t he key
el ement i n front of t he probe t hen adj ust t he GAIN
cont rol for maxi mum bri ght ness of t he rel evant SCA
LED (FeK i n t hi s exampl e). Then use t he st andard
bi scui t t o confi rm t he count -rat es are cl ose t o expect ed
val ues.

Adjusti ng the SCA Reference Vol t Setti ngs
If one of t he SCAs i s repl aced t hen t he LL and UL
di scri mi nat ors wi l l have t o be set up. Thi s i s done by
usi ng t he REFERENCE di al on t he MCA Access modul e
and adj ust i ng t he l evel s t o t he previ ous val ues by set t i ng
t he fol l owi ng swi t ches:

RUN/ TEST t o TEST

Wi nd t he UL t ri mpot ful l y cl ockwi se (10 t urns). Now set
t he REFERENCE di al t o t he LL val ue. If t he LL<<UL
LED i s al i ght , rot at e LL cl ockwi se unt i l i t i s on t he edge
of on/ off (fl i ckeri ng i ndi cat es 10 vol t power suppl y noi se
or AM994 faul t ). If i t i s off, rot at e LL ant i -cl ockwi se.
The l ower l evel (LL) i s now set . Change t he
REFERENCE t o t he upper l evel (UL) val ue. Turn t he UL
t ri mpot ant i -cl ockwi se unt i l t he LL<<UL LED i s on t he
edge of on/ off.



Then check t hat t he count -rat es for t hat channel wi t h t he
new SCA are cl ose t o what t hey were before i t fai l ed. If
t hey are si gni fi cant l y di fferent t hen very sl i ght l y furt her
adj ust t he LL and UL di scri mi nat ors or get an MCA and
i nvest i gat e for a more seri ous probl em.

9.4.7 Checking the MEP Detector
An i mmedi at e probl em wi t h t he MEP det ect or may be
i dent i fi ed by t he Opt i cal Reset and Bi as suppl y LEDs
di scussed i n sect i on 9. 3 and Table 9-4.

If bot h t he Opt i cal Reset and t he Bi as LEDs are off (wi t h
t he Bi as swi t ch t o ON) t hen t here may be a fai l ure of t he
FET/ Opt i cal LED assembl y i nsi de t he det ect or. Check for
t he presence of any ot her RED l i ght s and check cabl i ng t o
t he probe. If t he LEDs are st i l l off t hen cont act t he
Company i mmedi at el y t o arrange repai r.

Provi di ng t he AM963 modul e has not fai l ed t hen t he Bi as
LED red i ndi cat es t here may be moi st ure i n t he probe (see
l at er) or a compl et e fai l ure of t he det ect or. Low LN wi l l
t urn t he Bi as off al so and hence t he LED wi l l be off.

The Opt i cal reset LED i ndi cat es t wo di fferent t hi ngs about
t he i ncomi ng probe si gnal :
COLOUR
The col our green i ndi cat es t hat t he gross count -rat e
i s wi t hi n t he maxi mum al l owabl e rat e for t he ASP
fi t t ed. If t he count -rat e i s t oo hi gh i t goes red.
FLASH
It fl ashes once for each reset t ransi t i on det ect ed i n
t he probe si gnal . The col our of t he fl ash may be red
or green dependi ng on 1 above. At hi gh reset rat es
t he fl ashes wi l l merge i nt o an unst eady gl ow.

Because each reset al so regi st ers one or more count s,
al bei t out si de t he spect rum, i t i s possi bl e t hat t he
Opt i cal Reset wi l l t urn red moment ari l y duri ng t he bi as
ramp-up st age but t hi s i s of no consequence. Shoul d i t
t urn red duri ng normal operat i on i t may i ndi cat e one of
t he fol l owi ng probl ems:

The radi at i on l evel (X-ray fl ux) i s t oo hi gh, or
An excess of el ect ri cal noi se i s bei ng generat ed
i n t he probe.


Thi s may be due t o t he l oss of LN2 cool i ng or a
degraded vacuum or agei ng Si (Li ) det ect or or
FET and wi l l show some effect on t he spect ral
performance of t he probe.
One of t he t wo cards AM001/ . . or AM002/ . . i s
defect i ve.
El ect romagnet i c Int erference (EMI). Thi s can be
checked by ensuri ng t he fi l t er under t he dewar i s
present and okay and check al l eart hi ng poi nt s.
Al so l ook for possi bl e sources of EMI nearby eg.
vari abl e speed mot or dri ves, et c.

