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SOLA II Flare - Thermo Scientific

1. SOLA II Flare sulfur Online Analyzer User Manual PN 90 1312 0 Revision A 2015 Thermo Fisher Scientific Inc All rights reserved Dow Corning is a registered trademark of Dow Corning Corporation Kaowool is a trademark of Morgan Thermal Ceramics a business within the Morgan Ceramics Division of the The Morgan Crucible Company plc NetBurner is a trademark of NetBurner Inc National Instruments Lookout is a trademark of National Instruments Sulfinert is a registered trademark of SilcoTek Teflon is a registered trademark of E I du Pont de Nemours and Company Watlow and EZ ZONE are registered trademarks of Watlow Electric Manufacturing Company VICI is a registered trademark of Valco Instruments Co Inc and VICI AG All other trademarks are the property of Thermo Fisher Scientific Inc and its subsidiaries Thermo Fisher Scientific Thermo Scientific makes every effort to ensure the accuracy and completeness of this manual However we cannot be responsible for errors omissions or any loss of data as the result of errors or omissions Thermo Scientific reserves the right to make changes to the manual or improvements to the product at any time without notice The material in this manual is proprietary and cannot be reproduced in any form without express written consent from Thermo Scientific Revision History Revision Level Comments A 03 2015 Initial Relea
2. rer le V N Ba ee le BS A E Figure 5 7 2 Using a 24 hour format enter the time in hh mm ss a IA o en ME Sire is ua Ajo Set Time a EA ee 6 22 12 ai ab 3 V N ERICE RAL Se imal Pte Figure 5 8 3 Enter the date in mm dd yyyy format Es EI for Ec Pis om ee mes US ae HS So es late DA ae tte e SARE a eg EE V N Bid Bla File EERI a ee Figure 5 9 Thermo Scientific SOLA II Flare User Manual 5 3 Chapter 5 Configuration Modbus Setup 1 The Modbus Setup menu enables to you set the baud rates parity and IDs for COM 3 and COM 4 cs Nos aa ad E ea ee a ee OA La Di NOA Kay o Ea ES se ef US o V N ESENCE EIE a ST Figure 5 10 2 Select one of the baud rates available for RS485 COM 3 38400 19200 9600 4800 2400 or 1200 bps or select Disable MITOS GL oy Ba Es S SS ic use Coy pil amp MO os an Hs Bae Es Bal Say Sua Rel al as Fe te fae V N ay Be Eile a A ee Perle Figure 5 11 3 Set the parity for COM 3 Dis ey Eat ie a Stelele CORNE MIRO ee ion UN ES Da a E al al ays V N ne fe lela ne Rl ese A E Figure 5 12 4 Set the ID network address for COM 3 The address can be from 1 to E Dia Boa Eat Bay IS ES se cpus CO IE gt MA On er oe Fae ls ie EIS V N Be E Pale By SS fale Se Figure 5 13 5 Set the baud rate and the ID for COM 4 in the same manner using the submenus for COM 4 Thermo Scientific SOLA II Flare User Manual 5 4 Chapter 5 Configuration
3. the measured concentration specified in High Range Other Outputs The following outputs are also provided Alarm Relay Validation in Process Status Relay fail safe Malfunction Alarm Relay fail safe normally closed and Purge Alarm fail safe 1 0 Control The PLC or DAS connected to the SOLA II Flare drives the validation by commanding the SOLA II Flare to set the appropriate ranges for the Cal A low range and Cal B high range The SOLA II Flare then analyzes the validation gases and reports the values to the control system Each gas should be run for at least 10 minutes and the data latched at the end of each period The sequence of validation steps will be defined by the end user The SOLA II Flare will provide the following I O e SCS Interface Upto five Pneumatic Outputs Upto four Relay Dry Contact Outputs e Validation Control Two Modbus interface ports RS 485 and either Ethernet or RS 232 Thermo Scientific SOLA II Flare User Manual 2 3 Thermo Scientific Chapter 2 Installation Four Contact Inputs Dry switches Two 4 20 mA outputs Cal A and Cal B One Common Alarm Dry Contact Output One Contact Input Dry switch to force the temporary activation of the High Calibration Note Normally there are two possible modes of validation The local validation routes the validation gases from the switching panel to the SOLA II Flare The remote validation routes the validation gases
4. 89 LampVoltage dl LatchCal Y LowAlarm1 LowAlarm2 Maximum gp Maximum2 6 MBRemote g Minimum 65 Minimum2 8 MinutesToAutocal i y M db U A Farm Revise Modbus Secondary 1020964145 Ide Ml Figure E 2 5 If Mode is set to Modbus Ethernet a Set the IP address to the value assigned to the Bridge The required IP address depends on the configuration of the Modbus Ethernet Contact the person responsible for this network to obtain the correct IP address Thermo Scientific SOLA II Flare User Manual E 2 Appendix E The Workstation b Set the identifier to 1 6 Ifa serial port is used for the connection configure the serial port parameters as follows a Select Lookout Options gt Serial Ports b Verify that the port is configured as shown in Figure E 3 Note The specified Receive gap RTS delay and CTS time out are critical to achieve successful communication with the analyzer Depending on the PC used these numbers may need to be increased A Serial Port Settings com 2 a Figure E 3 Workstation Using the operation application with Lookout enables you to monitor and Operati on control analyzer operation from the remote workstation Real time data from the analyzer is collected displayed trended and archived on the remote computer hard drive The database files containing analyzer data are accessible by other programs using ODBC or SQL See the Lookout software m
5. A Maintenance Schedule Visual Inspection amp Thermo Scientific Cleaning Chapter 8 Maintenance Troubleshooting Caution Some internal components can be damaged by small amounts of static electricity Take appropriate precautions use a properly grounded antistatic wrist strap when handling electronic boards and components To avoid damaging internal components follow these precautions when performing any service procedure Wear an antistatic wrist strap that is properly connected to earth ground If an antistatic wrist strap is not available be sure to touch a grounded metal object before touching any internal components Handle all printed circuit boards by the edges Carefully observe the instructions in each procedure A Table 8 1 Maintenance schedule Frequency Tasks Monthly Calibrate the analyzer see Galibration Every three months Replace the injection valve rotors according to Appendix B Every six months Visually inspect and clean the instrument Check the instrument flow rates as explained later in this chapter Replace the valve body according to Appendix B Annually Test the instrument for internal leaks as explained later in this chapter Every 18 months Replace the pyrolyzer heater as explained later in this chapter The analyzer should be inspected occasionally for obvious visible defects such as loose connectors loose fittings cracked or clogged Teflon lines and excessive dust or d
6. Output scaling stops Table A 20 Oven settings Setup Page gt Output 2 Software Output Function Output Function Instance Default Display Comment SOLA II Flare User Manual A 12 Appendix A Watlow EZ Zone PM6 Series Table A 21 Oven settings Setup Page gt Alarm 1 Parameter Default Comment Display Software L Alarm Hysteresis 2 Alarm Logic Open On Alarm The output condition during an alarm state Alarm Sides Both Both high and low sides can trigger the alarm Alarm Latching Non Latching Alarm Blocking Off Alarm Silencing Off Alarm Display An alarm message will display when an alarm Is active EPRE REEE Alarm Delay Time ery i Table A 22 Oven settings Setup Page gt Function Key 1 Parameter Default Comment Display Software Software High Display Active Level I Action Function User Set Restore Function Instance 145 E Thermo Scientific SOLA II Flare User Manual A 13 Appendix A Watlow EZ Zone PM6 Series Table A 23 Oven settings Setup Page gt Global 1 Display Units CLE en LLE nn Zone m oo E S ES Cha e on des uses Comment Software Display units are in C 60 Hz The frequency to the applied AC line power source uN Gala o lt lt Both Both comm port 1 and 2 selected Off O 5 jr The Channel LED is on The number of display pairs The time delay for toggling between channel 1 and channel 2 Displ
7. Fi U Extemal D r 7 D ring pe e ln O ring De Tp e Pin O nngs ig o O ring phie a m m ls Driveshaft L N bo Nor counkerunl a a na bearing plate bs l wg j Hapai Balk CLU Female na p S fy A q Bal retainer Bushings 1 Ba ee Balls E l E i re ne Mew style ee Bean plate PE _Subassemblp _ r SETENE ql Cylinder as Beanng Thin arazer Extamal O ring a female and cap ee Fenale end cap e End capscrows A i Peek wathers Figure B 12 Exploded view of two position actuator Appendix B Rotary Valve Service SOLA II Flare User Manual B 13 Appendix C TCP IP Bridge The SOLA II Flare Modbus TCP IP option is a microprocessor driven board that provides a bridge between the SOLA U Flare standard serial Modbus and a TCP IP Modbus network using 10 100 Base T This function is provided by the NetBurner Hardware e TCP IP Bridge board installed inside the SOLA II Flare enclosure Configuration e SOLA II Flare Modbus configuration must be set to 38400 baud with Modbus ID 1 e Bridge board has a standard RJ45 connector for the 10 100 Base T cable Figure C 1 TCP IP Ethernet bridge board P N 55 1228 0 newer models Software As shipped the Bridge defaults to an IP address of 00 00 00 00 At power up Configuration with an IP address of 00 00 00 00 the Bridge attempts to negotiate an IP through a DHCP server If a DHCP server is not available or if it is desired to assign th
8. cable plugs must be fully seated Perform a visual check for electrical shorts Inspect the plug in cards ensure they are properly seated in their connectors Ensure the signal wiring is properly sized and connected 2 Verify proper plumbing a Ensure the correct supply tubing is properly connected to the instrument All sample lines to the analyzer must be cleaned and dried before initial use Check all tubing connections to ensure they are tight and free of leaks Pressure test the lines to check for leaks or use a liquid leak detector 3 Apply instrument purge air to the instrument for at least 15 minutes and set the pressure See application data sent with instrument for proper settings AN Warning For Zone II areas the initial purge must be carried out only when the area is known to be non hazardous A Thermo Scientific SOLA II Flare User Manual 3 1 Chapter 3 start Up amp Shutdown 4 Apply power to the instrument Note If the X Purge option is installed you must follow the instructions included in Appendix F A a Verify that temperature controllers are set as specified in the application notes shipped with the instrument or as recorded in the system logbook Note that the pyrolyzer and oven do not begin heating immediately due to the safety interlocks Note The pyrolyzer temperature controller does not accurately read low temperatures near ambient however it does read accurately at nor
9. e Analysis suspension SOLA II Flare User Manual 4 3 Chapter 5 Configuration There are five top level menus this chapter addresses the Configuration menu The Configuration menu contains eight setup menus Analyzer Setup Clock Setup Modbus Setup Inject Setup Alarms Setup Calibration Validation Setup and 4 20 mA Range Setup S ln dey iy S ie 4 4 H eee ey TD ey ie E EN MA 10 e ae G wy ale S oe z V N En t EN Sey at ic Figure 5 1 Top level configuration menu Ana lyzer Setup 1 Access the submenus within the Analyzer Setup menu by pressing Enter Clete Er re up wy a el 1 e pm Sm eae vl elz se E a V N Enee EIX Ilt Figure 5 2 2 The first submenu is Program Passcode The factory default is 0000 If the passcode remains 0000 you are not required to enter the passcode to access the menus Change the passcode to prevent unauthorized access to the menus lm eae vw I al e se E u 8 EN is O e al am EN Ra Si MS MEA Oa mela ee V N En Be E x 1i t Figure 5 3 Thermo Scientific SOLA II Flare User Manual 5 1 Chapter 5 Configuration 3 The Average Time submenu allows you to set the averaging time The average time is a period between 1 and 240 seconds during which the analyzer takes SO measurements used to determine a moving average of the results For example if you set the averaging time to 10 seconds the average concentration of the last 10 seconds is output at each u
10. e plop la life B Low V A Ent Ex ia EE Figure 5 41 13 This step moves the calibration line so the reading matches the user desired reading for Cal B Slap o ello a Sen at ea ip Adj ust B Reading V N En t AE AE AE Figure 5 42 14 The steps shown in Figures 5 43 through 5 46 permit the user to view and or modify the values latched during recalibration CAE 2 2 E E a A E E Setup High C a Il A K H z V A En t EG i t Figure 5 43 Thermo Scientific SOLA II Flare User Manual 5 16 Chapter 5 Configuration Chlalll r EI A a EA O le en Setup Low Cail A K H z V N Ent E x i t Figure 5 44 Chall r ON E a EA A o S Setup High C a I B K H z V N Ent E x i t Figure 5 45 Cha O OA Er Ba G 2 GU SH Setup Low Cail B K H z V N En t Ex i t Figure 5 46 Validation Setup Validation setup creates an automatic sequence to go through the stages that allow the user to select which pneumatic outputs and calibration are used Table 2 1 shows the validation requirements Review the following for instructions pertaining to automatic validation setup 1 Access the menu items by pressing Enter Configuration Validation Setup V A En t Exit Figure 5 47 Thermo Scientific SOLA II Flare User Manual 5 17 Thermo Scientific Chapter 5 Configuration 2 Select Enabled or Disabled to activate deactivate this feature WL asi Le te ee E LE O in SA Re eu Ep D a l v NZ Bas Bi pak Bas G ion T V N En t
11. flare systems and is suitable for analyzing over a dynamic range of 10 ppm to 100 sulfur by volume using a single analyzer system To meet this dynamic measurement range the SOLA II Flare uses dual PMT photomultiplier tube power supplies and dual sample injection valves to achieve two independent measurement ranges The low measurement range is configured as 1 of the high measurement range For example a high measurement range of 50 500 000 ppm v will set the low range at 5 000 ppm v The SOLA II Flare software will automatically select the appropriate measurement range based upon the sulfur output level being measured and will select the appropriate PMT power supply and sample injection valve for the measurement range The PUVF pulsed UV fluorescence detector utilizes a PMT to measure the SO present in the measuring cell The sensitivity of the PMT is adjusted by the supplied voltage Using dual power supplies allows the sensitivity of the two measurement ranges to be set independently By utilizing two sample injection valves the SOLA II Flare provides precise control of the amount of the sample that is injected as well as control of the dilution ratio typically 100 1 between the two injection valves For the low measurement range a 100 ul sample loop is used and for the high measurement range a 1 ul sample loop is used This allows approximately the same amount of total sulfur to be injected into the detector no matter which measu
12. 0 L i i A f E ol cm fob o V End cap Female Cylinder subassembly Male SC Teus end cap end cap Figure B 6 Steps 3 6 3 Use the 9 64 hex driver to remove the three end cap screws with PEEK washers some models have slotted head screws instead of hex head 4 Place the actuator on a hard work surface with the end cap screw holes up Push down on the cylinder and the female end cap pops up 5 While holding the cylinder and the rest of the assembly together pull the female end cap all the way off If the bearing and washers fall out set them aside 6 Repeat the procedure with the actuator inverted so that the cylinder slides loose from the male end cap Remove the cylinder subassembly Male end cap Figure B Steps 7 8 7 Pull the subassembly off the male end cap as indicated in Figure B 7 Note Recently purchased actuators may have a subassembly made primarily of molded plastic differing in appearance from the one shown in previous figures The procedures are the same for either type A 8 Loosen but do not remove the three slotted head screws that hold the subassembly together Thermo Scientific SOLA II Flare User Manual B 8 Replacement Thermo Scientific Appendix B Rotary Valve Service U ring plate Urweshaft Figure B 8 9 Take care to hold the rest of the subassembly together and slide the O Ring plate off the drive shaft Refer to reassembly instructions in Assembly
13. 5 Appendix B Rotary Valve Service Kumberofports IU letter towards 3 Fort 7 d Port Fort 4 D Port A 10 Fort 6 Internal sample Side of valve with four ports Rotor tab ID letter C Figure B 3 Location of ID letter on valve rotor lot in driver TP a N al pnn a wi g at h i N wen in a Oy x QQ v ae A N er gt u i i F i Fa gt 4 N N a N amp j i j if Ps nn MA 1 fam A La N p a a 4 1 is r x J dy oa 1 1 Le Y Ta f ban d Y LE a GL KA Ke Kal ASD J 0 ila accra 7 ala G bai AS ID letter on G A AD K Taa E l Pr y E N a tab toward Port 4 Figure B 4 C6 W valve with preload and rotor removed preload end view High temperature valves require conditioning when the rotor is replaced If a high temperature valve WT or UWT series is used at less than 300 C it may become sticky or difficult to turn This tendency can usually be eliminated by repeating the conditioning procedure that is initially done at the factory With carrier gas oxygen free flowing through all the ports rapidly heat the valve to 325 C When this temperature is reached cycle the valve 10 times and let it cool to operating temperature Thermo Scientific SOLA II Flare User Manual B 6 Appendix B Rotary Valve Service Conditioning High temperature valves require conditioning when the rotor is replaced If a Procedure for Hi gh er Super ae WT or ee series is used at less than UNE it may ecome
14. 5 Chapter 2 Installation Installation Checklist The following checklist may be copied for use during system installation Thermo Scientific Details for the installation and various specification requirements are contained in this manual application specific drawings and information supplied with the instrument Materials used meet specifications defined in Chapter 1 Operating environment meets requirements defined in Chapter 2 Mounting meets requirements defined in Chapter 2 _ Analyzer condition inspected as follows No physical damage broken parts or observable defects All electronic boards are securely seated _ All cables and wiring connectors are in place and fully seated No loose parts wires nuts screws cables debris etc All tubing is properly connected and fittings are tight _ Installation and flow connections adhere to the following Sample system properly designed to condition control pressure flow temperature and particulate sample as required by system Sample system fast loop panel is installed as close as possible to analyzer for fastest response time System gases meet quality and quantity pressure and flow specifications according to Chapter 1 PUVF vent is vented to atmospheric pressure PUVF vent is NOT connected to headers with varying pressure or that may accumulate liquids _ All tubing supply lines to analyzer are sized to matc
15. Commun ications Analog Outputs Two 4 20 mA dc outputs one assigned to each range Alarm Outputs One 1 global dry contact triggered by one or more of the following Low detector flow alarm Oven pyrolyzer temperature fault Injection valve fault Purge failure Detector temperature fault Detector lamp voltage fault One 1 out of service dry contact triggered by Analyzer in validation Suspension of analyzer Digital Data Dual channel RS 485 Modbus TCP IP Ethernet via Modbus TCP IP Communications encapsulated Modbus amp RS 485 Modbus Local HMI Status of all analyzer parameters e g pyrolyzer furnace and analytical oven temperatures PMT and lamp voltages detector flow rates etc and analytical results available on the front mounted displays push button menu access hazardous area classification remains intact while operating the local display SOLA II Flare Complete remote control of SOLA II Flare automatic logging of analysis Modbus Interface results and analytical parameters communication to SOLA II Flare via serial or TCP IP encapsulated Modbus enables remote diagnostics via modem SOLA Web Remote Complete remote control of the SOLA II Flare ability to download 24 hours of Interface analysis results and analyzer parameters communications to the SOLA II Flare via local area network TCP IP enables remote diagnostics via modem The Flare SOLA Web is limited to the replica of the front display on the SOLA ll Flare System Requ
16. Inject setup 1 Enter the Inject Setup menu to set injection parameters Ce Loa ak Irs Peal Be oy e a Be E oe En I Feta Fahl RES feed te 51 es es us ae V N Bars E BES LS Figure 5 14 Note The SOLA II Flare is preconfigured with a standard injection time and rate A 2 The injection time is the amount of time between sample injections The rate can be from 1 to 9999 seconds IE tae ail een ew E 51 ed De bh Ep pa ea e Fe aye Pais ms Re V N aa G le le Figure 5 15 3 The injection rate should be set to double the injection time TE a e Es IT Sy ze Mal Eu AS RT Aa Ep Res e e tl OA fae x a lt V N E tae Pe EEX T te Figure 5 16 Thermo Scientific SOLA II Flare User Manual 5 5 Chapter 5 Configuration Alarms Setu p Review the following for instructions pertaining to alarm setup 1 Access the menu items by pressing Enter Sn ea ETE CE rede I ee ele atte E Ou ar IN Mey 22 ik gt ee wl ye V N Bars E BES LS Figure 5 17 2 To set up a Chamber Flow alarm enter the set point at which the low flow alarm for the flow measured at the detector chamber in the PUVF should activate The value can be from 0 to 1000 cc m Me ee ae ne ES S eS ce wie Gy laa leery EO los ees lee E JA On haw Ze Baer V N Bu a Me HES acl ete Figure 5 18 3 To set up a Lamp Voltage alarm enter the high point lamp voltage at which the alarm should activate The value can be from 0 to 1200 V AS lA ed e
