Endress+Hauser SpectraSensors OXY5500 Overview Manual
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Endress+Hauser SpectraSensors OXY5500 Overview Manual

Sample conditioning system
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OXY5500 Sample
Conditioning System (SCS)
Overview Manual
P/N 4900002244 rev B

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  • Page 1 OXY5500 Sample Conditioning System (SCS) Overview Manual P/N 4900002244 rev B...
  • Page 3 OXY5500 Sample Conditioning System (SCS) Overview Manual Products of 4333 W Sam Houston Pkwy N, Suite 100 Houston, TX 77043-1223 Tel: 800.619.2861 Fax: 713.856.6623 www.spectrasensors.com Copyright © 2017 SpectraSensors, Inc. No part of this manual may be reproduced in whole or in part without the express written permission of SpectraSensors, Inc. SpectraSensors reserves the right to change product design and specifications at any time without prior notice.
  • Page 4 Revision History Revision Engineering Order Date EO16556 April 20, 2016 ECR16977 Feb. 21, 2017...

  • Page 5: Table Of Contents

    ABLE OF ONTENTS List of Figures/Tables ........iii Figures .
  • Page 6 Oxygen Analyzer Appendix C: Troubleshooting & Maintenance Potential Risks Affecting Personnel ....... . . C-1 Mitigating risks .
  • Page 7 IST OF IGURES ABLES Figures Figure 2–1. Typical OXY5500 with SCS on a panel ..... 2-2 Figure 2–2. Analyzer and probe interface ......2-4 Figure 3–1.
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  • Page 9: Who Should Read This Manual

    1 - I NTRODUCTION SpectraSensors’ OXY5500 sample conditioning system (SCS) is used as an option with the OXY5500 oxygen analyzer. This manual provides an overview of the SCS and its components, operation and troubleshooting. Other manuals related to operation, installation and maintenance of the OXY5500 system include: •...

  • Page 10: Conventions Used In This Manual

    OXY5500 Analyzer General notes and important information concerning the installation and operation of the analyzer. Failure to follow all directions may result in fire. Conventions Used in this Manual In addition to the symbols and instructional information, this manual is created with “hot links”...

  • Page 11: 2: Scs Overview

    2 - SCS O VERVIEW Personnel should have a thorough understanding of the operation of the OXY5500 analyzer and the SCS, including procedures presented here, before operating the sample conditioning system. The process sample at the sample tap may be at a high pressure. A field pressure reducing regulator is located at the sample tap to reduce the sample pressure and enable operation of the sample conditioning system at a low pressure.

  • Page 12: About The Scs

    OXY5500 Analyzer About the SCS Refer to the system drawings and schematics found in Appendix A of this manual for your specific system configuration. For a typical full-featured SCS, as shown in Figure 2–1, sample gas enters the sample conditioning unit [at the specified supply pressure set by an upstream regulator] via the sample supply port, passes through a shut-off valve, pressure regulator that maintains constant pressure in the measurement manifold, and membrane separator where any liquid in the stream is removed.

  • Page 13: Typical Scs Component Overview

    SCS Overview The flow exiting the bypass loop is combined with the flow exiting the measurement manifold and sent out the sample return port to be vented to a safe location. Typical SCS Component Overview Some of the typical components used in the SCS will be described in this section.

  • Page 14: Sample Conditioning System Filters

    OXY5500 Analyzer Figure 2–2 Analyzer and probe interface Sample Conditioning System Filters A guard filter is typically installed at the inlet to the SCS with a fine element to protect the flow controllers, flow meters and pressure regulators from fine particulates.

  • Page 15: Sample Transport Tubing

    SCS Overview Sample Transport Tubing Sample transport tubing must be made of an appropriate material, which may be coated, and of an appropriate diameter for the application. Many times the sample transport tubing must be heat-traced to prevent sample condensation or to prevent fluctuations in measurement due to changes in ambient temperature.
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  • Page 17: 3: Scs Installation

    3 - SCS I NSTALLATION This section covers specific instructions for mounting and installing the OXY5500 sample conditioning system (SCS). Refer to Appendix A for system drawings. Installing the SCS enclosure or panel is relatively easy requiring only a few steps that, when carefully followed, will ensure proper mounting and connection.