Increase i n LN
2
Usage
A probl em wi t h an MEP det ect or may be t he not i ceabl e
i ncrease (above 2 l i t res per day) i n LN
2
usage. If t hi s
occurs you wi l l st i l l get count -rat es (assays) but t he val ues
may not be t rue due t o degradat i on i n t he vacuum and
hence t he Probe Resol ut i on, especi al l y i f LN
2
usage
i ncreases beyond 3 l i t res per day.

If you t hi nk t hat t here i s a probl em wi t h an MEP det ect or,
t he most i mport ant t hi ng t o do fi rst i s t o measure t he probe
X-ray spect ral resol ut i on using t he st andard bi scui t and
compare i t agai nst t he l ast recorded val ue. If t here has
been a si gni fi cant i ncrease i n t he val ue and part i cul arl y i f
i t i s now >270eV; cont act t he Company i mmedi at el y t o
arrange repai r and re-evacuat i on of t he det ect or. The
procedure for measuri ng t he Probe Resolut i on i s provi ded
i n chapt er 5, Commi ssi oni ng.

Note:
If you have 4s or 2s ASP cards, t he probe resol ut i on
l i mi t s are 300eV or 330eV respect i vel y.

Note:
Re-evacuat i on i s a speci al i sed t ask and i s i nfrequent l y
needed. If i t becomes necessary, pl ease consul t t he
Company or l ocal agent for assi st ance.

Note:
Average l i fespan of t he Mul t i -El ement Probe i s 7 t o 10
years. Envi ronment al condi t i ons and consi st ency of
Li qui d Ni t rogen fi l l i ng are some fact ors whi ch affect
l i fespan.



Moi sture i n the Probe (Red Bi as LED)
If t he LN2 consumpt i on i s normal but al l count -rat es have
decreased and are unst abl e, t he probe Li ve Ti me Rat i o
(LTR) has changed, and t he Probe Resol ut i on (sharpness
of t he peaks) has det eri orat ed, t hen i t i s most l i kel y t hat
condensat i on has formed on t he hi gh vol t age component s
i n t he pre-ampl i fi er i nsi de t he probe i t sel f. Most oft en
t hi s wi l l be associ at ed wi t h t he BIAS LED on t he Bi as
Cont rol l er card remai ni ng red i nst ead of green. i . e. , t he
HV wi l l not ramp up t o t he requi red 500 vol t s, i n whi ch
case t he count -rat es (assays) wil l not be di spl ayed at t he
comput er. To remedy t hi s refer t o t he procedure; "Dryi ng
Out t he Probe Preampl i fi er", i n chapt er 8, Mai nt enance.

Si gni fi cant Decrease i n LTR
The Li ve Ti me Rat i o (LTR) gi ves an i ndi cat i on of any
el ect roni c probl ems t hat may be devel opi ng i n t he MEP
det ect or. Thi s val ue i s di spl ayed as t he fi rst channel i n t he
count -rat e t abul ar di spl ay at t he comput er.

In normal operat i on t he LTR wi l l remai n fai rl y const ant
and wi l l have a val ue great er t han 0. 50 (meani ng 50%).
70% t o 90% i s usual . It wi l l never exceed 1. 0 (100%) of
course and wi l l onl y approach t hat val ue when t he probe i s
not seei ng sampl e or sl urry. The operat i ng l i ve t i me
may possi bl y change up t o 5% as t he count -rat es i n t he
det ect or vary duri ng normal probe operat i on. LTR i s
affect ed by t he number of t ot al count s i n t he spect rum so
as el ement al concent rat i ons change, so wi l l LTR. LTR
may al so be affect ed by t emperat ure; t hi s i s normal .

If t he LTR begi ns t o decrease markedl y (i . e. by more t han
10), i t may i ndi cat e t hat t here i s an i ncrease i n acoust i c
noi se (mi crophoni cs) or t hat t he vacuum i n t he det ect or
chamber i s det eri orat i ng. Measure t he Probe Resol ut i on
and i f t hi s i s al so very poor (eg. >300eV), t hen t he FET
and or cryst al i nsi de t he det ect or may be damaged.

Warni ng:
If you t hi nk t here may be a seri ous probl em wi t h your
MEP det ect or t hen cont act t he Company aft er carryi ng out
t he checks det ai l ed above.



9.5 Locating a Fault with Metallurgical Samplers
The fol l owi ng t abl e i s a gui de for di agnosi ng probl ems
wi t h t he Met al l urgi cal Sampl ers i f t hey are fi t t ed t o your
Mul t i -St ream Anal yser.