17. Thermo Scientific Part Numbers HA 101812 Ferrules for pyrolyzer reaction tube fittings graphite 30 1025 0 63 1135 0 27 1108 0 29 1230 0 47 1362 0 47 1645 0 79 1340 0 79 1332 0 79 1399 0 45 1839 0 45 1823 0 79 1333 0 79 1343 0 63 1158 0 45 1871 0 45 1872 0 TE 8666 TE 57P713 1 89 2839 0 TE 8949 TE 8774 TE 9681 89 2898 0 Storage Chapter 1 Product Overview Table 1 6 SOLA II Flare spare part kits SOLA II Flare Spare Part Kits Valco Vapor Sample Injection Valve Kit Part Numbers Items Included in Kits Start Up 97 1589 DI1 97 1589 D12 97 1589 DI Pyrolyzer tube looped Pyrolyzer O ring 5 5 8 D x 5 7 8 0 D 1 8 width Thermocouple pyrolyzer S type Critical Operation 97 1589 DIC O O O LO oO Heater element for pyrolyzer assembly a 0 Filter clean air in line 2 micron filter assembly A Filter sample in line 0 5 micron filter assembly Sulfinert Valve complete 10 port for vapor samples 0 Je Valve complete 6 port for vapor samples CO COS E Rotor vapor sample 4 pt Rotor vapor sample low range less external ee loops 10 pt Rotor vapor sample Rotor vapor sample high range 1 0 pl B pt range 1 0 ul 6 pt nn CORRES CARR CURE oprane reas esemes fo fo ifs angetan fo H GHH fo fo jo regio cesa 025059 jo jo jo Ea fo jo ifs ETA jo jo jo rar secre fo jo fo ron Powers fo fo fo FO traga Pa Boa jo jo fo TI ee
18. V Figure 7 9 So ot bet ES ES r tos R x IS SOLA II Flare User Manual 7 6 Chapter 7 Diagnostics The available Coms selections are e Com 1 I O Boards e Com 2 Maintenance e Com 3 Modbus e Com 4 Modbus C om C om I1 V Figure 7 10 Por ts R x T x I O Boa r dos o Pulse UV Control Following are the menu items within the Pulse UV Control menu AN Caution This menu is intended for factory test only Incorrect settings can result in damage to the unit A Table 7 4 Menu Item Flash Lamp On Off Auto Gain On Off PMT Signal Gain Test Gains Test LED On Off Flash Frequency Flash Time S amp H Time Thermo Scientific Description Turn the UV lamp flashing on or off Turn the amplifier auto gain selection on or off Note Auto gain defaults to ON during normal operation A Select the amplifier gain 1 2 5 10 20 50 100 Note The selection is only valid when auto gain is turned OFF A Place the gain selection under manual control to verify the functionality of the programmable gain amplifier Test the LED by turning it on and off Change the UV lamp flash frequency normally 10 Hz Change the duration of the flashing pulse normally 100 us Change the duration of the sample portion of the sample and hold analog front end normally 100 us Sample portion is the amount of time the sample and hold device is in the SAMPLE state SOLA II Flare User Manual 7 1 Safety Precautions
19. and breaking the quartz tube The graphite will grip the quartz tube and twist it loosening will allow the ferrule to slip back while forming around the quartz tube A i Once the quartz tube is replaced repeat the leak test and make sure all pressures hold 9 Flows should be checked at the 3 way valves for the three clean air flows These flows should be close to those recorded on the instrument data sheet from the factory Add the three flows together and compare them with the flow at the PUVF vent The flows should be within 5 to 10cc If there is a difference of more than 10cc check the PUVF detector and associated tubing for leaks by tightening all fittings Thermo Scientific SOLA II Flare User Manual 8 3 Sample Flow Leak Test Chapter 8 Maintenance amp Troubleshooting AN Caution Purge all sample lines with nitrogen until the total sulfur reading Thermo Scientific stabilizes near zero ppm on the low range Once the reading stabilizes wait at least 15 minutes to ensure all sulfur is purged from the system Disconnect the communication lines to prevent remote actuation of gas selection valves Only clean air and nitrogen are needed for the leak check A Refer to the SOLA II Flare flow diagram Figure 1 2 for the following leak test Note All tubing connections in the sample flow path should be checked for tightness A Note This leak test is fairly complex and should be done in two stages There are two sample nitr
20. and click the Resources tab Table I 1 Technical bulletins TB TB 0417 001 TB 0417 003 TB 0417 004 TB 0417 005 Title Replacing a Watlow Series 93 Temperature Controller with a Watlow EZ ZONE PM6 Series Controller Increasing the Lifetime of the Pyrolyzer Heater in a Thermo Scientific SOLA Il Flare System Using the Watlow Series 93 Temperature Controller in a Thermo Scientific SOLA II Flare System Replacing the Pyrolyzer Heater in the Thermo Scientific SOLA II Flare Analyzer SOLA II Flare User Manual 1 Thermo Fisher Scientific 81 Wyman Street P O Box 9046 Waltham Massachusetts 02454 9046 United States www thermofisher com
21. from the X Purge unit A Caution Do not decrease the timer setting lower than the value specified in the application notes provided with the system or lower than the initial setting when received from Thermo Scientific A Caution If the timer setting is too short the analyzer system is not purged adequately before power is applied This can result in equipment damage and injury to personnel A The time delay relay uses digital switches to set the length of delay before applying power to the analyzer system The number of seconds for the delay can be determined by adding the numbers together for all switches that are set to the On position The switches are located on the top of the time delay relay inside the X Purge housing For example if switches 256 128 64 and 32 are On the time delay is 8 minutes i e 256 128 64 32 480 seconds When replacing the time delay relay the switches on the new relay must be set the same as on the relay being replaced SOLA II Flare User Manual F 9 ical Bench PUVF Opt Appendix G 1966 N d peog AUSUEIUL use c LIIS Ajquiasse yausc jeond 4 gt N LEP EN p eoquagouo S946 N d PIBOg J agucs due hL Ru alas e X E 9 ps a E 1076 Mid S 9 gt umop Bude A8y 1018007 u 2698 N d Alquiasse om eS Ea yo OS ETA gt a m Ha 0 TAU 2908 Nid e N aqry 181 d N01030144 e 0898 N d Ajquasse 1 4 BUISNO U JOU 9246 k
22. if the subassembly does come apart The O Rings to be replaced are in the two end caps and the O Ring plate The internal end cap O Rings are easier to access if the washers and bearing are removed Follow the steps below 1 Use a small screwdriver or awl to remove the old O Rings being careful not to scratch the metal 2 Use a lint free tissue to clean the O Ring grooves as completely as possible 3 Upon installation coat each new O Ring with a thin layer of Dow Corning DC 111 or similar silicone lubricant Thin Thick Thick Thin washen waste wasthar washer RS 7 0 i 0 H i awe i v as 1 TEL IF j T 4 0 A f 0 N 12 al Bearing Bearing Figure B 9 Locations of O Rings SOLA II Flare User Manual B 9 Assembly Thermo Scientific Appendix B Rotary Valve Service Where possible apply a slight rotating action to the parts as they go over or through the O Rings to help prevent any nicking or tearing of the new parts 1 Being careful that the subassembly does not come apart gently push the O Ring plate onto the drive shaft Make sure that the threaded holes in the plate are facing the subassembly Figure B 11 2 Screw the slotted head screws into the O Ring plate and push the drive shaft into the O Ring plate as far as it will go as shown in Figure B 10 3 Place the washers and bearing in the male end cap thin washers in first as shown Figure B 9 One of the flats on the drive shaft lines up wit
23. insulation that you removed earlier over the heater wires leaving 3 8 exposed Fiberglass insulation Exposed heater wire Figure 8 11 Add the fiberglass insulation SOLA II Flare User Manual 8 13 Chapter 8 Maintenance amp Troubleshooting 18 Insert the ends of the heater wires into the terminal block and tighten them Bend the wires as shown in the figure below Terminal block Bend the wires in the direction shown Figure 8 12 Heater wires inserted into terminal block 19 Inspect the O ring around the open end of the pyrolyzer housing If necessary replace it and apply a lubricant compound such as Dow Corning 111 around it Enclosure O ring and lubricant compound Figure 8 13 Pyrolyzer housing O ring 20 Gently slide the lid into the housing Note The pyrolyzer tube insulation and Kaowool insulation should still be attached to the lid Slide the lid back in carefully to avoid damaging the pyrolyzer tube A 21 Use the six screws and washers removed earlier to secure the lid to the housing Thermo Scientific SOLA II Flare User Manual 8 14 Chapter 8 Maintenance amp Troubleshooting 22 With an air gun placed at the end of one fitting blow out any dust or debris that may have dropped inside the pyrolyzer quartz or glass tube Figure 8 14 Blow out the debris 23 Secure the pyrolyzer housing to the oven enclosure using the screws removed earlier two mounting screws on top of hou
24. integral seconds The PID derivative seconds The offset to the proportional band The fixed level of output power when in manual open loop mode Comment The set point that will trigger a low alarm The set point that will trigger a high alarm SOLA II Flare User Manual A 8 Appendix A Watlow EZ Zone PM6 Series Table A 13 Pyrolyzer settings Factory Page gt Custom Setup 1 Parameter Default Comment Display Software Software A r Parameter Active Process Value The parameter that will appear in the oe custom Home Page Instance ID MES Dm je i Table A 14 Pyrolyzer settings Factory Page gt Custom Setup 2 Parameter Default Comment Display Software Software A r Parameter Active Set Point The parameter that will appear in the oe custom Home Page Instance ID E Dm se o Table A 15 Pyrolyzer settings Factory Page gt Custom Setup 3 Parameter Default Comment Display Software Software Parameter Autotune The parameter that will appear in the custom Home Page 0 gt ur Instance ID Table A 16 Pyrolyzer settings Lock Page gt Lock 1 Parameter Default Comment Display Software Software F gt r gt Operations Page The security level of the Operations Page O Password Enable Read Lock The level of read security clearance Write Security PASE rlol BL oL loll Locked Access Level coll PAS PASA The level of write security clear
25. interferences to any UVF or PUVF detector CO and water vapor are formed during the combustion process required to convert the sulfur compounds to SO The PUVF detector utilizes reflective band pass filters to optimize the light wavelength used for the excitation of the SO2 molecules in the temperature controlled measuring chamber This optimization of the light wavelength eliminates the CO interference When measuring total sulfur with a PUVF detector it is necessary to convert 100 of the sulfur compounds present in the sample to SO The combustion system is a design unique to Thermo Scientific and allows the SOLA II Flare to achieve the required conversion of all of the sulfur compounds to SO The combustion system uses no catalyst to complete the conversion and the simple U shaped quartz reaction tube is inexpensive and easily changed normally every 14 to 18 months The 100 conversion is accomplished while maintaining full scale linearity and repeatability The SOLA II Flare utilizes two air actuated microliter injection valves to precisely control the amount of sample injected into the zero grade air carrier gas For gaseous samples a backpressure regulator allows the pressure sample volume to be held constant in the sample loop of the injection valve Since the sample heads of the injection valves are inside the analytical oven the temperature variable is eliminated The sample passes into a mixing chamber where the hydrocarbons a
26. menu in the Items order in which they appear Specific instructions on the various calibration functions are discussed in the previous sections Configuration 2 Ea O A Eb nr ae ce o baa Setup V A En t E x i t Figure 5 29 Main menu heading 1 Select the engineering unit related to the concentration entered for the calibration values ppm ppb or mg L C a libration Setup CEHI Unit s V N En t EEx i ee Figure 5 30 2 Enter which valve is performing the Cal A injection V1 or V2 Catliiobratiooon Setup C a I A Inject Valve V N En t Ex ic Figure 5 31 3 Enter the concentration of the high calibration standard for Cal A See Manually Calibrating a High Value for more C a libration Setup H i g h Cail A Value V N En t Ex i t Figure 5 32 Thermo Scientific SOLA II Flare User Manual 5 13 Chapter 5 Configuration 4 Enter the concentration of the low calibration standard for Cal A If using only one calibration standard and nitrogen to calibrate the background enter zero See Manually Calibrating a Low Value for more Calibration Setup L ow Cail A Value V N En t E x i t Figure 5 33 5 Enter which valve is performing the Cal B injection V1 or V2 C a libration Setup C a l B I n ject Valve V N En t Elx ic Figure 5 34 6 Enter the concentration of the high calibration standard for Cal B See Manually Calibrating a High Value for more C a libration Setup H i g h Cail B Va lu
27. the calibration points will change the slope of the line This is illustrated in the next two graphs N x 5 D N T E E Figure 5 26 High calibration SOLA II Flare User Manual 5 9 Thermo Scientific N x 5 D N E bee E EEE AAA HR A AAA AAA A Figure 5 27 Low calibration Chapter 5 Configuration If necessary the Adjust Reading function in the Calibration Setup menu can be used to correct the calibration by moving the line without changing the slope Normalized kHz ETETE I ao y 144 44x 555 56 Figure 5 28 Corrected calibration SOLA II Flare User Manual There are several calibration functions that can be performed These are discussed in the following sections 5 10 Calibration Setup Manually Calibrating a Low Value Manually Calibrating a Thermo Scientific High Value Chapter 5 Configuration With this option you will need to configure each calibration Cal A and Cal B independently Both Cal A and Cal B have recalibrate functions but the function only operates with the currently running Cal selection The Calibration Setup menu consists of parameters for Cal A and Cal B Cal A items appear first Table 5 1 Calibration parameters Cal A Cal B Cal A Inject Valve V1 or V2 Cal B Inject Valve Cal A High Value Cal B High Value Cal A Low Value Cal B Low Value Recalibrate A High Recalibrate B High Recalibrate A Low Recalibrate
28. the parts referenced in this procedure With the exception of the heater being replaced the existing parts can be reused if in good condition The part numbers are provided here for convenience Table 8 2 Parts list for heater replacement P N 27 1108 0 29 1230 0 29 1231 0 30 1025 0 40 0025 06 1074 0 64 1301 0 65 1041 0 68 1269 2 89 2917 0 HA 101812 ls Thermo Scientific Oty Description Thermocouple S type Heater fiber insulated 60 V 450 W Insulation flameless burner Pyrolyzer tube looped 0 5 ft Kaowool insulation Terminal 2 pole ceramic block 30 A Heater wire sleeve flameless burner h ot Insulation fiberglass Red SS 11x4T Pyrolyzer tested assembly includes housing housing lid O ring screws washers Ferrule 1 4 graphite Follow the Maintenance Shutdown Procedure to shut down the analyzer system Allow the system to cool completely Carefully remove the two sample tubes from the top of the pyrolyzer housing using a backup wrench to keep the stainless steel fittings from turning Loosen the terminal block screws and disconnect the thermocouple wires Be sure to note the orientation of the wire colors If installed disconnect the wires from the oven temperature switches the wire between the two sensors can be left in place Slightly loosen the two screws that attach the bottom of the housing to the back of the oven Support the housing while removing the top tw
29. the required current All wiring installations must meet applicable electrical codes The fuse is located on the analyzer terminal block Caution If it becomes necessary to replace the fuse it must be replaced with one of the same rating Fuse 3 A S B p n TE 4510 A IN Warning Remove power prior to performing any work internal to the instrument An override is available for use in non hazardous areas however removal of components while the instrument is energized is not permitted A SOLA II Flare User Manual XV Thermo Scientific Function Chapter 1 Product Overview The Thermo Scientific SOLA II Flare sulfur online analyzer combines proven detection technology easy to use menu driven software and advanced diagnostics to offer unsurpassed flexibility and reliability The instrument offers field programmable ranges high sensitivity total sulfur measurement fast response time linearity through all ranges and low consumables Major components of the SOLA II Flare include a sample injection valve carrier gas flow control system mixing chamber pyrolyzer and a pulsed ultraviolet fluorescence PUVF detector The SOLA II flare is a single assembly with one software program and one user interface The SOLA II Flare is a specialized version of the widely used SOLA II total sulfur analyzer The SOLA II Flare is specially configured to accommodate the wide variety of sample conditions that can be experienced when monitoring
30. to prevent remote actuation of gas selection valves Only clean air and nitrogen are needed for the leak check A Once the system has been purged with nitrogen lower the oven air pressure below 4 psig to allow the oven and pyrolyzer to cool After the oven cools turn the oven air pressure regulator off All regulators for clean air nitrogen and sample should be set to zero psig Leave the power on as it will be needed during the leak test to actuate valves pi Clean air 1 2 and 3 flow paths are common to each other teed together downstream of the injection valves and before the mixing chamber as shown in the flow diagram Figure 1 2 Check all fittings in the clean air flow path for tightness 2 Ensure the three clean air regulators are set to zero psig Cap the tube exiting the pyrolyzer into the pneumatics at the 1 8 inch union Remove the 1 8 inch Teflon tube and cap the union This 1 8 inch Teflon tube goes into the inlet of the PUVF detector Without applying pressure to the PUVF detector check the fittings for tightness 4 After capping the union turn the pressure on the clean air 1 regulator to 15 psig As all three clean air flow paths are common downstream all three air gauges will slowly pressure up to 15 psig This will take several minutes as there are restrictors in the flow paths 5 Once all three clean air gauges read 15 psig back off the clean air 1 regulator The pressure may fall a few psig at first but
31. Appendix E The Workstation Clicking Diagnostics displays a list of current values for several status monitors and a trend chart showing historical values These status values are useful for troubleshooting LS Mapnoctics Trends Detector Frequency KHz __0 21000 Co ee E 0 000 40 000 29 813 a Chamber Pressure Figure E 5 Diagnostic Trends SOLA II Flare User Manual E 6 Appendix E The Workstation Diagnostic Signals A user can select the Diagnostics button on the workstation main screen and be presented with a snapshot of seven of the most significant values related to the SOLA II Flare operation P Diagnostic Signals PMT Frequency Lamp Voltage Lamp Intensity Chamber Temperature Chamber Flow PMT Voltage Chamber Pressure Figure E 6 Diagnostic Signals SCS Controls Clicking SCS Control displays a set of selections that allow the user to control the SOLA II Flare validation range Once a user selects an option the workstation will send a MODBUS command to the SOLA II Flare unit commanding the unit to change its pneumatic outputs to select one of the 11 available valve configurations IA SCS Control e Flare Sample Local Low Cal A Local Low Cal B Local Mid Cal A Local Mid Cal B Local High Cal B Probe Low Cal A Probe Low Cal B O Probe Mid Cal A Probe Mid Cal B Probe High Cal B Figure E 7 SCS Control Thermo Scientific SOLA II Flare Us
32. B Low Adjust A Reading Adjust B Reading High Cal A KHz High Cal B KHz Low Cal A KHz Low Cal B KHz oe SO eee ee ee Me age ot i oe ee ee Manipulate gases via the SCS Valve Select menu to allow the Range A or Range B Low calibration standard to flow into instrument Watch the instrument s display and wait for the sulfur value to stabilize Access the Configuration Menu on the SOLA II Flare s display Access the Calibration Setup Menu Select Recalibrate Low Total sulfur content will appear on the display The phrase Recalibrate Low will appear on the display Press the Yes button Manipulate the valve on the sample conditioning system to allow the sample to once again flow into the instrument Manipulate gases via the SCS Valve Select menu to allow the Range A or Range B High calibration standard to flow into instrument Watch the instrument s LCD and wait for the sulfur value to stabilize Access the Configuration Menu on the SOLA II Flare s display Access the Calibration Setup Menu Select Recalibrate High Total sulfur content will appear on the display The phrase Recalibrate High will appear on the display SOLA II Flare User Manual 5 11 Chapter 5 Configuration 8 Press the Yes button 9 Manipulate the valve on the sample conditioning system to allow the sample to once again flow into the instrument The Recalibrate High Use this function if manually introducing the high calibration standard to t