  • Page 18: Hardware And Tools For Installation

    OXY5500 Analyzer Hardware and Tools for Installation Depending on the particular configuration of accessories and options ordered, you may need the following hardware and tools to complete the installation process. Hardware • 1/4” (6 mm) Unistrut (or equivalent) bolts and spring nuts ®...

  • Page 19: Figure 3-1 Scs Panel Mounting Locations

    SCS Installation Mounting brackets for equipment intended to be mounted on a wall and/or parts that support heavy loads shall withstand four times the maximum static load. 1. Select a suitable location to mount the SCS enclosure or panel. Choose a shaded area or use an optional analyzer hood (or equivalent) to minimize sun exposure.

  • Page 20: Connecting The Standard Scs Panel Or Enclosure

    OXY5500 Analyzer 5. Hold the analyzer in place and fasten with the top screws. SpectraSensors recommends at least two individuals to support the analyzer SCS during the mounting process. 6. Repeat for the bottom mounting holes. Once all four screws are tightened the SCS should be very secure and ready for the electrical connections.

  • Page 21: Mounting The Scs Remote Panel

    SCS Installation Mounting the SCS remote panel The OXY5500 SCS remote panel is manufactured for wall or Unistrut ® equivalent) metal framing installations. Depending on your application and configuration, the SCS will come mounted on a plate or inside an enclosure. Refer to Appendix A for drawings with detailed mounting dimensions.

  • Page 22: Connecting The Scs Remote Panel

    OXY5500 Analyzer MOUNTING HOLES (BOTH SIDES) Figure 3–2 SCS remote panel mounting locations Once all four screws are tightened the SCS should be very secure and ready for the electrical connections. Connecting the SCS remote panel 1. Connect the oxygen sensor from the OXY5500 to the remote panel. Refer to "Connecting the oxygen sensor to the remote panel".

  • Page 23: Figure 3-3 Oxygen And Rtd Probes

    SCS Installation OXYGEN PROBE COLLAR OXYGEN PROBE RTD PROBE Figure 3–3 Oxygen and RTD probes 2. Loosen slightly the nut from the open end of the Swagelok T-fitting marked “Oxygen Probe” on the remote panel. 3. Look for the marking on the probe end. This marking indicates the depth to which the probe should be installed.

  • Page 24: Oxygen Sensor Without Bracket

    OXY5500 Analyzer PROBE MARKING Figure 3–5 Oxygen probe - insertion marking Figure 3–6 Oxygen probe bracket installed Oxygen sensor without bracket: 1. Remove the protective red cap from the probe tip. 2. Unscrew the collar from the hex nut and remove the collar. Refer to Figure 3–7.

  • Page 25: Figure 3-7 Remove Oxygen Probe Collar

    SCS Installation OXYGEN PROBE COLLAR Figure 3–7 Remove oxygen probe collar 6. Replace the collar over the probe tip and tighten against the bracket. Secure to finger tight. Refer to Figure 3–8. Figure 3–8 Feed oxygen probe through bracket opening and connect collar 7.

  • Page 26: Connecting The Rtd Probe To The Remote Panel

    OXY5500 Analyzer 11. Tighten the Swagelok nut using a 1/2” open-ended wrench or adjustable wrench. 12. Secure the bracket using a Phillips screwdriver to install the screws (x 2) in the pre-drilled holes on the remote panel. Refer to Figure 3–6.

  • Page 27: Starting Up The Scs

    SCS Installation 5. Confirm that the power is available to the analyzer, and if applicable, that the local switch is off. 6. Confirm that the field analog/digital and alarm signal wiring is connected properly (refer to the OXY5500 Operator’s Manual [P/N 4490000239] for more information).
  • Page 28 OXY5500 Analyzer To start up the sample bypass stream on process sample: 1. Open the atmospheric vent header shut-off valve for the combined sample bypass and measurement manifold effluent from the SCS, if applicable. 2. Open the sample supply port shut-off valve and slowly open the pressure regulator (turning knob clockwise).