REF FAULT CAUSE CHECK OR REMEDY
1
Sampler will not cut, and Red
LED on AM987 is on.
Sampler module has
timed out

Press white RESET button alongside the LED.
Check AM665 is set on Speed 1 to 5, not 0.
Try selecting another speed.
Replace AM987
Replace AM054/01

Jammed because of
mechanical problem
with cutter arm
Remove obstruction
Clean guide bars
Check cleanliness, clearances & alignment
2
All samplers will not cut in any
mode (ie. Shift, Calibration or
Manual Cut)
Sampler Power or
control fault
Check AM665 is set on Speed 1 to 5, not 0.
Try selecting another speed.
Check OI for error message
All AM987s must be present to complete the
request to cut current loop.

3
Sampler cuts one direction only Control fault

Limit switch fault

Dirty Guide Bars

Loose or missing
circlips or bronze
bushes on jockey
Check/Replace AM987 and/or AM054/01

Check/Replace Limit Switch

Clean guide bars & lubricate

Check/Replace circlips and/or bronze bushes

4
Sampler works in shift mode but
not in calibration mode
Either too many or zero
cuts requested in ISA
computer

No communications
between analyser and
ISA computer
Change number of cuts in ISA computer
configuration

Check/Repair communications to ISA
computer
5
Sampler cutter arm action is
jerky or doesnt always complete
a cut
Dirty guide bars

Loose or missing
circlips or bronze
bushes on jockey

Clean guide bars and lubricate

Check/Replace circlips and/or bronze bushes

Tabl e 9- 5 Faul t Di agnosi s f or Met al l ur gi cal Sampl er s


Note:
Refer Sect i on 8. 2 for Lubri cat i on Schedul e.

Note:
Al ways t urn off and l ock out t he MSA power before
repl aci ng ci rcui t cards or modul es.


10
Service &Warranty

10.1 Customer Service
The Company provi des ful l t el ephone, fax and emai l
servi ce support t o i t s Cust omers or al t ernat i vel y, t he
Company has a ful l compl ement of Cust omer Support
Engi neers avai l abl e t o vi si t si t e, i f necessary.

The Company al so offers i t s cust omers a Product Support
Agreement (PSA). Pl ease cont act t he Company for
furt her i nformat i on or vi si t our websi t e:
www. t hermogammamet ri cs. com. au

Thermo El ectron Corporati on Head Offi ce addresses i s:

Street Address: Thermo Electron Corporation
11 West Thebarton Road
THEBARTON South Australia 5031
AUSTRALIA
Postal Address: Thermo Electron Corporation
PO Box 292
Torrensville Plaza South Australia 5031
AUSTRALIA
Shipping
Address:
Rollerdoor, 4 Osman Place
THEBARTON South Australia 5031
AUSTRALIA
National International
TELEPHONE
FACSIMILE
(08) 8150 5300
(08) 8234 5882
+61 8 8150 5300
+61 8 8234 5882

Spare Parts Service & Warranty


10.2 Spare Parts
Recommended st art -up and operat i onal spare part s are
l i st ed i n chapt er 8, Mai nt enance.

Note:
Refer t o t he AnSt at Part s Li st Manual for a compl ete
l i st i ng of assembl y part s and drawi ngs.

If spares have not been purchased as part of your syst em
t hen t hey may be ordered di rect l y from your l ocal Thermo
El ect ron offi ce. Al l ow 2 t o 6 weeks del i very, ex Adel ai de,
Aust ral i a, dependi ng on avai l abi l i t y and l ocat i on of your
pl ant .

Al l i t ems of equi pment suppl i ed i ni t i al l y wi t h t he anal yser
syst em are covered by Warrant y (see sect i on 10. 3). When
request i ng a quot at i on, pl ease quot e t he 5-di gi t St ore
Number and Part Number (usual l y AM---/ -- or TE---/ --),
where avai l abl e as wel l as t he descri pt i ve name of t he part .

10.3 Equipment Warranty
The Company ensures t hat al l "Work" covered under a
cont ract scope of suppl y i ncl udi ng, but not l i mi t ed t o,
mat eri al workmanshi p conforms t o t he Cust omer
requi rement s and speci fi cat ion usi ng sound, est abl i shed
and modern engi neeri ng pract i ce and appl i cabl e st andards
(ISO 9001).