33. CH CH CHE we CC p p C3 l GC l CO l GC l O h y If storing the instrument the storage environment should be protected and free from extremes of temperatures and high humidity SOLA II Flare User Manual 1 12 Re quirements Sample Line Thermo Scientific Installation Chapter 2 Installation Material and power Consult the specifications for installation information e Operating environment For optimum reliability and equipment life we recommend that the analyzer be installed in a location protected from temperature and weather extremes The analyzer operates best in a controlled environment Ambient temperature and purge air must not exceed the limits listed in the specifications e Mounting requirements The mounting site must be as close as possible to the sampling point The analyzer must be sheltered from extreme weather conditions Avoid mounting the analyzer in high vibration areas Mount the analyzer in an accessible location e Cable glands used to supply electrical power must be IP40 rated metallic cable glands e Blanking elements or plugs used shall be in accordance with national standards Caution This product is extremely heavy Care must be taken at all times to avoid injury Never attempt to move this product alone or without the use of lift gear When handling the analyzer ensure that all four corners are supported A Note Sample lines into
34. Changing the parameters may adversely affect system performance A Pyrolyzer Settings The default settings for the pyrolyzer are provided in the tables on the following pages Table A 2 Pyrolyzer settings Setup Page gt Analog Input 1 Display Software Display Software Cial TC Linearization For Type S thermocouple Filter o 0 5 For smoothing the process signal rf Er Input Error Latching Off Thermo Scientific SOLA II Flare User Manual A 3 Parameter Display BRE POE E Parameter Display BBB Thermo Scientific Table A 3 Pyrolyzer settings Setup Page gt Control Loop 1 Software Heat Algorithm Cool Algorithm TRU TUNE Enable Default Display s Software lt Autotune Aggressiveness Troe User Failure Action Input Error Failure USES CI er AC Pe AO LE isc e en Table A 4 Pyrolyzer settings Setup Page gt Output 1 Output Control Output Time Base Output Low Power Scale Output High Power Scale Feb BERE SOLA II Flare User Manual Appendix A Watlow EZ Zone PM6 Series Comment The method of heat control Critical damped aggressiveness of autotuning calculations When user switches to manual mode controller sets output power to last open loop set point entered by user When an Input error switches control to manual mode controller sets output to 0 The minimum value of the closed loop set point range The maximum value of the
35. E x i t Figure 5 48 3 Enter the time of day hh mm ss that the SOLA II Flare is to begin the automatic validation process VA eI te alley ie O H Si Fe 564 500 pp Valt d as te on T ime V N Ent Pax a Figure 5 49 SOLA II Flare User Manual 5 18 Thermo Scientific Chapter 5 Configuration 4 Select Disabled or one of 10 predefined control output states 0 Disabled 1 Local Low Cal A 2 Local Low Cal B 3 Local Mid Cal A 4 Local Mid Cal B 5 Local High Cal B 6 Probe Low Cal A 7 Probe Low Cal B 8 Probe Mid Cal A 9 Probe Mid Cal B 10 Probe High Cal B Vz a A balla pe i Eon fim Si Fe 564 EU pp Sa ac ei Ep 1 ea DE Lea rca ines pia kon En V A Ent Eix a Figure 5 50 5 Enter the number of minutes 0 60 that the SOLA II Flare is to remain in this particular validation step Mea lp El E ES on SA eses up SPE e Ep 1 Time V N En t E x i t Figure 5 51 SOLA II Flare User Manual 5 19 Chapter 5 Configuration 6 Continue this selection process for up to six validation steps Wet lpi balay ce i O Gr Site T hua Ep S PE LG E fm Se IE Be Re te 2 jaw En V N En t E x i t Figure 5 52 7 Enter the number of minutes 0 60 that the SOLA II Flare is to remain in this particular validation step We 2 IE ball eye LT o m Sie deta hue Ep Sh eae ep 6 Time V N En t EN E rt Figure 5 53 4 20 mA Range Each calibration is configured to use a unique range for the 4 20 mA outpu
36. I Flare is in the high measurement range but could be reading low sulfur number if the sulfur level is not increasing During this short period the analyzer s accuracy will be poor but a sulfur number will be reported SOLA II Flare User Manual 1 4 Thermo Scientific Validation Calibration Principle of Operation Chapter 1 Product Overview The validation function can be performed with a preset time in the software or on demand This function is a programmed sequence and once activated the SOLA II Flare will complete the sequence and report the data for the validation To meet the daily reporting requirements the validation should be done on a timed basis controlled by a third party PLC The on demand function which can be activated via the front panel or the PLC should be used to determine if there is a problem with the analyzer system For further information see Validation Calibration should be performed after a validation failure For further information see Calibration The detector is based on the principle that SO molecules absorb UV light and become excited at one wavelength then decay to a lower energy state and emit UV light at a different wavelength Specifically S02 hvi S07 gt 502 hv2 Excited state hv Exposure light at excitation wavelength hv2 Emitted lignt at emission wavelength The sample in and sample out are routed into the oven through a heat traced line The traced bundl
37. Instead replace the tube according to the previous section A The analyzer has been designed to achieve a high level of reliability Only premium components are used to ensure that complete failure is rare In the event of problems or failure the troubleshooting guidelines presented in the following table should be helpful in isolating the fault Table 8 3 Troubleshooting Malfunction Possible Cause Action Analyzer does not No power Ensure instrument is connected to the start up proper source Digital electronics Ensure boards are seated properly and interconnecting cables are in place Replace boards one at a time to Isolate faulty board No response to Instrument problems Check for alarm messages and correct as sample necessary Bad calibration Ensure proper calibration Flasher power supply Replace with known good board Lamp trigger pack Replace with known good board Lamp Remove lamp and socket from flash holder EN Warning Do not look directly by loosening the single set screw Lamp into lamp without proper flash should be clearly visible at 20 yards eyewear A distance in well lit room PMT high voltage power supply Check voltage on high voltage power supply connector Should be close to the setting Replace with known good board Digital electronics Replace board one at a time to Isolate faulty board Low or no sample flow Check trend of chamber flow at workstation If chamber flow is low or trendin
38. Modbus and or discrete signals e Utilize the X Purge s alarm contacts to drive interposing relays configured such that the Modbus and or discrete signal wiring continuity is broken upon loss of main analyzer power Thermo Scientific SOLA II Flare User Manual F 7 Appendix F The X Purge System Maintenance A Caution Placing the Normal Bypass switch in the Bypass position disables safe operation of the system The Bypass position is to be used only when required for maintenance and only if the area is non hazardous A AN Caution Do not open the explosion proof housing for the X Purge unless the area is known to be non hazardous A AN Caution Do not leave the Normal Bypass switch in the Bypass position after maintenance is completed Do not leave the analyzer system unattended when the Normal Bypass switch is in the Bypass position Personnel must remove power from the system immediately if hazardous conditions are suspected A Thermo Scientific SOLA II Flare User Manual F 8 Timer Adjustment Thermo Scientific Appendix F The X Purge System The required time delay for safe operation is determined at the factory Adjustment of the time delay should not normally be required Do not adjust the time delay unless you are absolutely sure that you will not create a potentially hazardous situation Caution Do not open the explosion proof housing for the X Purge unless the area is known to be non hazardous or the power is removed
39. P Closed Loop Set Point 110 0 C The set point the controller will automatically control to Jj 6 Idle Set Point 25 0 C The closed loop set point that can be triggered by an event state L L Heat Proportional Band 14 0 C The PID proportional band for the heat outputs Heat Hysteresis 20 C The process value needs to be this far into the On region before the output turns on r p L Cool Proportional Band 14 0 6 The PID proportional band for the cool outputs Cool Hysteresis 2 0 C The process value needs to be this far into the On region before the output turns on gt i Time Integral The PID integral seconds osp Open Loop Set Point 0 0 The fixed level of output power when in manual open loop mode Comment i Thermo Scientific SOLA II Flare User Manual A 15 Parameter Display T Ahi Parameter Display PAC t i g Parameter Display Pac 110 Parameter Display Par I d Thermo Scientific Table A 27 Oven settings Operations Page gt Alarm 1 Default Table A 28 Oven settings Factory Page gt Custom Setup 1 Default Table A 29 Oven settings Factory Page gt Custom Setup 2 Table A 30 Oven settings Factory Page gt Custom Setup 3 T BUE er SOLA II Flare User Manual Appendix A Watlow EZ Zone PM6 Series Comment The set point that will trigger a low alarm The set point that will trigger a high alarm Comment The parameter t
40. al 8 4 Chapter 8 Maintenance amp Troubleshooting 7 Each sample flow path flows through a dedicated check valve Once the flow exits the check valve outlet the flow paths tee together and pass into the inlet of the back pressure regulator If one of the check valves is leaking or malfunctioning this could simulate a leak In the first stage of the leak test the flow moves through the six port valve to the check valve on that flow path Cap the inlet of the check valve on the 10 port valve s flow path to ensure the check valve is functioning properly 8 Turn the external source of nitrogen off but leave it connected so pressure remains on the system Pressure should be at 30 psig on the forward and back pressure regulator gauges Monitor this for at least 15 minutes to make sure this pressure holds steady and does not bleed down If the pressure holds remove the cap from the check valve and make sure the pressure continues to hold 9 Ifthe pressure bleeds down once the cap has been removed the check valve must be disassembled and cleaned or replaced and then rechecked for a leak 10 Once pressure without the cap remains continuous replace the tubing 11 Turn V3 On in the Diagnostics menu refer to step 2 This will push the external nitrogen source through the 10 port valve Turn the external source of nitrogen back on and repeat steps 6 9 above including capping the inlet of the check valve from the sample outlet of the 6 p
41. alarm View Ack Alarm s Perea 1 Mea Im fp e Er ad Er Be V A A c k Ex it Figure 6 2 For a complete list of alarms see Figure 3 3 SOLA II Flare User Manual 6 1 Input amp Output Test set Outputs Thermo Scientific Chapter 7 Diagnostics There are four submenus within the Diagnostics top level menu Input amp Output Test View Parameters Com Ports RX TX and Pulse UV Control Se ES ER EI 6 E SALE ES E S Diagnostics V N Ent E ex ie et Figure 7 1 The Input amp Output Test menu consists of four groups of submenus Set Outputs Menu View Mux Analogs 4 20 mA Inputs and View Digital Inputs DE Fa es os thi eins Input amp Output Ae ea Ess Et V N Ent Ex it Figure 7 2 In the Set Outputs group press Tgle on the system display to toggle the associated relay on and off Input amp Output F esit Sieft Out put s V N En t sera Figure 7 3 SOLA II Flare User Manual 7 1 Thermo Scientific Chapter 7 Diagnostics Following are the relays that can be accessed through the Set Outputs group Table 7 1 Output RLY 1 Spare RLY 2 Spare RLY 3 Spare RLY 4 Spare RLY 5 Spare RLY 6 Spare RLY 7 Spare RLY 8 Spare In V1 Solenoid Inj V2 Solenoid Rng V3 Solenoid V4 Solenoid 1 Solenoid Solenoid 5 solenoid 6 Solenoid 7 solenoid 8 Chn 1 4 20 Chn 2 4 20 PMT Supply CNTRL 00 LED CNTRL 01 UV Lamp Bench CNTRL CNTRL 7 S amp H CNTRL Gain Function Spare relay Spare re
42. an tissue Blow with clean compressed gas to remove any lint left by the tissue Visually inspect the rotor If it shows any scratches and or a narrowing of the flow passages replacement is necessary pi Rotor As sembly Place the clean rotor on the pencil magnet and orient it so that the tab properly engages the slot of the drive mechanism The list in Figure B 3 shows how to orient the ID letter for different VICI valves A COW is shown in Figure B 4 2 Insert the rotor into the valve body being careful that the tab does not touch the polished interior of the valve body Make sure the rotor tab Figure B 4 is fully inserted into the slot in the driver 3 Using a pencil or other small pointed object hold the rotor in place in the valve body while pulling the magnet free 4 Replace the knurled preload assembly tightening it into the valve body by hand just beyond the point where it touches the rotor Cycle the valve 10 times to seat the sealing surfaces leaving the valve fully in its clockwise or counterclockwise position 5 Tighten the preload in quarter turn increments cycling the valve 10 times after each step The preload must end up fully bottomed out but attempts to further tighten do not affect the sealing forces Note Make certain that the valve is never left partially actuated It should always be in either its fully clockwise or fully counterclockwise position A Thermo Scientific SOLA II Flare User Manual B
43. ance O Rolling Password User Password O ow dl O Administrator Password nl Thermo Scientific SOLA II Flare User Manual A 9 Appendix A Watlow EZ Zone PM6 Series Oven Settings The default settings for the pyrolyzer are provided in the tables on the following pages Table A 17 Oven settings Setup Page gt Analog Input 1 U CD eb Cc P Parameter Comment Software Software sensor Type RTD 100 Ohm Display Cia Don TC Linearization r l RID Leads For Type S thermocouple The number of leads on the RTD wired to this input i mos Units Process The type of units measured by the sensor L Scale Low The low scale for process inputs Scale High 20 00 The high scale for process inputs r 5 Range Low 18 0 C The output low range r L i Range High 5337 06 The output high range Process Error Enable Off Process Error Low Value EEE PEL Fil Filter er od EL oO al For smoothing the process signal Input Error Latching Off Display Precision Tenths SELL Thermo Scientific SOLA II Flare User Manual A 10 Appendix A Watlow EZ Zone PM6 Series Table A 18 Oven settings Setup Page gt Control Loop 1 Display Software Heat Algorithm CA9 Cool Algorithm TRU TUNE Enable Display Software The method of heat control Off No TRU TUNE Band a T Autotune Aggressiveness Critical Critical damped aggressiveness of autotuning calcul
44. anty period Thermo Scientific shall have the right to inspect such products at Buyer s plant or to require Buyer to return such products to the Thermo Scientific plant In the event Thermo Scientific requests the return of its products Buyer shall ship with transportation charges paid by the Buyer to the Thermo Scientific plant Shipment of repaired or replacement goods from the Thermo Scientific plant shall be F O B Thermo Scientific plant The customer will receive a quotation of proposed work before repair work begins Thermo Scientific shall be liable only to replace or repair at its option free of charge products that are found by Thermo Scientific to be defective in material or workmanship and which are reported to Thermo Scientific within the warranty period as provided above This right to replacement shall be Buyer s exclusive remedy against Thermo Scientific Thermo Scientific shall not be liable for labor charges or other losses or damages of any kind or description including but not limited to incidental special or consequential damages caused by defective products This warranty shall be void if recommendations provided by Thermo Scientific or its Sales Representatives are not followed concerning methods of operation usage and storage or exposure to harsh conditions Materials and or products furnished to Thermo Scientific by other suppliers shall carry no warranty with the exception of suppliers warranties as to mat
45. anual provided with the system or instructions in the software you are using for more information Thermo Scientific SOLA II Flare User Manual E 3 Thermo Scientific Appendix E The Workstation Data from the analyzer is also saved on the hard drive in CSV format for easy use with spreadsheets databases statistical analysis and other software programs The data is stored in the c Program Files National Instruments Lookout sola directory with subdirectories that match the year month and date for the analysis ET Lookout SOLA SOLA I Flare Ele Ede Gebers gama r re Bun Help Statistics Time Reset 50 05 28 Average 48 7 Max 124 2 Min 0 3 STD 17 60 Cal A Low 0 0 q KHz High 1000 0 10000 KHz Response 10 000 KHz ppm Cal B Low 0 0 0 KHz High 1000 0 10000 KHz Response 10 000 KHz ppm Signals Validation Start 03851554 Administrator Diagnostics SCS Control Switch to i High Range Flare TS Thermo Electron Figure E 4 Workstation main screen 97 alarmna As shown in Figure E 4 the main screen is divided into several operating sectors that are described in the following sections III Note The workstation collects real time data form the analyzer For proper operation the workstation should be run continuously with a connection to the analyzer A SOLA II Flare User Manual E 4 Statistics Total Sulfur amp Frequency Plot Analyzer St
46. aters Ea ES S 2 cl eye Lam p vo Ou MALO ta eats Ec Ne u el R ra ET V N ae E A hele Fee Figure 5 19 Thermo Scientific SOLA II Flare User Manual 5 6 Chapter 5 Configuration 4 To set up a Lamp Intensity alarm enter the low point lamp frequency at which the alarm should activate The value can be from 0 to 50 000 Hz Mel a2 A 57 2 e 78 Llamp IE ie ie Ss S ae ie oy zu ALA eae em V N Eee ray ets BEI eda ote Figure 5 20 5 To set up a Lamp Voltage Rate of Change alarm enter the rate of change in lamp voltage at which the alarm should activate The value can be from 1 to 50 V per 30 seconds A le Vicia ee ETA ES Se ec wi je ID IES V mle e e CA E ea mm V N EEN TE te Ser E Figure 5 21 6 Set up a Chamber Temperature alarm by entering the deviation from 45 C at which the alarm should activate zu O ey e A ES 57 e ule Slap ep A ey 7 wy ey joy Me eye fire V N E Jae ie Be eo la St Figure 5 22 Thermo Scientific SOLA II Flare User Manual 5 Chapter 5 Configuration 7 The Purge alarm will remain active for a default time of 15 minutes at startup or after the purge is restored A l arms Setup Purge Alarm Timeout V N En t O IAE Figure 5 23 8 Set the Status Alarms Mode to Latching or Non Latching This value allows the user the option to latch an alarm condition or not to allow for after the fact troubleshooting of intermittent problems or user ackno
47. ations Peltier Delay ide Tw N Hin User Failure Action User When user switches to manual mode controller sets output power to last open loop set point entered by user Input Error Failure Off When an Input error switches control to manual mode controller sets output to 0 Fixed Power 0 0 Open Loop Detect Enable N ii Open Loop Detect Time 240 0 C Open Loop Detect Deviation ep me ft nics PTa a H L Low Set Point 0 C The minimum value of the closed loop set point range High Set Point 130 0 C The maximum value of the closed loop set point range tll Set Point Open Limit Low 100 0 The minimum value of the open loop set point range L set Point Open Limit High 100 0 The maximum value of the open loop set point range RRR Thermo Scientific SOLA II Flare User Manual A 11 Parameter Display BB Parameter Display He Thermo Scientific Appendix A Watlow EZ Zone PM6 Series Table A 19 Oven settings Setup Page gt Output 1 Software Output Function Output Function Instance Default RERE EEE Comment Software Heat 1 Output Control FEB Fixed Time Base Output Low Power Scale Output High Power Scale 0 The power output will never be less than the value specified and will represent the value at which output scaling begins 70 The power output will never be greater than the value specified and will represent the value at which