  • Page 29: System Power Up

    SCS Installation System Power Up When all the start-up procedures have been completed, follow the steps below to start up the OXY5500 system. The electrical installation to which the apparatus is connected must be protected against transients. The protective device has to be set at a level not exceeding 140% of the peak rated voltage values at the power supply terminals (according to clause 13.c) of standard EN 60079-15).
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  • Page 31: Appendix A: Specifications And Drawings

    Appendix A: Specifications and Drawings Table A–1 OXY5500 SCS specifications Settings Enclosure Enclosure Remote Mount Mount Mount (Heated) Component Panel Mount Sample Inlet 1/4” Swagelok Tube Fitting (6 mm optional) Connection Sample Outlet 1/2” Swagelok Tube Fitting (12 mm optional) Connection Sample Inlet Pressure 1.4 - 2.8 barg (20 - 40 PSIG)

  • Page 32: Figure A-1 Scs, Panel Mount, Standard Configuration, Dimensions

    COMMUNICATION SIGNAL CONNECTIONS 3/4 NPT or M20 x 1.5 POWER CONNECTIONS 3/4 NPT or M20 x 1.5 Figure A–1 SCS, panel mount, standard configuration, dimensions...
  • Page 33 COMMUNICATION SIGNAL CONNECTIONS 3/4 NPT or M20 X 1.5 POWER CONNECTIONS 3/4 NPT or M20 x 1.5 Figure A–2 SCS, panel mount, standard configuration...

  • Page 34: Figure A-3. Scs, Panel Mount, Standard Configuration With H2S Purge

    COMMUNICATION SIGNAL CONNECTIONS 3/4 NPT or M20 x 1.5 POWER CONNECTIONS 3/4 NPT or M20 x 1.5 Figure A–3 SCS, panel mount, standard configuration with H S purge...

  • Page 35: Figure A-4 Scs, Remote Mount, Standard Configuration, Dimensions

    Figure A–4 SCS, remote mount, standard configuration, dimensions...

  • Page 36: Figure A-5 Scs, Remote Mount, Standard Configuration

    Figure A–5 SCS, remote mount, standard configuration...

  • Page 37: Figure A-6 Scs, Remote Mount, Standard Configuration With H2S Purge

    Figure A–6 SCS, remote mount, standard configuration with H2S purge...

  • Page 38: Figure A-7 Scs, Enclosure, Standard Configuration, Dimensions

    COMMUNICATION SIGNAL CONNECTIONS 3/4 NPT or M20 x 1.5 POWER CONNECTIONS 3/4 NPT or M20 x 1.5 ENTRY SIZE 1” x M20 M6 STAINLESS STEEL EARTH STUD Figure A–7 SCS, enclosure, standard configuration, dimensions...
  • Page 39 COMMUNICATIONS SIGNAL CONNECTIONS 3/4 NPT or M20 x 1.5 POWER CONNECTIONS 3/4 NPT or M20 x 1.5 HEATER CONNECTION 3/4 NPT Figure A–8 SCS, enclosure, standard configuration...

  • Page 40: Figure A-9. Scs, Enclosure, Standard Configuration With H2S Purge

    COMMUNICATION SIGNAL CONNECTIONS 3/4 NPT or M20 x 1.5 POWER CONNECTIONS 3/4 NPT or M20 x 1.5 HEATER CONNECTIONS 3/4 NPT Figure A–9 SCS, enclosure, standard configuration with S purge...

  • Page 41: Figure A-10 Scs, Enclosure, Heater Wiring Diagram

    Figure A–10 SCS, enclosure, heater wiring diagram...
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  • Page 43: Appendix B: Spare Parts

    Appendix B: Spare Parts Below is a list of spare parts for the OXY5500 sample conditioning system (SCS) with recommended quantities for 2 years of operation. Not all parts listed are included on every analyzer. When ordering, please specify the system serial number to ensure that the correct parts are identified.
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  • Page 45: Appendix C: Troubleshooting & Maintenance

    Appendix C: Troubleshooting & Maintenance This chapter presents recommendations and solutions to common problems, such as "Gas Leaks", "Contamination" and "Excessive Sampling Gas Temperatures and Pressures". If your analyzer does not appear to be hampered by one of these related problems, contact “Customer Service” on page C-8.