The Company guarant ees t hat t he equi pment i s free from
defect i n workmanshi p and mat eri al s under normal
operat i onal use, t he Company wi l l make good, by repai r,
or at i t s opt i on, by repl acement , defect s whi ch, under
proper use i n Company opi ni on, appear i n t he equi pment
wi t hi n t wel ve (12) mont hs from t he dat e of dat e of suppl y
of t he equi pment or part .

Any goods t hat are suppl i ed under repl acement shal l be
suppl i ed FCA, from Thermo El ect ron, Adel ai de, Aust ral i a.
Al l frei ght , i nsurance, t axes, i mpost s, dut i es and l evi es
et c. , wi l l be t o t he Cust omers account . INCOTERMS
2000 Edi t i on appl i es.
Service & Warranty Equipment Warranty


Equi pment wi l l be repai red under warrant y, free of charge,
at our works provi di ng t hat i t i s ret urned t o t he Company,
f rei ght pai d. Al t ernat i vel y, any repai rs necessary may be
carri ed out on-si t e provi di ng t hat any t ravel ,
accommodat i on and expenses i ncurred are pai d by t he
Cust omer. Shoul d t he Company be cal l ed t o carry out work
under warrant y and fi nd t hat t he faul t l i es out si de our
responsi bi l i t y t hen any cost i nvol ved wi l l be t o t he
Cust omers account .

Thi s warrant y i s i n l i eu of al l ot her guarant ees and
warrant i es expressed or i mpl i ed, and does not appl y t o
repl acement or repai rs whi ch are requi red as a resul t of
negl i gent use, i mproper i nst al l at i on by ot hers,
mal adj ust ment , modi fi cat i on or l ack of rout i ne
mai nt enance by ot hers. The Company does not guarant ee
t he overal l performance of any pl ant or t he resul t of any
process on whi ch t hei r equi pment i s used.

Thi s warrant y does not appl y t o any i t ems consi dered t o be
of consumabl e nat ure, i . e. al l i t ems l i st ed as "Tool s &
Consumabl es" and i ncl udi ng any ot her such part s
suscept i bl e t o wear and t ear, eg. probe wi ndows, pump
hoses, rubber and pl ast i c pi pes/ t ubes, i mpel l ers, st i rrer
shaft s, mi l d or st ai nl ess st eel t anks and Pri mary Sampl er
i nt ernal l i ni ngs, i ncl udi ng sampl e cut t ers, sampl e nozzl es,
et c. Thi s warrant y al so does not cover any form of surface
coat i ng, eg. rubber l i ni ng, pai nt coat i ngs, et c.

The warrant y does not ext end t o, and t he Company accept s
no responsi bi l i t y for, consequent i al and/ or secondary
damages or l osses of any ki nd sust ai ned di rect l y or
i ndi rect l y as a resul t of a defect i n any product s, mat eri al s
or i nst al l at i on.

Out si de t he warrant y peri od, where a si t e vi si t for repai r,
re-cal i brat i on, t rai ni ng et c i s requi red, current st andard, or
servi ce agreement rat es wi l l be charged. Travel days,
ret urn ai r fares and t ransi t expenses wi l l be charged as a
fi xed mobi l i sat i on cost . Accommodat i on, meal s and on-si t e
t ransport wi l l be charged accordi ngl y.

Thi s warrant y does not ext end t o non-Company suppl i ed
comput er and peri pheral s. It i s t he Cust omer' s
responsi bi l i t y t o arrange for servi ce and warrant y
agreement s for t hose i t ems wi t h t hei r l ocal suppl i er.
Repairs
Service & Warranty


10.4 Repairs
For i ndi vi dual assembl i es, modul es and cards, i f i t ' s
broken t hen we can probabl y fi x i t . Cont act your regi onal
support offi ce for advi ce or j ust package and l abel t he
part (s) and send, al ong wi t h a faul t descri pt i on and cont act
det ai l s t o our Head Offi ce. We wi l l assess t he repai rabi l i t y
of t he part and advi se t he cust omer.

Shi p To:
Thermo El ect ron Corporat i on
Rol l erdoor, 4 Osman Pl ace,
Thebart on, Adel ai de,
Sout h Aust ral i a 5031
Aust ral i a

At t ent i on: Repai rs Depart ment

Cauti on:
Do Not di spat ch radi oi sot ope sources wi t h equi pment for
repai r.

Warni ng:
An MEP det ect or requi res speci al packagi ng for ret urn for
repai r. Consul t wi t h t he Company bef ore packagi ng and
shi ppi ng.

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11 West Thebarton Road

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