48. atus Thermo Scientific Appendix E The Workstation The left sector displays statistics for the analyses of Cal A and Cal B if second stream option is installed on the analyzer Clicking Reset zeroes the statistics and starts accumulation of information Time period displays the length of time for which the data has been accumulating The Total Sulfur and Frequency Plot area displays the trend of measured total sulfur for Cal A and Cal B The arrows triangles on the bar along the top of the plot area permit scrolling left or right along the time axis for viewing the plot When scrolling the red indicator at the right end of the bar turns on to indicate that viewed data is historical rather than real time Clicking the lower indicator of the two turns that indicator green and returns the plot to real time data display The total time period displayed on the plot can be varied from 5 minutes to 24 hours by moving the slider below the plot area The hyper cursor in the middle of the upper bar can be selected and moved to any point along the trend to display an instantaneous value of the concentration in percentage of full scale The two indicators at the lower left of the main screen display the status of the analyzer by placing a green indicator to the right of Validation Start and Abort If the indicators are not green the system is running a sample analysis SOLA II Flare User Manual E 5 Diagnostic Trends Thermo Scientific
49. ay Time User Settings Save 1 rr User Settings Restore Table A 24 Oven settings Operations Page gt Analog Input 1 Analog Input Value The process value C Em Er Input Error The cause of the most recent error Possible displays listed below None Open Fail shorted Measurement Error Bad Calibration Data Ambient Error RTD Error Not Sourced Calibration Offset The offset applied to the input reading to compensate factors that cause the input reading to vary from the actual process value C Default 0 None None U o o 3 D ED Description pu Thermo Scientific SOLA II Flare User Manual A 14 Appendix A Watlow EZ Zone PM6 Series Table A 25 Oven settings Operations Page gt Monitor 1 Parameter Description Display Software Control Mode Active The control mode currently in effect Possible displays listed below Auto Manual Heat Power The current heat output level Cool Power The current cool output level Closed Loop Set Point The set point currently in effect C if Process Value Active The current filtered process value using the control input C Table A 26 Oven settings Operations Page gt Control Loop 1 Parameter Default Display Software Display Software r n d Control Mode The loop will use automatic control AESP Autotune Set Point 90 The percentange of the current set point that will be used by autotune CAJE Mn Ead e CS
50. closed loop set point range The minimum value of the open loop set point range The maximum value of the open loop set point range Comment The power output will never be less than the value specified and will represent the value at which output scaling begins The power output will never be greater than the value specified and will represent the value at which output scaling stops A 4 Appendix A Watlow EZ Zone PM6 Series Table A 5 Pyrolyzer settings Setup Page gt Output 2 Display Software Software Dm o lt Output Function Alarm Output Function Instance L E Table A 6 Pyrolyzer settings Setup Page gt Alarm Parameter Default Comment Display Software Software Alarm Type Deviation Alarm Alarm Hysteresis h Alarm Logic Open On Alarm The output condition during an alarm state Alarm Sides Both Both high and low sides can trigger the alarm Alarm Latching Non Latching NO O Alarm Blocking Off Alarm Silencing Off Alarm Display An alarm message will display when an alarm Is active SE REEE Alarm Delay Time ae i Table A 7 Pyrolyzer settings Setup Page gt Function Key Parameter Default Comment Display Software Display Software Ew hh AAN rr esther E pwe O S Thermo Scientific SOLA II Flare User Manual A 5 Appendix A Watlow EZ Zone PM6 Series Table A 8 Pyrolyzer settings Setup Page gt Global Display Units H r L AC Lin
51. drops too low It also automatically removes power from the analyzer if the instrument air pressure at the X Purge regulator is lower than about 10 psig To manually remove power from the system perform the following steps 1 Perform all shutdown steps listed in the shutdown procedure in the instrument user s guide up to the point where power is turned off to the system 2 Remove power to the X Purge system 3 Complete the remaining shutdown steps listed in the applicable shutdown procedure in the instrument user s guide Power or Purge Loss _ If ac power or purge pressure is lost the X Purge unit shuts off power to the Shutdown analyzer system When the power or purge pressure is restored the X Purge begins the purge timer After the required purge time is achieved the X Purge unit applies power to the analyzer system The X Purge controller interrupts the incoming analyzer electrical power Power to 4 20 mA outputs is interrupted upon loss of purge or power as the analyzer powers these outputs The device receiving discrete and or Modbus signals from the analyzer may apply power Consequently the purged analyzer enclosure could contain powered wiring even when power to the analyzer is interrupted To ensure that the purged analyzer enclosure contains only non incendiary power upon interruption of main analyzer power you may elect to implement one of the following e Install the appropriate Intrinsically Safe IS barriers on
52. e V N En t E x i t Figure 5 35 Thermo Scientific SOLA II Flare User Manual 5 14 Chapter 5 Configuration 7 Enter the concentration of the low calibration standard for Cal B This can be the same standard used for calibration of the High Cal A or can use nitrogen as a zero standard Slap ete IS Er a C popa Si ed Et a Ep L ow Gran B Value V A Ent een Figure 5 36 8 This step will latch the detector response and associate it to the High Cal A value Cahe ED Ba fee et oe en Shea at us p Rielelall ajitmpeale ey O piety et e eh V A E n t Be xs tet Figure 5 37 9 This step will associate the response of the detector to the Low Cal A value 07 Rae O r be Sr a C3 et LOS en Si ced bts hee Ep RO Te fice ad IA ie b ar a PT es FAN E O we V A E n Pt A E A 1 Figure 5 38 10 This step moves the calibration line so the reading matches the user desired reading for Cal A Ca LA iy DA ets ea lee ton En Se ht sar Ep Adj ust AR ea rea IS RS o V N En t Ex i t Figure 5 39 Thermo Scientific SOLA II Flare User Manual 5 15 Chapter 5 Configuration 11 This step will latch the detector response and associate it to the High Cal B value 09 Rare el IS Ab er eae ft et OS en Se tw p R e ca libert ate B Hi gh V A Ent En as aro 16 Figure 5 40 12 This step will associate the response of the detector to the Low Cal B value C aa ole fate On tl ea Ei Los En Ss re et Ku Ep E EA ca Ea
53. e EZ ZONE PM6 are shown below and described in the table that follows EZ ZONE Upper display Zone display Lower display Figure A 1 EZ ZONE PM6 series controller Thermo Scientific SOLA II Flare User Manual A 1 Thermo Scientific Appendix A Watlow EZ Zone PM6 Series Table A 1 Controller display amp keys Display Key Upper display Zone display Lower display v d a 1 through 5 Description When in the Home page displays the process value Otherwise the upper display shows the value of the parameter in the lower display Indicates the controller zone 1 9 Zones 1 through 9 A Zone 10 b Zone 11 C Zone 12 d Zone 13 E Zone 14 F Zone 15 h Zone 16 Indicates the set point or output power value during operation or the parameter associated with the value shown in the upper display Indicates whether the temperature is displayed in degrees Fahrenheit or Celsius The percent LED lights when values are displayed as a percentage or when the open loop set point is displayed This LED indicates the status of a profile When lit a profile is running When flashing a profile is paused Indicates communication activity by flashing when another device is communicating with the controller The number LEDs indicate output activity Press the Infinity key to back up one level or press and hold the key for two seconds to return to the Home page Once on the Home page this k
54. e Frequency UL Ed Communications LED Action 2onE Chan Display Pairs Display Time User Settings Save User Settings Restore Table A 9 Pyrolyzer settings Operations Page gt Analog Input 1 Software Display units are in C 60 Hz The frequency to the applied AC line power source b N eo D l Both Both comm port 1 and 2 selected HE Off O The Channel LED is on The number of display pairs The time delay for toggling between channel 1 and channel 2 None None en jr Parameter Description Ain Analog Input Value The process value C Input Error The cause of the most recent error Possible displays listed below None Open Fail shorted Measurement Error Bad Calibration Data Ambient Error RID Error Not Sourced Calibration Offset The offset applied to the input reading to compensate factors that cause the input reading to vary from the actual process value C Default 0 Im Thermo Scientific SOLA II Flare User Manual A 6 Appendix A Cool Power The current cool output level EP re ESP Closed Loop Set Point The set point currently in effect C Watlow EZ Zone PM6 Series Table A 10 Pyrolyzer settings Operations Page gt Monitor 1 Parameter Description Control Mode Active The control mode currently in effect Possible displays listed below pf N S n Manual L r The current heat output level D IS Process Value Active The current filtered proces
55. e enters through a hole in the oven and a heat shrinking boot typically provided by the system integrator The sample is mixed with air and passes through a pyrolyzer furnace that oxidizes the sulfur molecules in the sample to produce SO2 The sample then flows into the fluorescence chamber where pulsating UV light excites the SO molecules The condensing lens focuses the pulsating UV light onto a mirror assembly The mirror assembly contains four selective mirrors that reflect only the wavelengths that excite SO molecules As the excited SO molecules decay to lower energy states they emit UV light that is proportional to the total sulfur concentration in the sample The bandpass filter allows only the wavelengths emitted by the excited SO molecules to reach the PMT which detects the UV light emission The photo detector located at the back of the fluorescence chamber continuously monitors the pulsating UV light source to provide compensation for fluctuations The measured SO concentration representing the total sulfur in the sample is processed displayed on the front panel display and sent to the analog outputs SOLA II Flare User Manual 1 5 Chapter 1 Product Overview PUVF Detector The PUVF detector includes and controls the following e UV pulsed light and associated systems e Reaction chamber temperature control e Digitizing of the PMT signal e Smoothing of the measurement signal using the moving average Pyrolyzer Measu
56. e instrument a static IP use the provided utility program to set up the IP address Perform the following steps to search for the Bridge on the network and assign an IP address 1 Locate the IPSetup exe utility that is included with the disk that ships with the TCP IP Bridge option Thermo Scientific SOLA II Flare User Manual C 1 Thermo Scientific Appendix C TCP IP Bridge 2 Run the IPSetup exe utility from any IBM compatible PC connected to the same network as the Bridge The utility automatically searches the network and reports any bridges found 3 If more than one bridge is installed on the network each can be identified by its MAC address The MAC address is recorded on the label near the RJ45 connector on the Bridge board 4 Record the IP address assigned to the bridge This is the IP address required for configuring a workstation or DCS to query the SOLA II Flare On the TCP IP Modbus frame the unit ID must always be set to Network Mask P K Gateway fo Tu Set gt pss fo fo fo fo Badate 115000 Mac Address Warme Figure C 2 Example display with DHCP server present To set a static IP enter the IP address and press the Set gt button The SOLA II Flare offers the option for the user to remotely connect to the SOLA II Flare via web browser and be presented with a full representation of the display on the front of the unit This provides the user with all of the same functionality as standing in
57. enu the status of the inputs is reported but the functions are ignored Input amp Output Tred Ese 56 View P I G I ET a In put s V N En t Exc Figure 7 6 Following is a list of inputs and their functions Table 7 2 Input Function Purge Fail Displays the status of the purge sense pressure switch Flow Switch Displays the status of the flow monitoring switch Watlow Alarm Displays the status of the Watlow alarm input I O Board Displays the status of all eight inputs simultaneously Zero 0 denotes open One 1 denotes closed CPU Digital In Dip Switches Displays the positions of dip switches located in the motherboard dip switches are used to indicate options installed I O Board Option 4 20 mA Input Option Not used in SOLA II Flare Com 4 Modem Modbus input Remote Suspend Displays the status of the remote suspend switch View Parameters Each menu item within the View Parameters menu displays the parameter name current value minimum value and maximum value Displaying the minimum maximum and current values for a period of time enables you to monitor signal stability Il Note When you select a parameter to view the minimum and maximum values are briefly reset to the current value A Thermo Scientific SOLA II Flare User Manual 7 4 Thermo Scientific Chapter 7 Diagnostics Diagnostics V i ew Pasrameteor s V A Ent Es i bt Figure 7 7 Parameter name Current Value Minimum Value Cl
58. er Manual E 7 Appendix F The X Purge System De scription The optional X Purge assembly is used to provide safe operation of analyzer systems in Class 1 Division 1 Groups B C and D NFPA and Zone 1 Ex d p IIC T4 ATEX and IECEx hazardous areas Safe operation is achieved by automatically disconnecting power from the analyzer system if the purge pressure is lost in any of the monitored enclosures or if purge flow out of either enclosure exhaust port is lost The X Purge system also ensures that the system is safe before it permits power to be applied to the analyzer system To ensure continued safe operation of the analyzer system the X Purge unit must not be disabled or adjusted improperly On power up the X Purge system checks the purge pressure in all monitored enclosures and for flow exiting the exhaust ports of the enclosures When all monitored enclosures register pressures at least 0 3 inch of water 0 75 mbar above the reference pressure adequate flow is present at the enclosure exhaust ports and the instrument air pressure is greater than 10 psig a time delay relay begins its timed cycle Typically the time delay is used to ensure that at least four volumes of air are exchanged in the enclosures before power is applied to the system The number of exchanged volumes may be higher in some situations After the preset time delay is accomplished the time delay relay applies power to the analyzer system Typically the X P
59. erials and workmanship Thermo Scientific disclaims all warranties expressed or implied with respect to such products EXCEPT AS OTHERWISE AGREED TO IN WRITING BY Thermo Scientific THE WARRANTIES GIVEN ABOVE ARE IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED AND Thermo Scientific HEREBY DISCLAIMS ALL OTHER WARRANTIES INCLUDING THOSE OF MERCHANTABILITY AND FITNESS FOR PURPOSE Thermo Scientific SOLA II Flare User Manual 9 2 Chapter 9 Support Items Not Covered The following parts are considered consumable items and are not covered under Under Warranty Thermo Scientific the warranty Injection valve and associated parts Inline filter UV lamp Combustion tube quartz Pyrolyzer O Ring silicone Combustion tube graphite ferrules SOLA II Flare User Manual 9 3 Appendix A Watlow EZ Zone PM6 Series Controller The Watlow EZ ZONE PM6 series controller is used to control the Des cripti on temperatures of the pyrolyzer furnace and the analyzer oven The controller provides a signal output if the zone temperature is outside a specified range This appendix provides basic operating instructions and default configuration settings For complete operating information and troubleshooting refer to the EZ ZONE PM PID Controller user s manual Hardware Setup The EZ ZONE PM6 is wired at the factory according to your application No other hardware settings are required Display amp Keys The display and keys on th
60. ers of operating procedures practices conditions etc which may result in equipment damage if not carefully observed or followed A SOLA II Flare User Manual XIII safety Information amp Guidelines AN Caution Static sensitive component Appropriate handling precautions required to prevent damage A Note Notes emphasize important or essential information or a statement of company policy regarding an operating procedure practice condition etc A Safety Operating This section contains general safety and operating information applicable to Information analytical systems which must be understood by all persons installing using or maintaining the analyzer system This information is designed to aid personnel in the safe installation operation and service of the analyzer and sample systems It is not designed to replace or limit appropriate safety measures applicable to work performed by personnel Any additional safety and operating measures that are required must be determined by and followed by personnel performing work on the system AN Caution Failure to heed the following information may lead to equipment damage or injury to personnel A Protective eyewear glasses with side shields or goggles as appropriate must be worn when servicing any part of the analyzer or sample system When servicing the sample system chemical resistant gloves appropriate for the materials in the system must be worn When servicing the hot ana
61. ey may be used to clear alarms and errors if they may be cleared Press the Advance key to enter the selected menu When in the Home page use the Up and Down keys to adjust the set point in the lower display When in other pages use the keys to change the upper display to a higher or lower value or to change a parameter selection SOLA II Flare User Manual A 2 Appendix A Watlow EZ Zone PM6 Series Software There are two ways to configure the EZ ZONE PM6 You can use the menu Confi gur ation m built into the controller and configure it using the display and appropriate keys to navigate through the system or alternatively you can use the EZ ZONE Configurator software Instructions for both methods of configuration are provided in the EZ ZONE PM PID Controller user s manual The built in menu system and configuration software have the following main pages e Setup page Used to set up a control prior to operation e Operations page Used to monitor or change runtime settings e Factory Page Used to enable password protection create a custom Home Page and perform other tasks that do not have an effect on the control when running e Home Page The page that is displayed when the control is initially powered up Parameters for the EZ ZONE PM6 are set to the optimum values for your application at the factory The defaults settings are provided here in the event the configuration is changed without authorization AN Caution
62. fective or low sensitivity PMT Check electronics and replace if necessary No 4 20 mA de Incorrect or damaged wiring Check wiring diagrams to ensure 4 20 mA output current de signal connected to proper terminals with correct polarity Check for short or open in wiring Inaccurate 4 20 mA Incorrect or damaged wiring Check wiring diagrams to ensure 4 20 mA de output current de signal connected to proper terminals with correct polarity Check for short or open in wiring Unstable span Flasher lamp Replace with known good lamp to see if problem is resolved Internal instrument leak Check for leaks Lamp trigger pack Replace Low lamp intensity Flasher lamp Ensure lamp and trigger pack are securely fastened Determine the alarm type by accessing the View Ack Alarm menu Fault on the I O PCB SOLA II Flare User Manual 8 20 Contact Information III Thermo Scientific Chapter 9 Support The local representative is your first contact for support and is well equipped to answer questions and provide application assistance You can also obtain support by contacting Thermo Scientific directly Process Instruments 1410 Gillingham Lane sugar Land TX 77478 USA lon Path Road Three Winsford Cheshire CW7 3GA UNITED KINGDOM 1 800 437 7979 1 713 272 0404 direct 1 713 4573 fax 44 0 1606 548700 44 0 1606 548711 fax Units 702 715 7th Floor Tower West Yonghe Plaza A 101 1CC Trade Tower se
63. front of the unit itself 5014 E Control Panel Mozilla Firefcor 1621054115 clrepley hi SIL 0 00 ppm Analyzing 000 cc m ALARM Figure C 3 Browser connect screen SOLA II Flare User Manual C 2 Appendix D Sample SOLA II Flare Modbus Register Modbus Map Note 32 bit integer values are transmitted in two consecutive 16 bit holding registers The first register contains the most significant word and the next register the least significant The SOLA analyzer supports a sub set of the TCP IP Modbus Protocol Each SOLA requires a unique IP The identifier is always 1 Modbus Function Supported e Function 01 Read Coils e Function 02 Read Status Inputs e Function 03 Read Holding Registers e Function 04 Read Input Registers e Function 05 Set Single Coil e Function 06 Set Single Holding Register e Function 15 Set Multiple Coils e Function 16 Set Multiple Holding Registers Note Register numbering follows the standard Modbus encoding The actual number sent in the function query is one less than the number referred in the documentation The most significant number in parenthesis indicates the data type and function used To avoid confusion and help in the initial test a sync register with a constant value is provided so communications between the PLC and the Flares can be verified A A block of Holding Registers accessible with functions 03 06 and 16 are added to the standard SOLA II Flare Modbus Ma