  • Page 46: Electrocution Hazard

    Oxygen Analyzer 3. If no gas leak is detected, open the SCS enclosure door. Follow all safety protocols governing toxic gases and potential leaks. Electrocution hazard 1. Shut off power at the main disconnect external to the analyzer and open the enclosure. Complete this action before performing any service that requires working near the main input power or disconnecting any wiring or other electrical components.

  • Page 47: Contamination

    Troubleshooting & Maintenance Process samples may contain hazardous material in potentially flammable and/or toxic concentrations. Personnel should have a thorough knowledge and understanding of the physical properties and safety precautions for the sample contents before operating the SCS. Contamination Contamination and long exposure to high humidity are valid reasons for periodically cleaning the gas sampling lines.

  • Page 48: Replacing The Membrane Separator

    Oxygen Analyzer Replacing the Membrane Separator Use the following steps to replace a membrane separator. 1. Close the sample supply valve. 2. Unscrew the cap from the membrane separator. If the membrane filter is dry: 3. Check if there are any contaminants or discoloring of the white membrane.
  • Page 49 Troubleshooting & Maintenance To isolate the analyzer for short-term shutdown: The analyzer can be isolated from the process sample tap for short-term shutdown or maintenance of the analyzer without requiring the shutdown of the field pressure reducing station. Process samples may contain hazardous material in potentially flammable and/or toxic concentrations.
  • Page 50 Oxygen Analyzer To isolate the analyzer for long-term shutdown: If the analyzer is to be out of service for an extended period, the analyzer must be isolated at the process sample tap. Process samples may contain hazardous material in potentially flammable and/or toxic concentrations.

  • Page 51: Troubleshooting

    Troubleshooting & Maintenance 9. Turn off power to the analyzer. 10. Turn off the AC power to the sample tracer, if applicable, at the power distribution panel. Although power could be shut off to the sample supply electric tracer, it is advisable to allow this line to remain heated unless the SCS is to be out of service for an extended period or maintenance is required on the line.

  • Page 52: Service Contact

    Oxygen Analyzer Table C-1 Potential instrument problems and solutions (Continued) Symptom Response Clean the membrane housing. Slow measurement response Replace the membrane separator. Refer to “Replacing the Membrane Sep- arator” on page C-4. Service Contact If the troubleshooting solutions do not resolve the problem, contact customer service.

  • Page 53: Packing And Storage

    Troubleshooting & Maintenance Packing and Storage SpectraSensors’ OXY5500 analyzers and auxiliary equipment are shipped from the factory in appropriate packaging. Depending on the size and weight, the packaging may consist of a cardboard-skinned container or a wooden crate. All inlets and vents are capped and protected when packaged for shipment. If the equipment is to be shipped or stored for any length of time, it should be packed in the original packaging when shipped from the factory.

  • Page 54: Disclaimers

    Oxygen Analyzer be exposed to direct sun, rain, snow, condensing humidity or corrosive environments. Disclaimers SpectraSensors accepts no responsibility for consequential damages arising from the use of this equipment. Liability is limited to replacement and/or repair of defective components. This manual contains information protected by copyright. No part of this guide may be photocopied or reproduced in any form without prior written consent from SpectraSensors.

  • Page 55: Index

    NDEX Gas leaks C–2 C–3 Power connection A–3 Acetone C–3 Analyzer Lifting/carrying 3–1 Analyzer shutdown Hardware 3–2 Long-term C–6 Short-term C–5 Icons Warning symbols 1–1 Cautions 1–1 Cleaning Gas sampling lines C–3 Connection Remote SCS panel 3–6 Leak detector C–3 Standard SCS panel or enclosure 3–4 Contamination C–3 Control system...
  • Page 56 OXY5500 Analyzer Sample bypass 3–11 C–5 Start-up 3–12 Sample conditioning system (SCS) 2–1 3–11 Shut down C–4 Start-up 3–11 Sample gas 2–2 Sample probe 2–1 3–10 3–12 C–4 Service contact C–9 Stainless steel tubing C–2 Temperature controller Electric tracer 3–11 Tools 3–2 Troubleshooting Contamination C–3...

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