64. g down check for stoppage at the injection valve SOLA II Flare User Manual 8 18 Malfunction sample Flow alarm displayed Chamber Flow alarm displayed Lamp Voltage alarm displayed Chamber Temperature alarm displayed Inject Temperature alarm displayed Valve Fault alarm displayed Thermo Scientific Possible Cause sample supply inadequate or valves are closed or misaligned Filtration system obstructed Fast loop bypass flow set too high Blocked line from mixing chamber to valve Inadequate supply of combustion alr UV lamp is old deteriorated Bench contaminated with incompletely combusted materials Detector temperature not stabilized after service or enclosure opened Ambient temperature or purge air is outside ambient temperature limits Thermistor not positioned correctly Instrument is starting up and not reaching control temperature for the pyrolyzer and oven Pyrolyzer heater failure Pyrolyzer or oven temperature failure Injection valve worn or scratched causing port to port leakage Defective flasher lamp trigger pack or lamp intensity control electronics Chapter 8 Maintenance amp Troubleshooting Action Check process conditions and availability of sample supply Ensure all valves are properly aligned Clean or replace filters Adjust bypass flow rate Check lines Replace UV lamp Purge system with carrier air no sample until o
65. h a line drawn between two of the holes in the O Ring plate Figure B 11 4 Slide the subassembly onto the pins of the male end cap with this flat lined up with the air inlet on the end cap 5 Install the cylinder sliding it over the subassembly and pressing the male end cap into it 6 Place the washers and bearing in the female end cap Press the end cap into the cylinder making sure that the air inlet hole is in the same orientation as the one in the male end cap 7 Install the three end cap screws with the PEEK washers provided Replace the valve mounting hardware and air supply lines SOLA II Flare User Manual B 10 Appendix B Rotary Valve Service 9 Apply air pressure to the actuator inlet nearest the valve so that the actuator is in the same position as it was when the valve was removed 10 Slide the valve with its standoff into the clamp ring making sure that the square hole in the valve coupling or in the end of the standoff drive shaft is fully engaged by the square of the actuator drive shaft Tighten the clamp ring screw Valve Al ignment Valves installed using two 3 way solenoids or a Valco Digital Valve Thermo Scientific Interface do not maintain actuation force after they have been actuated For accurate valve alignment a temporary method of supplying continuous air pressure to the selected actuator inlet must be contrived Follow the instructions below 1 Switch the actuator from one position to t
66. h or exceed connector size on the analyzer _ All internal and external tubing fittings are physically checked for tightness and tested for leaks Installation and electrical connections adhere to the following AC power wiring meets requirements _ AC power wiring is properly connected to the instrument with proper earth grounding Signal wiring dc signals communications etc meets requirements Signal wires properly connected to the instrument All electrical conduit seals poured with sealing compound such as Chico A5r or equivalent SOLA II Flare User Manual 2 6 Chapter 3 Start Up amp Shutdown Initial Sta rt Up Perform this procedure when starting up a new installation or when major service work is performed Otherwise perform the procedure according to the section titled Start Up After Short Term Shutdown See the application data that shipped with the instrument and the Specifications and Installation instructions in this manual for information necessary in performing the following procedure 1 Verify proper electrical power and connections a g Ensure the instrument electrical power wiring is properly sized and connected Ensure the power voltage and frequency matches the instrument requirements Ensure a suitable circuit breaker and power switch is installed Ensure the instrument is properly grounded Inspect all electrical connections Terminals must be snug wire and
67. hat will appear in the custom Home Page Comment The parameter that will appear in the custom Home Page Comment The parameter that will appear in the custom Home Page A 16 Appendix A Watlow EZ Zone PM6 Series Table A 31 Oven settings Lock Page gt Lock Display Software Display Software P IS 5 E Password Enable NL The security level of the Operations Page The level of read security clearance The level of write security clearance Slol Write Security PRE orem The Lockout Menu Each menu has a security level assigned to it You can change the read and write access to these menus and pages through the Lockout menu LoC These security functions are described in detail in the EZ ZONE PM PID Controller users manual Thermo Scientific SOLA II Flare User Manual A 17 Initial Precautions Thermo Scientific III III III III Appendix B Rotary Valve Service All SOLA II Flare analyzers use 10 and 6 port rotary injection valves plus a 4 port range select valve This appendix references a typical 6 port rotary injection valve These are manufactured by Valco Instruments Co Inc VICI This appendix describes operation and cleaning instructions for the valves typically used The material in this appendix is taken from VICI Technical Note 201 TN 201 9 00 copyright 2000 VICI and from VICI Technical Note 409 TN 409 4 01 copyright 2001 VICI Technical Notes used with permi
68. he Function analyzer 1 Go to Configuration gt Calibration Setup gt High Cal A Value Set the high calibration value to match the concentration of the standard used Exit the menu 2 Connect the calibration standard to the unit and let it flow through the injection valve 3 Let the reported concentration reach a new value and stabilize Go to Configuration gt Calibration Setup gt Recalibrate A High Press Yes to accept the new high calibration At this point the current average of the detector signal is latched to correspond to the high calibration value concentration Adjusting the Reading If the reported value of the SOLA II Flare does not match a known sample value or the standard flowing through the instrument you can adjust the reading To do so go to Configuration gt Calibration Setup gt Adjust Reading The current reading will be displayed in an editing screen so that you can modify the reading to match the desired reading Note Do not use this function if the difference between the expected reading and the analyzer s reported reading is significant The Adjust Reading function should only be used for making minor corrections to the calibration Using this function improperly can hide malfunctions in the unit that need to be corrected A Thermo Scientific SOLA II Flare User Manual 5 12 Chapter 5 Configuration Calibration Setup Menu This section contains the menu items within the Calibration Setup
69. he other several times to make sure that the play in the coupling mechanism has been absorbed 2 Visually inspect the valve body cutout to determine if the rotor pin is against the stop If so proceed to step 3 If not skip to step 4 3 Switch the actuator to its other position and repeat the visual inspection If the rotor pin is touching the stop in this position also the valve and actuator are properly aligned If the pin does not touch the stop proceed with step 4 4 Switch the actuator to the other position Slowly loosen the clamp ring screw until the valve body moves indicating that the actuator has traveled to the end of its stroke Immediately retighten the clamp ring screw 6 Repeat the visual inspection If the steps have been executed correctly the rotor pin should contact the stops in both positions If it does not repeat the entire procedure SOLA II Flare User Manual B 11 Appendix B Rotary Valve Service Rebuild the Follow these steps to rebuild the subassembly Assembly 1 Puta liberal coating of Dow Corning DC 111 on the slots in the drive shaft 2 Place the ball retainer over the shaft so that the holes in the retainer line up with the slots in the shaft 3 Put the balls in the holes of the retainer so that they rest in the slots They should be held in place by the thick lubricant 4 Notice that the slots in the female race extend all the way to one end but not the other Observe also that one e
70. ic SOLA II Flare User Manual 3 7 Chapter 4 Operation The Interface The analyzer utilizes a 4 line by 20 character vacuum fluorescent display and four push buttons as the user interface All programming and adjustments are accomplished using the push buttons Following is an example of how to use the interface to enter the passcode For information on programming the passcode Analyzer Setup 1 Press any button and you are prompted to enter the passcode 2 Press the button below Ent Enter To increase the first digit s value press the button below the up arrow A Decrease the value by pressing the button below the down arrow v When the correct number is displayed press the button below the right arrow gt to enter the next digit 4 Repeat the process used to enter the first digit for the remaining digits 5 Once the passcode is complete press the button below Done You can access all program features and edit parameters by following these steps Note For instructions on programming the passcode see Analyzer Setup A ck ta te S 15 EN Mal Sl Msi ME ON ec E On MO ON 10 A V gt Du on Ea Me Modify digits Advance cursor Figure 4 1 Beg n Ana UH ng 1 Ifthe analyzer is shut down start up the instrument by following the appropriate set of instructions in Chapter 3 2 Ifthe system power is off open the instrument and carrier air flows to the analyzer and adjust the pressures to the appropriate settings
71. icles lt bu ISA grade hydrocarbon free 110 Vac 50 60 Hz Caution Before attempting to install the X Purge controller review all safety information in this manual and all other applicable documents A Caution Applicable permits must be obtained and appropriate precautions must be taken to prevent possible injury to personnel or equipment damage when installing the system A SOLA II Flare User Manual F 3 Thermo Scientific AC Power Appendix F The X Purge System AC power to the X Purge is connected by the customer Power wiring and circuit breakers must be sized appropriately Refer to drawings provided with the system for connection information and power requirements Customers must provide a suitable power switch near the system for use by maintenance personnel Warning Electrical power must be free of spikes sags surges or electrical noise A AC power to any system using the X Purge is connected directly to the X Purge unit rather than the analyzer The X Purge unit controls the power to the instrument to ensure safe operation in hazardous areas Consult the following table for ac power connections to the X Purge unit Table F 4 Power Terminal Hot TB1 1 Neutral TB1 3 Ground TB1 5 Power out switched TB1 6 Terminals 1 and 2 are jumpered together Terminals 3 and 4 are jumpered together SOLA II Flare User Manual F 4 Appendix F The X Purge System Alarm Signal The X Purge provides dry alar
72. igh Comi Parity Recalibrate B Low Modbus Com3 ID Adjust B Reading odbus Com4 Baud High Cal A Khz Com4 Parity Low Cal A Khz Modbus Com4 ID High Cal B Khz Low Cal B Khz Figure 3 3 Configuration menu Thermo Scientific SOLA II Flare User Manual 3 5 Chapter 3 start Up amp Shutdown Diagnostics Input amp Output Test al Com Ports Rx Tx i Pulse UV Control View Mux Analogs 4 20ma Inputs View Digital Inputs TS Reading Com 1 VO Board Flash Lamp On Off Relay 8 4 20ma Input Opt Intemal Temp Inj V1 Solenoid Com4 Modem PMT Supply stream Select 1 Stream Select Chamber Temp Inj V2 Solenoid Chamber Flow Chamber Pressure Range Control Lamp Alm Counter Remote Cal Lamp Voltage Remote Suspend Chn 2 4 20ma a Bnch CNTL 09 aA CNTL 15 Gain Figure 3 4 Diagnostics Menu Thermo Scientific SOLA II Flare User Manual 3 6 Chapter 3 start Up Shutdown SCS Valve Select Flare Sample Local Low Cal A Local Low Cal B Local Mid Cal 4 Local Mid Cal B Local High Cal B Probe Low Cal 4 Probe Low Cal B Probe Mid Cal A Probe Mid Cal B Probe High Cal D Figure 3 5 SCS Valve Select menu The SCS Controls section of the software allows you to manually manipulate the SCS This can be used pi During commissioning to ensure the SCS is plumbed correctly 2 During recalibration 3 At other times when it might be useful to control the SCS system Thermo Scientif
73. ion valves allow for two completely separate measuring ranges in the PUVF Detector e The Low Range uses a 10 port sample injection valve with a 100u sample loop and the low measurement range calibrated in the detector e The High Range uses a 6 port sample injection valve with a 1u sample loop and the high measurement range calibrated in the detector The results of the sulfur concentration level being measured by the SOLA II Flare are selected by the auto ranging function gt Inject Valve V1 Low Range 10 Port Ext Loops 100ul 7 Range Select Valve V3 4 Port Inject Valve V2 Hi Range 6 Port Int Loop 1ul Figure 1 4 Dual inject valves Valco w o calibration valve in oven SOLA II Flare User Manual 1 7 Chapter 1 Product Overview Inject Valve V1 Low Range 10 Port Ext Loops 100ul Stream Valid Select V4 4 Port Range Select Valve V3 4 Port Inject Valve V2 Hi Range 6 Port Int Loop 1ul Figure 1 5 Dual inject valves Valco w calibration valve in oven optional Dual PMT Power A dual PMT power supply is used in the SOLA II Flare This lets the user set Supplies the sensitivity of the PUVF detector and allows the appropriate measuring range to be automatically selected by the analyzer software Figure 1 6 Thermo Scientific SOLA II Flare User Manual 1 8 Specifications Analytical Specifications Thermo Scientific Chapter 1 Product Over
74. irements Table 1 3 Dimensions Area Ambient Temperature 54 to 104 def F 12 40 deg C Classifications Ingress Protection IP 51 dustproof and dripping water Input Voltage 110VAC optional 220VAC to 110VAC Step Down Transformer Power 20 amp circuit recommended 17 amp maximum during warm up cycle 7 8 amps once operation temperature achieved Dimensions Zone 1 Div 1 Configurations 1581 15 mm 62 25 in high x 647 70 mm 25 50 in wide x 476 25 mm 18 75 in deep Zone 2 Div 2 Configurations 1104 39 mm 43 48 in high x 647 70 mm 25 50 in wide x 476 25 mm 18 75 in deep Available Certifications CSA US Class Div 2 Groups B C amp D T3 CSA US Class Div 1 Groups B C amp D T3 ATEX Zone 2 3 G Ex pz IIC T3 Thermo Scientific SOLA II Flare User Manual 1 10 Requirements Mi Temperature Power Available Certifications system Configuration Chapter 1 Product Overview 54 to 104 F 12 40 C Ingress Protection IP 51 dustproof and dripping water 110 Vac optional 220 Vac 50 60 Hz at 2000 watts 10 volts 20 amp circuit recommended 17 amps maximum during warm up cycle 7 8 amps once achieving operational temperatures CSA NRTL Class 1 Division 2 Group B C amp D standard CSA NRTL Class 1 Division 1 Group B C amp D optional Dimensions 44 H x 26 W x 18 D 1118H x 660W x 457D mm Weight 250 Ibs estimated 114 kg estimated Site Requirements The customer is responsible for installati
75. irt accumulation Dust and dirt can accumulate in the instrument and can cause overheating or component failure Dirt on the components prevents efficient heat dissipation and may provide conducting paths for electricity AR Warning Remove all instrument power before cleaning electronics A The best way to clean the inside of the instrument is to first carefully vacuum all accessible areas and then blow away the remaining dust with low pressure compressed air Use a soft paintbrush or cloth to remove stubborn dirt SOLA II Flare User Manual 8 1 Leak Tests Clean Air Leak Test Thermo Scientific Chapter 8 Maintenance amp Troubleshooting A leak test should be completed when starting up a new unit or replacing components such as valves rotors regulators gauges etc in the flow paths of the clean air flow nitrogen flow and sample flow These three flow paths are critical and must not leak The clean air and nitrogen used should be zero grade and sulfur free as they are used in the sulfur analysis flow paths Instrument air is used for the oven air electronics purge and valve actuation Small leaks in the instrument air flow are not critical but check to ensure fittings are tight Caution Purge all sample lines with nitrogen until the total sulfur reading stabilizes near zero ppm on the low range Once the reading stabilizes wait at least 15 minutes to ensure all sulfur is purged from the system Disconnect the communication lines
76. lay Spare relay Spare relay Spare relay Spare relay Spare relay Spare relay Controls 10 port injection valve Controls 6 port injection valve Range selection valve Cal sample select Generic output for sample control Generic output for sample control Generic output for sample control Generic output for sample control Press Enter to change the 4 20 mA output for Cal A to 4 8 12 16 or 20 mA Press Enter to change the 4 20 mA output for Cal B to 4 8 12 16 or 20 mA shows only the active supply voltage Control output for LED indicator Control output for UV lamp Reserved for factory test only the 2 pound signs indicate the control output sample amp Hold control Gain Control SOLA II Flare User Manual 7 2 Chapter 7 Diagnostics View MUX Analogs You can view the MUX analogs by accessing this menu Note that all signals are displayed as raw frequencies Diagnostics View Mu x Ana logs V N En t AE AE 1 Figure 7 4 Following are the analogs in the order they appear within menu 1 ADC 0 Lamp V 2 ADC 1 Chamber Flow 3 ADC 7 Pressure 4 ADC 9 PMT V 5 ADC 10 Chamber T 6 ADC 11 Ambient T View 4 20 mA Inputs Access this submenu to view the optional 4 20 mA inputs Input amp Output A ea Usa E 4 2 0 m A Input V N Eo Et E a L T Figure 7 5 Thermo Scientific SOLA II Flare User Manual 7 3 Chapter 7 Diagnostics View Digital Inputs When you access the View Digital Inputs m
77. lyzer oven internal components e g detectors or hot sample system components appropriate gloves must be worn Heated components should be allowed to cool before servicing if possible Other appropriate equipment or clothing must be used as required by the type of work performed AN Caution Ovens internal components and sample systems may be hot even when power is not applied to the unit Take appropriate precautions to prevent injury resulting from contact with hot items A All applicable regulations and procedures must be followed for the work performed Before beginning any work on the system carefully consider all the potential hazards and ensure that appropriate measures are taken to prevent injury to personnel and damage to equipment Thermo Scientific SOLA II Flare User Manual XIV Electrical Power Thermo Scientific A safety Information amp Guidelines The system uses AC power at 110 Vac an optional step down transformer is available for 220 Vac The AC power is converted to DC at several voltage levels Appropriate precautions must be taken to prevent sparks present in the analyzer environment that may ignite combustible materials Precautions must also be taken to prevent electrical shock if the analyzer or sample system enclosures are opened The AC power to the system must be free from noise surges sags and spikes for proper system operation AC power circuit breakers and wiring must be sized properly for
78. m contacts To use the alarm contacts refer to the following connection table The alarm contacts are rated for 10 A at 120 Vac 240 Vac for 240 Vac units Table F 5 Alarm Terminal Terminal Open on alarm closed when power is applied to the analyzer system TB1 7 Common TB1 8 Closed on alarm closed when purge is lost or during fast purge of analyzer TB1 9 system The following procedure should be performed when starting up any analyzer tartup g Pp p g up any analy system that uses the X Purge system AN Caution Before initially starting the system electrical power wiring must be checked for correct size and routing All sample system plumbing must be thoroughly tested for leaks A AN Caution Do not open the explosion proof X Purge enclosure in a hazardous area even when de energized unless area has been properly tested and is known as being free from explosive gases A The following procedure only addresses the application of power to the system Consult the start up procedures in the instrument user s guide for additional requirements for system start up 1 Consult the start up procedures in the instrument user s guide for general information on system start up All requirements prior to applying power to the system must be performed before proceeding to the rest of this procedure 2 Open the instrument air supply to the analyzer 3 Close the oven door securely and adjust the oven air pressure regulator to the val
79. mal operating temperatures A b Verify that the display is functioning Figure 3 1 appears displaying the version and whether a valid configuration is loaded Version number 7 Version Date S IE la Fl ee ES 4 4 Lil 118 yy aye E O Pa cy tl E IE we a ic A a lly O a el S el Figure 3 1 c Verify that the configuration settings in the menus match the application data sheet or system logbook d See Suspending an Analysis to prevent accidental injection of sample while setting up the instrument 5 Apply carrier air to the instrument and set the flows See application data sent with the instrument for proper settings a Verify that the pyrolyzer and oven heater temperature come up to temperature and stabilize at the control point b Adjust the zero carrier air pressure and flow again after the pyrolyzer and oven stabilize at the correct temperature 6 Turn on the sample flow to the instrument and adjust it to the correct pressure and flow Note that this procedure varies depending on the installed sampling system Consult the application notes and drawings provided with the instrument for more information Thermo Scientific SOLA II Flare User Manual 3 2 Startup After Short Term Shutdown Short Term Shutdown Thermo Scientific Chapter 3 start Up Shutdown 7 Enable analysis of the sample by taking the instrument out of the suspend mode The unit begins injecting and analyzing sample when the ins
80. napati Bapat Road Andingmen East Street Pune 100007 Beijing 411 016 CHINA INDIA 86 10 8419 3588 86 10 8419 3580 fax 91 20 6626 7000 91 20 6626 7001 fax www thermoscientific com For returns contact Thermo Scientific for specific instructions If it becomes necessary to contact Thermo Scientific with software or hardware problems please have information on the ranges and installed options available Note In the interest of completeness manuals and drawings included with the system may provide information pertaining to options not included with your system Information in application notes supersedes general information in these documents A Additional information can be obtained from the following sources e System drawings e Application notes for the supplied system e Manuals and data sheets for other associated equipment The application notes supplied with each system include information specific to the configuration of the installed system These notes will typically include pressure settings flow settings temperature settings and other special situations or adjustments SOLA II Flare User Manual 9 1 Chapter 9 Support Warra nty Thermo Scientific products are warranted as free from defects in material and workmanship either for 12 months from date of installation or 18 months from date of shipment whichever occurs earlier Any claimed defects of Thermo Scientific products must be reported within the warr
81. nd of the drive shaft has a 1 4 hole Put that end of the drive shaft into the end of the female race that has the slot openings sliding the balls into the slots 5 Place the male end cap on a flat work surface Set the O Ring plate on the end cap with the pins lined up to go through the three small O Rings Pressing the plate in dislodges the O Rings do not press the plate in 6 The two bearing plates are identical except that one has three countersunk holes to accept the subassembly screw heads Locate the bearing plate that is not countersunk and line it up on top of the O Ring plate if both bearing plates are countersunk they are interchangeable Press down to force the pins through the O Rings and bearing plate continuing until the two parts are riding about half way down the pins 7 Slide the three bushings over the pins Install the drive shaft ball assembly with the 1 4 hole end down The female race should between the bushings 9 Place the remaining bearing plate in position with the countersunk holes up and screw the entire assembly together Tighten the screws in rotation to insure optimum alignment 10 Pull the subassembly off the male end cap so that its orientation can be checked and proceed with step 2 of Assembly Thermo Scientific SOLA II Flare User Manual B 12 Thermo Scientific Mala and cap E K C s Extsmal D ring pop a mao T Hs Aalia Thin washer Thick washar F 23 Bearing H
82. nd sulfur compounds are mixed with the oxygen in zero grade air The thoroughly mixed gases flow into the pyrolyzer furnace where the oxygen present in the carrier air is used to combust the sample and convert the carbon and sulfur compounds to CO and SOs respectively A small amount of water vapor is created during the combustion process but as the amount is so negligible it is of no concern to the PUVF detector The SOLA II Flare offers a comprehensive diagnostics and communications package as a standard feature The communications package offers the user a wide variety of options from analog and contact closure communications to Modbus based communications over Ethernet or RS485 based communications The SOLA II Flare also provides a comprehensive diagnostic package designed to minimize down time and provide useful troubleshooting information Several diagnostic points are continually monitored and will trip the global alarm The monitored points are SOLA II Flare User Manual 1 3 Dynamic Range Thermo Scientific Switching Chapter 1 Product Overview e Low detector carrier flow e Low detector temperature e Lamp voltage change e Low pyrolyzer temperature e Low analytical oven temperature e Purge failure e Injection valve failure During non flaring times the SOLA II Flare operates using the low measurement range When operating in the low measurement range the analyzer uses the low range sample injection valve
83. nncnanano nono E 1 Installing SOLA II Flare 20TWarg E 1 A A A E 3 e E 5 Total Sulfur amp Frequency Plata E 5 Analyzer A An E 5 PP T TO E 6 A a N AE E 7 SL OO E AA ee Ve E AS E 7 Thermo Scientific SOLA II Flare User Manual Thermo Scientific Appendix F The X Purge SySteM ooooonncccccccoocccccononccononananancnananonccnnnnnnnaso F 1 Deia F 1 X Purge Specifications oia F 3 A O O F 3 ARO Wii iii F 4 ASIS arruinan F 5 a EE EET E EET F 5 IE le TTT F Foweror Purge LOSS SIMUL OWN Eisen F INA LO ALICE este este ee F 8 MERA US MEN as F 9 Appendix G PUVF Optical Bench eee G 1 Appendix H Toxic 4 Hazardous Substances Tablos H 1 Appendix Related Technical Bulletins eee eee 1 SOLA II Flare User Manual xl Safety Considerations Safety Summary Thermo Scientific Safety Information amp Guidelines This section contains information that must be read and understood by all persons installing using or maintaining this equipment Failure to follow appropriate safety procedures or inappropriate use of the equipment described in this manual can lead to equipment damage or injury to personnel Any person working with or on the equipment described in this manual is required to evaluate all functions and operations for potential safety hazards before commencing work Appropriate precautions must be taken as necessary to prevent potential damage to equipment or injury to personnel The informati
84. nstalled Thermo Scientific SOLA II Flare User Manual D 2 Appendix E The Workstation Installing SOLA The SOLA II Flare workstation software is an application developed to run Flare Software under National Instruments Lookout software The software consists of the following items Lookout Development System Floppy disk with a subdirectory named SOLA containing the following files fdews 4t fdcws l4p fdews lks fdews lka Copy the SOLA subdirectory from the CD to the c Program Files Nationallnstruments Lookout subdirectory on the computer hard drive Remove the disk from the drive and store in a safe place Click on fdews l4p to open the workstation through Lookout 3 The workstation is configured to connect to the analyzer using the Com Thermo Scientific port 1 at 9600 baud and to expect the analyzer Modbus address to be 1 If the analyzer is equipped with the Serial to 10 100 Base T Bridge or if a different com port is used in the PC the Modbus 1 object needs to be edited Beginning at the Lookout main menu a Select Edit and switch to edit mode b Select Object gt Modify gt Modbus1 Figure E 1 c Edit the Modbus object to select a different COM port or Modbus Ethernet Figure E 2 SOLA II Flare User Manual E 1 Appendix E The Workstation Select object to modify Histogram1 lo Histogram2 i oy HyperTrend1 4 IinjectionCycle gl InjectionTime i dz Lamp
85. nsulation 10 Loosen the fittings around the heater wires and remove the wire sleeves Set the sleeves and fittings aside 11 Loosen the thermocouple fitting and remove the thermocouple from the housing Set it aside for re installation later 12 You should now be able to remove the heater from the housing SOLA II Flare User Manual 8 11 Thermo Scientific Chapter 8 Maintenance amp Troubleshooting 13 Insert the replacement heater into the housing Pyrolyzer housing Figure 8 7 Insert replacement heater into housing 14 Feed the two heater wires through the two fittings on the other side of the housing Heater wires Figure 8 8 Heater wires fed through fittings 15 Slide the wire sleeves onto the heater wires Tighten the stainless steel fittings Heater wire sleeves Figure 8 9 Wire sleeves and fittings SOLA II Flare User Manual 8 12 Thermo Scientific Chapter 8 Maintenance amp Troubleshooting 16 You will need to make a hole in the heater insulation to accommodate the thermocouple Insert a drill bit through the fitting in the housing for the thermocouple and press it through the heater insulation to make the hole Remove the bit and then carefully feed the thermocouple tube through the stainless steel fitting on the housing Tighten the thermocouple fitting to secure it to the housing Thermocouple Figure 8 10 Insert the thermocouple 17 Slide the two pieces of fiberglass
86. nt capability of the alarm contacts is 2 A at 240 Vac or 10 A at 24 Vdc Voltage is not supplied to the relay contacts by the analyzer DCS amp External The following inputs and outputs can be connected to a Distributed Control Connections System DCS or other devices as desired MALFUNCTION FAIL SAFE ALARM NC VALIDATION IN PROGRESS PURGE FAIL SWITCH 1 ON STANDARD 1 0 BD 9 SUSPEND d RELAY 5 d RELAY 6 RELAY 7 a u a l Own Won RELAY 8 CALA 4 205 I O BD 89 2898 0 Figure 2 1 Thermo Scientific SOLA II Flare User Manual 2 2 Chapter 2 Installation e Remote Suspend To suspend analysis short the Remote Suspend connection to the Remote Suspend common terminal To restart analysis open the connection across the Remote Suspend connectors The remote control function must be enabled Analyzer Setup Analog Outputs The following outputs are available with the analyzer See 4 20 mA Range Setup and refer to the wiring diagrams shipped with your instrument for wiring details e Cal A output This 4 20 mA dc signal represents the measured concentration of Cal A The zero value 4 mA dc represents zero measured concentration in the sample Full scale 20 mA dc represents the measured concentration specified in High Range e Cal B output This 4 20 mA dc signal represents the measured concentration of Cal B The zero value 4 mA dc represents zero measured concentration in the sample Full scale 20 mA dc represents
87. o ferrule on the tube This ensures that the minimum connection volume is obtained For more information on installing fittings refer to VICI Technical Note 503 Fitting Instructions SOLA II Flare User Manual B 1 Appendix B Rotary Valve Service Valve Disassembly AN Caution Do not disassemble the valve unless the system malfunction is definitely isolated to the valve perform all other system checks first If disassembly is required make certain that the following instructions are carefully observed A Disassembly operations must be performed in a clean well lighted area Flush all hazardous or toxic materials from the valve before starting Please read the entire procedure before beginning Socket adjustment SCTE Freload assembly Figure B 1 Rotary valve disassembly As this figure illustrates the valve can be disassembled for cleaning and or rotor replacement without removing the loops and tubing from the valve or removing the valve from the actuator or mounting bracket 1 Unscrew the entire knurled preload assembly Do not tamper with the preset socket adjustment screw 2 Engage the end of the rotor with a pencil type magnet available from VICI or any electronic components supplier Cycle the valve one time to break the shear seal between the rotor and the valve body Thermo Scientific SOLA II Flare User Manual B 2 Thermo Scientific Appendix B Rotary Valve Service Figure B 2 Preload rem
88. o mounting screws that hold it to the back of the oven After both screws have been removed lift the pyrolyzer up and out of the oven Do not discard the mounting screws You will need them later SOLA II Flare User Manual 8 9 Thermo Scientific Chapter 8 Maintenance amp Troubleshooting 7 Remove the six screws and washers from the lid of the housing Set them aside for later use Screws and washers six places Figure 8 3 Remove the pyrolyzer housing lid 8 Gently lift the lid off and set it aside Note The pyrolyzer tube insulation and Kaowool insulation will be attached to the lid Carefully lift all of it out to avoid damaging the pyrolyzer tube A Pyrolyzer tube Housing lid Fittings Insulation and Kaowool insulation Figure 8 4 Housing lid with insulation and pyrolyzer tube attached SOLA II Flare User Manual 8 10 Thermo Scientific Chapter 8 Maintenance amp Troubleshooting 9 As shown in the following figure the heater wires are attached to the terminal block Remove the heater wires from the terminal block and straighten the wires Remove the fiberglass insulation that covers the heater wires Set the insulation aside You will need it later r o a Heater wires connected to terminal block Thermocouple and fitting Wire sleeves and fittings Figure 8 5 Heater wires and thermocouple Fiberglass insulation Figure 8 6 Remove the fiberglass i
89. o supply electrical power must be IP40 rated metallic cable glands A Note Blanking elements or plugs used shall be in accordance with national standards A Figure F 1 Purge control unit ATEX version shown NFPA version has key switch inside enclosure Thermo Scientific SOLA II Flare User Manual F 2 X Purge Specifications Installation A A Thermo Scientific Table F 1 General specifications Certifications Programming Function Table F 2 Normal conditions Normal conditions Power Switches X Purge pressure Oven air pressure Oven door Electronic housing door Instrument air ball valve for X Purge unit Table F 3 Utility requirements Utility requirements Instrument air Instrument air quality AC power Appendix F The X Purge System CSA with C and US Mark Class 1 Div 1 Groups B C D hazardous areas ATEX Zone 1 Ex px II T IECEx Ex dlp IIC T4 Programmable time delay Monitors two pressurized enclosures and two exhaust port flows AC applied to X Purge unit Normal Bypass Set to NORMAL Time delay relay Set to number of seconds for delay time delay typically set from 480 to 600 seconds see application notes for individual system Minimum 10 psig Minimum 10 psig or as specified in instrument application notes or system log books Closed tightly Closed tightly Open 60 80 psig 8 SCFM maximum Water and oil free 40 C 40 F dew point part
90. ock Maximum Value Figure 7 8 SOLA II Flare User Manual 7 5 Com Ports RX TX Thermo Scientific Chapter 7 Diagnostics Following are the menu items within the View Parameters menu Table 7 3 Menu Item TS Reading Cal A Response Factors Cal B Response Factors Working Average Sec AVG PMT signal kHz Normalized PMT kHz PMT Signal kHz PMT Voltage Internal Temperature Chamber Temperature Chamber Flow Chamber Pressure Lamp Alm Counter Lamp Voltage Description The concentration reading The slope kHz ppm or kHz ppb sensitivity and the offset calculated at 0 concentration The slope kHz ppm or kHz ppb sensitivity and the offset calculated at 0 concentration When switching from the normal average to the fast average and back to normal the average time used can be observed from this menu item The average of the raw detector signal The frequency proportional to the PMT output normalized to the gain of 100 also displays the gain currently selected The actual frequency proportional to the PMT output also displays the gain currently selected The input voltage to the PMT The temperature inside the electronics enclosure The temperature inside the reaction chamber The flow through the reaction chamber The pressure sensed at the reaction chamber The frequency proportional to the lamp intensity The lamp input voltage This menu displays activity for Coms 1 4 Diagno C om P o
91. ogen Leak esta aa 8 5 PONR CEC eE E Eee 8 6 INe ssi ainda 8 7 The Mixing PP 8 7 Replacing the Pyrolyzer Hess ee 8 8 he Pyrolyzer Reaction WUD ee ee A 8 16 REE ESA E AE EA A T AE ee 8 16 IE ONC lca en A 8 18 General OMICS INO IN nee 8 18 ENAP EIS UDO Tee ee 9 1 Sonar ao 9 1 Wan tl lie lei ee 9 2 Items Not Covered Under Warranty 9 3 Appendix A Watlow EZ Zone PM6 Series A 1 E A a T A 1 HardWare Se WD outeu a ernten A 1 Thermo Scientific SOLA II Flare User Manual IX He E ee ee A 1 SO Ware COn Aqua Mi Nos A 3 Ss ran heran A 3 EUT Ee isis aria E A 10 TNELOCKOUT WIEN een A 17 Appendix B Rotary Valve Service ee B 1 Mual Tee A A B 1 Vae Dicas MU indias B 2 Cleaning the Valve DO ta een B 4 EOE ROO A A AET B 5 GPT Sh hk ls hak Se sce a Sa B 5 Conditioning Procedure for High Temperature Valves ancen B Two Position Air Actuator O Ring Replacement 22u2 240 nn B SAS SOMO Ve O hase eset oe B BG ETIE cee E N Re eR re ee ee Nae OE aE B 9 PS SUMO calorias B 10 A A een ehe B 11 HEDULLO UG ASSEMDIV sn teen B 12 Appendix C TCP IP Bildge u nn ee C 1 Hardware Configuration c cccccccccccescssssesescssesescssssesersssseeseaserersesiteneatterensenes C 1 SO Wate CONO OM ee ee ee eg C 1 Appendix D Sample SOLA II Flare Modbus Register D 1 A Sch Se aera hich Fa ene oe eee ee D 1 Appendix E The Workstation o ooooooccccccconcconaccccnonocinanannoncnn
92. ogen flow paths Depending on the range selected the sample will flow through one injection valve while nitrogen is purging the other injection valve A 1 To begin connect an external source of nitrogen to the sample inlet of the SOLA II Flare Set the pressure to 30 psig 2 Set the clean nitrogen regulator located in the pneumatic section of the SOLA II Flare to zero psig Set the 1 8 inch four port range select valve to the Off position using the input output test under the diagnostic menu of the SOLA II Flare Go to Diagnostics gt Input Output Test gt Set Outputs gt Rng V3 Solenoid and turn the valve off This will push the external nitrogen source through the six port injection valve 3 Disconnect any tubing and cap the outlet of the internal back pressure regulator in the oven 4 Set the internal forward pressure regulator in the oven to 30 psig Fully open the internal back pressure regulator counter clockwise This will allow 30 psig of pressure all the way to the capped outlet port of the back pressure regulator 6 Referring to the flow diagram inspect all connections in the sample flow path with liquid leak detector Additionally inspect the valve slots where the valve actuation pins are located as well as the valve preload assemblies with liquid leak detector If these show external valve leaks replace or align the valves See the valve alignment procedure for further information SOLA II Flare User Manu
93. on in this manual is designed to aid personnel to correctly and safely install operate and maintain the system described however personnel are still responsible for considering all actions and procedures for potential hazards or conditions that may not have been anticipated in the written procedures If a procedure cannot be performed safely it must not be performed until appropriate actions can be taken to ensure the safety of the equipment and personnel The procedures in this manual are not designed to replace or supersede required or common sense safety practices All safety warnings listed in any documentation applicable to equipment and parts used in or with the system described in this manual must be read and understood prior to working on or with any part of the system Failure to correctly perform the instructions and procedures in this manual or other documents pertaining to this system can result in equipment malfunction equipment damage and or injury to personnel The following admonitions are used throughout this manual to alert users to potential hazards or important information Failure to heed the warnings and cautions in this manual can lead to injury or equipment damage AN AN AN Warning Warnings notify users of procedures practices conditions etc which A may result in injury or death if not carefully observed or followed The triangular icons with warnings vary depending on the hazard A Caution Cautions notify us
94. on of the analyzer system including all sample vent utility electrical and signal connections The installation should be completed prior to a Thermo Scientific service technician s arrival at the analyzer location Table 1 5 Analyzer Sample Vent sample Carrier amp Auxiliary Air Instrument Air Operational Nitrogen Sweep Gas Power Thermo Scientific No backpressure may be applied and the PUVF Detector sample vent the vented gases will contain C02 H20 and high levels of SO The suggested sample input pressure is dependent upon the type of sample and therefore is application dependent For most flare applications the sample delivered to the SOLA II Flare needs to be in the 25 30 psig range Air Carrier Gas Zero grade air Minimum input pressure is 80 psig The air used as a carrier gas must be clean dry and sulfur free Cylinder air is recommended to obtain this quality Consumption is 250 300 cc min Minimum input pressure 60 psig The instrument air must be clean dry and oil free Instrument air is required for both the cabinet purge and the ul injection valve Consumption is 6 7 SCFM Minimum input pressure 60 psig The nitrogen must be clean dry and oil free nitrogen Is required for sweeping the unused valve only Consumption when required 120 Vac 50 60 Hz The power supply to the analyzer system should be stable within 10 volts SOLA II Flare User Manual 1 11 Spare Parts
95. ort valve If all pressures hold remove the external source of nitrogen from the forward pressure regulator 12 Continue on to test the clean nitrogen inlet Clean Nitrogen Leak The last critical flow path is that of the clean nitrogen The clean nitrogen Test regulator located in the pneumatic section of the SOLA II Flare should be set at 30 psig Additionally an external source of nitrogen should be connected to the clean nitrogen bulkhead on the left side of the unit The external source should also be set at 30 psig This flow path is through V3 the range select valve All tubing leaving V3 should already be leak tested from the sample flow leak test The only port on the V3 valve that has not been checked is the clean nitrogen inlet 1 Ensure the outlet of the back pressure regulator outlet is still capped 2 Make sure the clean nitrogen is set at 30 psig and verify that pressure is at 30 psig on the back pressure regulator gauge Thermo Scientific SOLA II Flare User Manual 8 5 Flow Rate Checks Thermo Scientific Chapter 8 Maintenance amp Troubleshooting Turn the external source of nitrogen off but leave it connected so pressure remains on the system Check all clean nitrogen connections from the entrance bulkhead up to V3 with liquid leak detector Monitor the pressure for 15 minutes to make sure it holds steady When complete remove the cap on the outlet of the back pressure regulator and reconnect any previo
96. oved preload end view Caution Any contact between the interior of the valve body and the metal of the rotor or any tool used is likely to cause damage A Carefully withdraw the rotor from the valve body with the magnet Once the rotor is removed note the orientation of the rotor tab which is marked with an ID letter denoting the type of seal material SOLA II Flare User Manual B 3 Appendix B Rotary Valve Service Cle aning the Valve Follow these instructions to clean the valve body Body 1 Wet a cotton swab with a solvent compatible with the chromatographic system Isopropyl alcohol is recommended 2 Gently swab the polished interior of the valve to remove any loose residue 3 Blow with clean compressed gas to remove any lint left by the swab 4 Visually inspect the interior of the valve body The conical surface should appear highly polished If any scratches are visible between the ports or anywhere that might suggest a potential leakage path or wear source the valve should be returned to the factory for grinding and polishing Thermo Scientific SOLA II Flare User Manual B 4 Appendix B Rotary Valve Service pi Cleaning the Rotor Carefully grasp the rotor on either end and briefly immerse it in solvent If it is difficult to grip the rotor securely hemostats or needle nosed pliers may be helpful Grip the tab end being careful not to mar the metal or touch the polymer 2 Gently wipe the polymer with a cle
97. p specially dedicated to the Flare Monitoring Project e Holding Registers 16 bits e Read Function 03 e Write Functions 06 and 16 Thermo Scientific SOLA II Flare User Manual D 1 Appendix D sample SOLA II Flare Modbus Register Table D 1 Register Comments 4 0060 Fix values to verify communication mapping 4 0061 32 bit integer range 0 to 10000000 4 0062 Interpreted as xxxxxx x ppm 4 0063 See 1 0 Table Table 2 1 4 0064 Alarm Status Bit Position Encoding 16 bits read only register Description 0 Analyzer Purge Failure High Lamp Voltage Rate of Change Alarm Oven Pyrolyzer Temperature Alarm Chamber Temperature Alarm Chamber Flow Alarm Lamp Voltage Alarm E Reserved future usage Reserved future usage EN Reserved future usage ENS Reserved future usage Reserved future usage Reserved future usage Reserved future usage Reserved future usage Reserved future usage Reserved future usage 4 0065 0 to 21000 KHz recommended historical logging 4 0066 cc minute recommended historical logging 4 0067 0 to 50000 recommended historical logging 4 0068 0 to 13000 volts recommended historical logging 4 0069 Deg C 10 recommended historical logging 4 0070 Write 1 by DCS to force high cal cleared by SOLA II Flare 4 0071 Starts a remote validation SOLA II Flare clears it 4 0072 Aborts the validation SOLA II Flare clears it 4 0073 Future Usage 4 0074 Future Usage 4 0075 Future Usage Must be i
98. pdate If you set the averaging time to 60 seconds the average concentration of the last 60 seconds is output at each update Thus a lower averaging time means a faster response to concentration changes Longer averaging times are typically used to smooth output data See the figure below HS Via eek PL a Ez E S ie ie Average ES S I e V N E rs IE E E A e Figure 5 4 4 The average override is expressed as a percentage of change and determines when the unit switches to the fast average As the reading stabilizes at the new level the analyzer progressively increases the average used until it reaches the programmed average time im e PL a 21 ea S ES a A ES A a e el Sad Ea e O Ee e are Mae dla Es V N Pia as ele 3 Se eae fete Figure 5 5 5 The fast average time provides the ability to respond to changes faster without sacrificing stability achieved using a longer average time Note Both the regular and fast average times need to be set at multiples of the injection rate For example if the rate is two injections per minute averages should be set to 30 60 90 120 150 180 210 or 240 seconds A Thermo Scientific SOLA II Flare User Manual 5 2 Chapter 5 Configuration alla pe 28 Seel ie En Bes Sd ie Average a eels A fae V N By ce le EN E A E Figure 5 6 Clock Setup 1 Access the Clock Setup menu to change the time and date er Boa ur ICE Er Ea ur Peel ee ee en Bag Ros IE x
99. peration If an injection valve begins leaking due to damage or wear excess sample begins flowing to the pyrolyzer This extra load of sample in the pyrolyzer exceeds the ability to fully combust the materials in the sample When these incompletely combusted materials enter the PUVF optical bench they absorb UV light The PUVF includes a system to monitor and compensate for decreases in the UV light output as the bulb ages However in the case of injection valve failure the PUVF system begins rapidly increasing the UV lamp output in an effort to compensate for the absorption of UV by incompletely combusted sample products The user can enter the rate of change that triggers this alarm The programmable range is from 1 to 50 V 30 seconds If the analyzer detects the programmed rate of change in UV lamp voltage it triggers the Injection Valve Failure alarm to protect the system by stopping the sample injection and reducing the stabilization time for the PUVF bench on system restart Note This alarm can also be triggered by an electronics failure causing improper flashing of the lamp A When the Injection Valve Failure or Chamber Flow alarm activates the SOLA II Flare stops air flow to the sampling system pneumatic valves This prevents excess sample and incomplete combustion products from further contaminating the system This happens under the following conditions e Injection failure alarm e Instrument power loss e Instrument air loss
100. punoduas SEE b Y alaa Nd BUS Noy Jaljd yjnuojougq 1 Optical bench assembly exploded diagram PN TE 57P713 1 Figure G G 1 SOLA II Flare User Manual Thermo Scientific Thermo Scientific Appendix H Toxic amp Hazardous Substances Tables The English and Chinese versions of the Toxic and Hazardous Substances tables are shown below Table H 1 SOLA II Flare toxic amp hazardous substances table For Chinese Regulation Administrative Measure on the Control of Pollution Caused by Electronic Information Products Names and Content of Toxic and Hazardous Substances or Elements Toxic and Hazardous Substances or Elements Sensor Group o Indicates that this toxic or hazardous substance contained in all of the homogeneous materials for this part is below the limit requirement in SJT11363 2006 x Indicates that this toxic or hazardous substance contained in at least one of the homogeneous materials used for this part is above the limit requirement in 5J 111363 2006 A IN E RRR OMA EA PAM W SEST 11363 HEN Z 01 REFF Xi UNEN kee ERA eB argasas 11363 20067 EHEN BR BER SOLA II Flare User Manual H 1 Thermo Scientific Appendix Related Technical Bulletins This appendix provides a list of technical bulletins related to this product as of the release date of this document revision For the most current bulletins please go to thermoscientific com Enter the product name SOLA II Flare as the search term
101. rding to Chapter 4 The Rota ry Valve For detailed instructions on maintaining removing and replacing the rotary valve refer to Appendix B The Mixing Chamber To remove the mixing chamber follow the steps below 1 Shut down the system according to Chapter 3 2 Loosen the fittings that connect the tubing to the mixing chamber 3 Loosen the screw in the center of the bracket holding the mixing chamber to the bottom of the enclosure 4 Carefully slide the mixing chamber from the bracket To reinstall the mixing chamber follow the steps below 1 Carefully slide the mixing chamber into the bracket 2 Tighten the screw in the center of the bracket to hold the mixing chamber to the bottom of the enclosure Thermo Scientific SOLA II Flare User Manual 8 7 Chapter 8 Maintenance amp Troubleshooting 3 Tighten the fittings that connect the tubing to the mixing chamber 4 Restart the system Replacing the Pyrolyzer Heater AR Warning The pyrolyzer can be extremely hot even after power is turned off Use extreme care to prevent burns A The pyrolyzer heater is enclosed in the pyrolyzer housing which is shown in the figure below Mounting screws Sample tubing and stainless steel fittings Oven temperature switches Heater wires Figure 8 2 Pyrolyzer housing Thermo Scientific SOLA II Flare User Manual 8 8 Chapter 8 Maintenance amp Troubleshooting The following table lists the part numbers for
102. refer to application data that shipped with the analyzer Thermo Scientific SOLA II Flare User Manual 4 1 Chapter 4 Operation 3 Open sample flow to the analyzer 4 Apply power to the instrument 5 Analysis begins automatically when the pyrolyzer and oven reach operating temperature If you need to change the configuration press any button and enter the passcode Suspending an Follow these steps to suspend an analysis Ana lysis 1 Enter the Analyzer Mode top level menu 2 Select Suspended to suspend the analysis In suspended mode the analyzer stops injecting and shuts off the air to the sampling system pneumatic and allows only air to run through the burner and mixing chamber 3 To resume the analysis go to the Analyzer Mode menu and select Active ar Il we ae a6 Ml S cl ES DN e ee iva ke A V BA Ra ee Toggle Figure 4 2 Injection Valve Over time the injection valves begin to wear resulting in an increased potential for port to port leakage of sample Such leakage can cause erroneous measurement and materials buildup in the system When the analyzer detects sample leakage through the injection valve it triggers the Injection Valve Failure alarm and stops airflow to the pneumatic valves Failure Alarm Note The Injection Valve Failure alarm must be acknowledged after valve repair or replacement A Thermo Scientific SOLA II Flare User Manual 4 2 Thermo Scientific III Chapter 4 O
103. rement range is in use SOLA II Flare User Manual 1 1 Thermo Scientific Chapter 1 Product Overview These two features provide complete flexibility within a single analyzer system The lower detectable limit for the low measuring range is based upon the high range selected for example if the high range is set to 1 000 000 ppm 100 the low range is automatically fixed at 10 000 ppm 1 of full scale This would dictate a lower detectable limit on the low range of 100 200 ppm depending upon the final set up used To PUVF Detector AY Clean Air Sample In a SIG N a SH Clean Aw 2 Mixing Chamber Y P C x V2 Clean Air 3 k ad OVEN S W wi BPI L N internal 1 pl loop Sample Return c A ey Figure 1 1 Typical SOLA II Flare analytical oven flow diagram Set up and programming of the SOLA II Flare is easy using the front panel display When compared to a zinc continuous lamp the Xenon flash lamp in the SOLA II Flare has a cooler operating temperature This allows for a longer lifespan of the lamp as well as increased sensitivity to the high energy generated when the lamp pulses The PUVF detector uses a 120 second rolling average that updates the output every second providing an excellent response time to process changes SOLA II Flare User Manual 1 2 Oxidative Pyrolysis system Diagnostics and Communication Options Thermo Scientific Chapter 1 Product Overview The potential
104. ring total sulfur with the PUVF detection method requires the conversion of all sulfur compounds in the sample to SO This is typically accomplished with the pyrolyzer an electrically heated furnace designed by Thermo Scientific The pyrolyzer typically operates at a temperature of 1100 C 2012 F to oxidize sulfur without the need for a catalyst Air bath oven operates up to 110 C to maintain the sample in the vapor phase Process Cal Panel selection valve optional Pyrolyzer operates at 1100 C 10 port low range sample injection valve Back pressure regulator Range select valve Mixing chamber 6 port high range sample injection valve Forward pressure regulator Figure 1 2 Pyrolyzer Injection Valve Using two sample injection volumes low range 100 ul sample loop high range 1 ul sample loop to achieve the 100 1 dilution ratio allows approximately the same amount of sulfur to the detector when operating at the high end of both measuring ranges Thermo Scientific SOLA II Flare User Manual 1 6 Mixing Chamber Dual Measuring Range Thermo Scientific Chapter 1 Product Overview The mixing chamber mixes the sample and air before they enter the pyrolyzer a L U L vL da m kad Figure 1 3 Typical mixing chamber All SOLA II Flare systems utilize a dual measuring range configuration The dual ranges are achieved by using two sample injection valves to achieve a 100 1 dilution ratio The two inject
105. s less than 0 5 ppm or reported sulfur value has not changed by more than 2 for 15 minutes Note If possible switch sample selection to nitrogen to sweep the system A SOLA II Flare User Manual 3 3 Chapter 3 start Up amp Shutdown Maintenance The analyzer system must be fully shut down and the sample system Shutdown decontaminated as appropriate prior to performing maintenance Follow this procedure when shutting down the analyzer for maintenance or a long term outage 1 Close the sample flow to the instrument and purge the sample from the unit using nitrogen 2 Turn off power to the analyzer 3 Allow the instrument to cool AN Caution Failure to allow adequate cooling time before opening the oven can lead to equipment damage or injury to personnel A 4 Turn off all air supplies Caution Parts of the instrument may be hot even after power is removed Allow the system to cool completely before performing maintenance A Emergency Shutdown 1 Close the sample supply to the system 2 Turn off the main power to the system Thermo Scientific SOLA II Flare User Manual 3 4 Chapter 3 start Up Shutdown SOLA II Flare Menus Start Validation Abort Validation Analyzer Mode View Ack Alarms Figure 3 2 Top level menu Program Passcode Status Alarms Mode Average Override step 1 Selection Recalibrate A Low Inject Setup Injection Rate Modbus Setup Adjust A Reading lodbus Com3 Bauc Recalibrate B H
106. s value using the control input C MC MAUT Thermo Scientific SOLA II Flare User Manual A 7 Parameter Display CFE AESP HUE ESP ds hPb RAY Table A 11 Pyrolyzer settings Operations Page gt Control Loop 1 Software Control Mode Autotune Set Point Autotune Closed Loop Set Point Idle Set Point Heat Proportional Band Heat Hysteresis Cool Proportional Band Cool Hysteresis Parameter Display _ lo Ah Thermo Scientific Time Integral Time Derivative Dead Band Open Loop Set Point Default Display HUE a oO O i Software Auto 90 Pa C3 1100 C 24 C 14 C 14 C NO O O 180 0 0 Table A 12 Pyrolyzer settings Operations Page gt Alarm 1 Software Alarm Low Set Point Alarm High Set Point Default Display Software 5 C 5 C Appendix A Watlow EZ Zone PM6 Series Comment The loop will use automatic control The percentange of the current set point that will be used by autotune The set point the controller will automatically control to The closed loop set point that can be triggered by an event state The PID proportional band for the heat outputs The process value needs to be this far into the On region before the output turns on The PID proportional band for the cool outputs The process value needs to be this far into the On region before the output turns on The PID
107. se per ERO 8626 Thermo Scientific SOLA II Flare User Manual Contents Safety Information amp Guidelines sss e xiii Sale LONSIdET AL ONS a XII Sale DNA een XII Safety Operating 1JnTormatipn si oia XIV A A en east XV Chapter 1 Product OVervViIeW o oocononncccccccoooccccononananinanoncnconon cnn nc cana nnconnnos 1 1 A ee 1 1 Oxidative Pyrolysis SYSTEM sra ricas 1 3 Diagnostics and Communication Options oooioonnnnnnnonnnniononicionacinnacinss 1 3 Dynamic Range Switching 1 4 WIG UO a A EURER 1 5 VAT AO ae ee ee E 1 5 Pancipleor DEL e Waacrers nckssesaceinast caste S 1 5 UND oi 1 6 IN tio caspa 1 6 MEC neo 1 6 MEDICS AAA A iei eiai 1 7 Dual Measuring NE lana 1 7 MEA a 1 8 SELL EIC HNO Sr E E N A E E E N E 1 9 Analytical S06CITICaiOnS renacer canos 1 9 Analog Discrete Data LCOmmunicatiOng 1 10 system Requirements Dimensions Area Llassifications 1 10 System equi MENS puntal olla 1 11 PP rer 1 11 PRE A ene ere ASA 1 12 A O tenets 1 12 EnapterZ IAStalla OM teniendo luli 2 1 BOCU MO T T T E N TT 2 1 Sample Line sta caida 2 1 Electrical a dnesn pre shnelieihestnnetanderhehe 2 2 Thermo Scientific SOLA II Flare User Manual vil DES Aaa CN era 2 2 A sense 2 3 A A cacao stan 2 3 OOO arto 2 3 Installation Checklist no non no noncn nacos 2 6 Ghapter 3 Start Up Ge onutdOWN iii ie ee ees 3 1 ual are eienn e ne iade iaai 3 1 Startup After Short Term ShutdOWn ccc cscs cssscsssssesesessensssee
108. should then hold steady on all three gauges since these are non relieving regulators and the downstream tube has been capped SOLA II Flare User Manual 8 2 Chapter 8 Maintenance amp Troubleshooting 6 Monitor these pressure gauges for 15 minutes to make sure the pressure does not decrease If the pressure does decrease pressure everything back up to 15 psig and use a liquid leak detector to find the leak Repeat the above steps once the leak has been resolved 7 Ensure the quartz tube in the pyrolyzer is not cracked or leaking at the graphite ferrules The pyrolyzer is a sealed assembly meaning the quartz tube could be cracked and leaking without being obvious because the entire pyrolyzer case could pressure up 8 Once the clean air gauges are all stable at around 15 psig and the clean air regulators are all backed off with pressure holding steady remove the Y4 inch cap at the bottom of the pyrolyzer to vent the pyrolyzer case a If the pressure holds replace the cap and the clean air leak test is complete b Ifthe pressure falls then either the quartz tube is cracked and must be replaced or the fittings holding the tube at the top of the pyrolyzer need to be tightened Care must be taken when tightening these fittings to avoid breaking the quartz tube Note When replacing a quartz tube and graphite ferrules it is advisable to loosen the fitting while tightening and forming the soft graphite ferrule to keep from twisting
109. sing two on bottom 24 If necessary reconnect the wires from the oven temperature switches 25 Reconnect the heater wires to the pyrolyzer 26 Reconnect the thermocouple wires 27 Reconnect the sample tubing 28 Follow the Initial Startup procedure to restart the analyzer Thermo Scientific SOLA II Flare User Manual 8 15 Chapter 8 Maintenance amp Troubleshooting The Pyrolyzer Reaction Tube Replacement To replace the pyrolyzer tube p n 30 1025 0 first complete steps 1 through 7 in the previous section Replacing the Pyrolyzer Heater 1 Gently lift the lid off the housing Note The pyrolyzer tube insulation and Kaowool insulation will be attached to the lid Carefully lift all of it out of the housing A Pyrolyzer tube Housing lid Fittings Insulation and Kaowool insulation Figure 8 15 Housing lid with insulation and pyrolyzer tube attached 2 To remove the existing pyrolyzer tube unscrew the two fittings from the lid while holding the tube in place Remove the pyrolyzer tube and set it in a safe location Set the fittings insulation and Kaowool insulation aside for use in the next steps 3 Carefully push both ends of the replacement pyrolyzer tube through holes of the insulation Figure 8 16 Pyrolyzer tube inserted into the insulation Thermo Scientific SOLA II Flare User Manual 8 16 Chapter 8 Maintenance amp Troubleshooting 4 Holding the pyrolyzer tube in place apply the Kao
110. ssion www VICI com Caution The sample line must be purged with air to remove all sample prior to performing valve maintenance to prevent sample leaking to the pyrolyzer Open the oven and disconnect the tubing from the injection valve to the pyrolyzer before servicing the valve A After unpacking the valve do not remove the protective tape from the valve ports until you are ready to install the valve As supplied all surfaces are clean and free of contaminants and must be kept clean to prevent valve damage Open ports and fittings cause unnecessary risk of particulate matter entering the valve and scratching the sealing surfaces which is the most frequent cause of premature valve failure Note For Valco W and UW Type valves A Note The most common source of particulate and chemical contamination is tubing which has not been properly cleaned before installation in the valve To avoid this problem Valco Instruments suggests using their electrolytically pre cut and polished tubing available in standard lengths for any plumbing requirement A Note If other tubing is to be used make certain that all tubing ends are free of burrs and cut square with the tube axis and that all tubing has been chemically and mechanically cleaned A Note Failure to observe proper cleanliness procedures during installation of the valve voids the manufacturer s warranty A Make sure that tubes are seated completely before forming the one piece Valc
111. sssesesseees 3 3 E energie 3 3 Maintenance Una es ee 3 4 EDER oT OW ee ee ee 3 4 SLOW A RN FREREEKEN ANRIDRERLEL iai 3 5 Chapter AV Heratian e een 4 1 INC Ne Ic rer 4 1 DEIA Arena dra aN a G 4 1 Suspending an AM AV SIS cies seele 4 2 Injection Valve Failure AM 4 2 Chapter Reli Reis a een 5 1 Anao CU ata een 5 1 PE DE LUD ee se E ETN 5 3 VOUS SO LUND en ee een 5 4 MEC dd 5 5 AMS UU oi 5 6 Geille cid e a een e RO er en nee eee 5 8 CON stadia cg oe BEER Eaa Taa HUREN R 5 8 Galoran SOU ction tne ee 5 11 Manually Calibrating a Low Valug 5 11 Manually Calibrating a High Value 0 0 cece cece esteeeeeenteres 5 11 The Recalibrate High EunctiOn 5 12 Adjusting the Reading 5 12 Calibration Setup Menu Items See 5 13 S TID ee 5 17 A a T a m7 ners 5 20 Thermo Scientific SOLA II Flare User Manual vili Chapter 6 Viewing AlarmS oononnncccnnnnoccccnononancninnnnananinonananonanananonnnos 6 1 Chapter 7 DINOS T 7 1 Tis 25 91 Test unserer 7 1 GST ee 7 1 VIEW IA ANAO Seesen ee ee ei 7 3 View 4 20 MA NpUtS coat 7 3 View Digital INputs seen 7 4 Diea Teze eT 7 4 Eet NR Te T IA iieii 7 6 A TS OLIN lee ee ne athena hte ee 7 7 Chapter 8 Maintenance amp Troubleshooting ooooocoonnnnccccncnnonncnnonnno 8 1 A E 8 1 Maintenance cil 8 1 Visual Inspection amp Cleaning eeeieeieieieeeeesieirierrsrsrsrsrrrrirsrererrirrrereren 8 1 LOAK edad datos 8 2 AE ebene 8 2 Sample Flow Bale tutti 8 4 Glean Nitr
112. sticky or difficult to turn This tendency can usually be eliminated by Temperature Valves repeating the conditioning procedure that is initially done at the factory With carrier gas oxygen free flowing through all the ports rapidly heat the valve to 325 C When this temperature is reached cycle the valve 10 times and let it cool to operating temperature Two Position Air You will need the following to perform the tasks described in this section Actuator O Ring e 9 64 hex driver Replacement e 3 8 open end wrench e 3 16 screwdriver e An awl or small jeweler s screwdriver e Silicone lubricant such as Dow Corning DC 111 e Lint free tissues and a clean shop rag e Standard O Ring kit VICI P N OR e High temperature O Ring kit VICI P N ORT Disassembly 1 Apply air pressure to the actuator inlet nearest the valve Then use the open end wrench to remove the air supply lines from the actuator HW WSC s08 106 standoff Figure B 5 2 Remove the valve and valve mounting hardware from the actuator as shown in Figure B 5 a Use the 9 64 hex driver to loosen the HWSC SC8 10B socket head screw in the black anodized CR3 clamp ring on the actuator b Pull off the standoff with the valve attached c Use the 9 64 hex driver to remove the two HWSC SC8 6 socket head screws that hold the clamp ring to the actuator Thermo Scientific SOLA II Flare User Manual B 7 Appendix B Rotary Valve Service Tom
113. t Setup The low end of the range 4 mA always corresponds to zero sulfur concentration and the upper end of the range 20 mA is configurable for each calibration 1 Enter the 20 mA value for the Calibration A Range 4 t o 2 0 m A Ranges 09 E LO 500 Blo Er an Er EI on En ER ee RE eae Enz fos Be V N Ent Ex i t Figure 5 54 Thermo Scientific SOLA II Flare User Manual 5 20 Chapter 5 Configuration 2 Enter the 20 mA value for the Calibration B Range 4 t o 2 0 m A Ranges Cial bitrate on B Range V N En t Ex aie Figure 5 55 3 Enter a value at which the high range will timeout switch back to the low range 4 t o 2 0 m A Ranges High Range T pan ee pany V N EN ie Ex i t Figure 5 56 4 Enter the switch hysteresis value a percentage of value change needed to switch ranges 4 t o 2 0 m A Ranges Switch H y N et O a O N lad N V N En t Ex i t Figure 5 57 Note During auto ranging the change of ranges is controlled by the calibration value plus or minus the hysteresis percentage value A Thermo Scientific SOLA II Flare User Manual 5 21 Thermo Scientific Chapter 6 Viewing Alarms The second top level menu is the View Ack Alarms menu Access this menu to review all active alarms The display will scroll through the alarms automatically S LII F 4 4 ia Di I nen es EL ES V Le wl Ack Al arms V N En t Ex it Figure 6 1 Press Ack on the system display to acknowledge the
114. the SOLA II Flare must be heat traced due to the potential of high dew points A There must be no back pressure on the vent or drain lines All vents must be referenced to atmospheric pressure If the analyzer is installed in a pressurized analyzer shelter route all vents from the purge controllers and the PUVF detector to the exterior of the shelter All sample lines must be as short as possible Sample lines must use pre cleaned pre treated Sulfinert tubing The analyzer will produce erratic readings if backpressure is created or varied by an obstructed or improperly routed vent SOLA II Flare User Manual 2 1 Chapter 2 Installation Electrical Refer to the following ac power and wiring information when planning and Connections connecting power for the analyzer e Power source specification 110 or optional 220 Vac 50 60 Hz 2000 W e Power wiring specification Use stranded three wire copper or tin plated copper power wire rated for at least 600 Vac and 20 A at the required length Warning This apparatus must be earth grounded A gt gt Warning Installation of this instrument requires an external lockable electrical power isolation switch supplied by the customer A If the optional X Purge unit is installed refer to Appendix F for important installation and operation information Wiring to the relay contacts should be sized according to the load imposed by the alarm systems installed by the user Maximum curre
115. to the probe and back to the switching panel as the normal flare sample A Five pneumatic outputs from the SOLA II Flare can drive a sample select valve e Flare Sample e Low Gas e Mid Gas e High Gas e Local Probe selection Two Relay Outputs can be used during the probe validations to drive signals to the Probe Box See Relays 5 and 6 on the I O Table The SOLA II Flare can be commanded to select any of the following possible states Normal Flare Monitoring auto range Local Low Gas Cal A Local Low Gas Cal B Local Mid gas Cal A Local Mid gas Cal B Local High gas Cal B Probe Low Gas Cal A Probe Low Gas Cal B Probe Mid Gas Cal A Probe Mid Gas Cal B 10 Probe High Gas Cal B er ee ad SORE Te A a SOLA II Flare User Manual 2 4 Chapter 2 Installation Table 2 1 1 0 Table Solenoid Solenoid Solenoid Solenoid Solenoid 8 Cal Modbus 1 5 Low 6 Mid a Local Probe Selected register 4 0063 Flare V4 Gas Gas Valve Control Auto 0 a A ee et Ss ee fe es be E waman aa amt x ae a a X Flare Local Low Cal A cal gh Cl AAA IT be LCA S bb Tre Probe Low Cal B Probe Mid Gas Cal A Probe Mid Gas Cal B oe gh Cl a bee as CO l GO l J Id oy AIIN x X m eee a A a ER Note The table above applies to standard SOLA II Flare units For information on inputs and outputs on modified units contact Thermo Scientific A Thermo Scientific SOLA II Flare User Manual 2
116. trument temperatures reach operating levels 8 Allow the analyzer system to stabilize Monitor the measured values on the front panel for consistent analysis readings to determine when the analyzer system has stabilized If initially starting the analyzer or if major service was performed use the initial start up procedure detailed in the previous section Initial Start Up When starting the analyzer after a short term shutdown perform the following 1 Open the instrument and purge air and carrier air to the instrument Refer to the applications information manuals and drawings shipped with the instrument and adjust the pressure regulators to the appropriate settings 2 Apply power to the analyzer Note If the X Purge option is installed you must follow the instructions include in Appendix F A 3 Allow the analyzer to warm up until the instrument stabilizes 4 Adjust the flow rates 5 Turn on sample to the instrument The analyzer includes an interlock system that prevents the injection valve from operating until the pyrolyzer and oven temperatures reach the operating value Follow this procedure when temporarily shutting down the analyzer To shut down the analyzer for maintenance purposes or for a long term shutdown refer to the following section Maintenance Shutdown 1 Observe reported sulfur value 2 Do not interrupt power instrument air carrier or auxiliary air or open oven doors until reported sulfur value i
117. ue required for the analyzer refer to the application notes or logbook for the analyzer Thermo Scientific SOLA II Flare User Manual F 5 Thermo Scientific Appendix F The X Purge System 4 Close the electronic enclosure door Ensure that it is tightened securely 5 Apply power to the X Purge unit 6 After the predetermined purge time the X Purge unit applies power to the analyzer system Typically this takes about 10 minutes but it may vary depending upon the system Refer to the system application notes or logbook for the correct purge time AN Caution Do not open the X Purge housing unless power is removed from the X Purge or the area is known to be non hazardous A If the unit does not apply power to the analyzer system after the required length of time check for the following possible problems d b C d Purge pressure at the analyzer purge pressure gauge is too low Oven heater air pressure regulators set too low Oven door open or leaking air Electronic enclosure door open or leaking air 7 Complete the remaining steps listed in the start up procedure included in the start up instructions in the instrument user s guide SOLA II Flare User Manual F 6 Appendix F The X Purge System Shutdown The X Purge unit automatically removes power from the analyzer system if the purge pressure becomes less than 0 3 inch of water 0 75 mbar in any monitored zone or if enclosure exhaust airflow
118. urge assembly is designed for monitoring two enclosure purge pressures and two exhaust port flows All of the pressures in the monitored enclosures must be at least 0 3 inch of water 0 75 mbar higher than the atmospheric pressure around the analyzer system This ensures that hazardous materials are less likely to leak into the purged enclosures Pressure differential switches compare the pressure in the monitored enclosures with the pressure in the explosion proof X Purge enclosure The inside of the X Purge enclosure is referenced to ambient pressure using a 1 4 inch breather drain with flame suppression A flame arrestor is also installed between each pressure differential switch and the associated pressure enclosure that it monitors A spark arrestor vent is used for exhaust purposes and to maintain appropriate backpressure on the electronic enclosure and oven Thermo Scientific SOLA II Flare User Manual F 1 Appendix F The X Purge System For T3 or T4 ratings a bottled air backup source supplies air for purging the instrument in the event that instrument air pressure is lost Instruments with a T3 rating must be allowed to cool for at least 45 minutes before opening the oven door Instruments with a T4 rating must be allowed to cool for at least 140 minutes before opening the oven door AY Caution Failure to allow adequate cooling before opening the oven can lead to injury of personnel or damage to equipment A Note Cable glands used t
119. usly disconnected tubing Figure 8 1 Three way valve for measuring flow rates l 4 Obtain a precision flow measurement instrument such as a bubble meter Ensure that all pressure regulators are set to the correct pressures as shown on the calibration data shipped with the instrument or as recorded in the instrument logbook Ensure that the analyzer is stabilized at normal operating temperatures before proceeding Suspend the analyzer according to Chapter 4 Turn the Meas Clean Air 1 three way valves to point down for flow measurement SOLA II Flare User Manual 8 6 Chapter 8 Maintenance amp Troubleshooting 6 Connect the flow meter to the Meas Clean Air 1 port and adjust the Clean Air 1 regulator to obtain the required flow 7 Turn the Meas Clean Air 1 three way valves to point up for normal Operation 8 Turn the Meas Clean Air 2 three way valves to point down for flow measurement 9 Connect the flow meter to the Meas Clean Air 2 port and adjust the Clean Air 2 regulator to obtain the required flow 10 Turn the Meas Clean Air 2 three way valves to point up for normal operation 11 Turn the Meas Clean Air 3 three way valves to point down for flow measurement 12 Connect the flow meter to the Meas Clean Air 3 port and adjust the Clean Air 3 regulator to obtain the required flow 13 Turn the Meas Clean Air 3 three way valves to point up for normal Operation 14 Restart the analyzer acco
120. utput signal stabilizes May take several days in severe cases Close doors and allow system to stabilize Measure ambient and purge air temperatures and correct as necessary Reposition Thermistor Normal alarm during start up until pyrolyzer and oven temperatures stabilize Check pyrolyzer temperature If much lower than normal and not increasing check for voltage across the heater terminals If voltage is present shut down the instrument disconnect the pyrolyzer heater contacts and measure heater continuity Replace heater if it shows open Check electronics and replace if necessary Replace valve rotor In extreme cases replace entire valve head Check filtration system to ensure particulate is not getting to the injection valve Check lamp trigger pack and electronics Replace if necessary SOLA II Flare User Manual 8 19 Thermo Scientific Chapter 8 Maintenance amp Troubleshooting Malfunction Possible Cause Action Purge Fail alarm Loss of instrument air pressure Check instrument air source pressure i 1 aisplayen Improper settings Ensure oven air and purge pressures are set properly Leakage at oven or electronic Ensure oven and electronics enclosure enclosure doors doors are closed tightly and that door seals are In good condition Leakage throughout electrical Ensure electrical conduit seals are poured conduit Excessive signal Internal sample or carrier Check instrument for leaks noise leakage De
121. view During initial setup and calibration of a SOLA II Flare the optimum PMT supply voltage is set so that the highest concentration expected produces a signal that is within the range that the rest of the electronics can process The voltage applied to the PMT is a negative dc voltage and the lower the PMT voltage the greater the sensitivity of the detector The Dual PMT Supply option adds the capability of two independent analytical calibrations During setup and calibration supply A is assigned to one range and supply B to the other The voltage on each supply is adjusted using the corresponding PMT voltage adjustment to accommodate the desired range The analyzer is then calibrated and tested for each range During normal operation the supply voltage to the PMT is routed from either supply under software control Table 1 1 Detector Pulsed UV Fluorescence PUVF with pyrolyzer for Total Sulfur Measurement as S02 Repeatability Two sample injections minute 1 of full scale at one standard deviation One sample injections minute 2 of full scale at one standard deviation Linearity 1 of full scale measurement range Response Time semi continuous 120 second rolling average with the output updated each second 1 90 response time of four to seven minutes Process Streams One Calibration On demand Validation Automatic or on demand SOLA II Flare User Manual 1 9 Chapter 1 Product Overview Analog Discrete Data Table 1 2
122. which has a 100 ul sample loop When a flaring event with high sulfur content occurs the first injection using the 100 ul sample loop will most likely over range the analyzer detector Therefore an external trigger can be utilized to immediately switch the SOLA II Flare to the high measurement range and prepare the analyzer for the increased level of sulfur The high range sample injection valve has a 1 ul sample loop Options for an external trigger include a flow meter a pressure transmitter or the water seal level system Once the analyzer is in the high measurement range the increased sulfur level will not over range the analyzer detector and the sulfur level can be tracked during the flaring event If the external trigger is not used the SOLA II Flare recovers within five to seven minutes and no external action is required to resume normal operation There is the possibility that a flaring event can occur where the overall sulfur content does not increase For these situations there is a user definable dwell time associated with the external trigger Once the external trigger tells the analyzer to switch to the high range the analyzer will monitor the sulfur level for a programmed period typically 5 to 10 minutes to confirm that the sulfur level is increasing If the sulfur level does not increase at the end of the dwell time the SOLA II Flare will automatically switch back to the low measurement range During the dwell time the SOLA I
123. wledgment of an alarm A lar m s Setup Safe a t uo Es Ala rms M o d e V N En t E x Ere Figure 5 24 Calibration Overview The analyzer requires a two point linear calibration During the calibration procedure the average of the raw detector signals corresponding to two known sulfur concentrations are latched by the unit and retained in non volatile memory During normal operation the average detector reading is interpolated on the line to derive the sulfur concentration reported Thermo Scientific SOLA II Flare User Manual 5 8 Thermo Scientific Chapter 5 Configuration The graph below illustrates a typical SOLA II Flare calibration N x 3 D N T E E Figure 5 25 Typical SOLA II Flare calibration Prior to calibrating the instrument the sulfur concentration expected at the two points must be entered in the calibration setup menus Configuration gt Calibration Setup In the software these points are referred to as high and low calibration values For the graph above the values would be Low cal value 0 00 ppm Low cal 555 560 kHz High cal value 100 00 ppm High cal 15 000 000 kHz The high calibration value needs to be as close as possible to the full range sulfur concentration expected in the process and the low calibration value is normally set to zero so that only one standard is required for calibration The high and low calibration can be performed independently Changing either one of
124. wool insulation over the top of the insulation Figure 8 17 Apply the Kaowool insulation 5 Holding the insulation and pyrolyzer tube gently attach the housing lid against the insulation allowing both ends of the tube to come out of the lid approximately 1 2 Attach one of the graphite ferrules and one of the fittings removed earlier to each of the pyrolyzer tube ends Graphite ferrule Ends of pyrolyzer tube Figure 8 18 Reattach the ferrules and fittings 6 Gently slide the lid back into the housing and secure it using the screws and washers removed earlier 7 With an air gun placed at the end of one fitting blow out any dust or debris that may have dropped inside the pyrolyzer quartz or glass tube Figure 8 14 8 Follow steps 22 through 27 in the previous section Replacing the Pyrolyzer Heater to re install the housing and complete this procedure Thermo Scientific SOLA II Flare User Manual 8 17 Decoking III General Troubleshooting Thermo Scientific Chapter 8 Maintenance amp Troubleshooting Coking carbon buildup can occur in the pyrolyzer reaction tube when sample or calibration flow is too high or when there is no airflow It is evidenced by a light brown or black coating on the inside of the reaction tube Carbon buildup in the reaction tube absorbs SO resulting in poor instrument performance and invalid results Note Thermo Scientific does not recommend decoking the tube

SOLA II Flare - Thermo Scientific

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