Endress+Hauser SpectraSensors 2-Pack Analyzer System Hardware Installation And Maintenance Manual
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Endress+Hauser SpectraSensors 2-Pack Analyzer System Hardware Installation And Maintenance Manual

Endress+Hauser SpectraSensors 2-Pack Analyzer System Hardware Installation And Maintenance Manual

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4900002256 Rev B
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Hardware Installation and Maintenance Manual
2-Pack Analyzer System
Class I, Division 2, Grp. B, C and D, T3/T3C IP66
Class I, Zone 2 IIB+H2 T3/T3C IP66
Copyright © 2021 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
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  • Page 1 Products Solutions Services 4900002256 Rev B Hardware Installation and Maintenance Manual 2-Pack Analyzer System Class I, Division 2, Grp. B, C and D, T3/T3C IP66 Class I, Zone 2 IIB+H2 T3/T3C IP66 Copyright © 2021 SpectraSensors, Inc. No part of this manual may be reproduced in whole or in part without the express written permission of SpectraSensors, Inc.
  • Page 3 Product/Firmware Matrix HC12 PRODUCT MODEL Firmware Firmware Firmware SS2100, SS2100a, Not used Used for Used for non- SS2100i-1, SS2100i-2 differential differential analyzers analyzers 2-Pack/3-Pack Used on right- Used on left- Not used side analyzer side analyzer electronics electronics SS1000, SS500, Used Not used Not used...

  • Page 5: Table Of Contents

    ABLE OF ONTENTS List of Figures ..........v List of Tables .
  • Page 6 2-Pack Analyzer System Connecting the Gas Lines........3-19 To connect the sample supply lines .
  • Page 7 Table of Contents Disposal of Used Scrubbers ........B-26 Instrument Issues.
  • Page 8 2-Pack Analyzer System THIS PAGE INTENTIONALLY LEFT BLANK 4900002256 rev. B 4-13-21...

  • Page 9: List Of Figures

    IST OF IGURES Figure 1–1. Schematic of a typical laser diode absorption spectrometer ..1-6 Figure 1–2. Typical raw signal from a laser diode absorption spectrometer with and without mirror contamination ....1-7 Figure 1–3.
  • Page 10 2-Pack Analyzer System Figure A–8. Power and signal wiring diagram, fixed mount, non-validation, optional analyzer electronics port for 2-Pack analyzer system . . . A-12 Figure A–9. Power and signal wiring diagram, fixed mount, non-validation, optional air-actuated valve for 2-Pack analyzer system ..A-13 Figure B–1.

  • Page 11: List Of Tables

    IST OF ABLES Table 1–1. Fuse specifications (Analyzer A) ......1-15 Table 1–2. Fuse specifications (Analyzer B) ......1-16 Table 3–1.
  • Page 12 2-Pack Analyzer System THIS PAGE INTENTIONALLY LEFT BLANK. viii 4900002256 rev. B 4-13-21...

  • Page 13: Who Should Read This Manual

    1 - I NTRODUCTION SpectraSensors’ 2-Pack analyzer system uses high-speed, laser-diode based extractive analyzers designed for extremely reliable monitoring of parts per million (ppm) to percentage concentrations of specific components in various background gases. In order to ensure that the analyzer performs as specified, it is important to closely review the contents of this manual.

  • Page 14: Safety Warning Label

    2-Pack Analyzer System within this manual and must be observed when operating and servicing the analyzer. Some symbols are provided for instructional purposes only and are not labeled on the system. Safety warning label The warning label shown below will be affixed to the front side of all analyzer enclosures that contain sample gas.

  • Page 15: Equipment Labels

    Introduction Equipment labels Warning statement for hazardous voltage. Contact may cause electric shock or burns. Turn off and lock out system before servicing. Failure to follow all directions may result in damage or malfunction of the analyzer. Maximum voltage and current specifications for the fuse closest to label.

  • Page 16: Instructional Symbols

    Headquartered in Houston, Texas, SpectraSensors was incorporated in 1999 as a spin-off of the NASA/Caltech Jet Propulsion Laboratory (JPL) for the purpose of commercializing space-proven measurement technologies initially developed at JPL. SpectraSensors was acquired by the Endress+Hauser Group in 2012. Manufacturer Address SpectraSensors, Inc.

  • Page 17: About The Gas Analyzers

    Introduction About the Gas Analyzers The 2-Pack analyzer system includes tunable diode laser (TDL) absorption spectrometers operating in the near to short wavelength infrared. Each compact sensor consists of a TDL light source, sample cell and detector specifically configured to enable high sensitivity measurement of a particular component within the presences of other gas phase constituents in the stream.
  • Page 18 2-Pack Analyzer System system, sample gas flows continuously through the sample cell ensuring that the sample is always representative of the flow in the main pipe. OPTICAL HEAD OPTICAL DETECTOR LASER HEAD LASER DETECTOR WINDOW INLET WINDOW INLET PRESSURE PRESSURE SENSOR SENSOR OUTLET...
  • Page 19 Introduction Figure 1–2 on page 1–7 below shows the typical raw data (in arbitrary units [a.u.]) from a laser absorption spectrometer scan including the incident laser intensity, I (), and the transmitted intensity, I(), for a clean system and one with contaminated mirrors (shown to illustrate the system’s relative intensity to mirror contamination).

  • Page 20: Differential Tdlas

    2-Pack Analyzer System Normalized Absorption Signal Wavelength [a.u.] Figure 1–3 Typical normalized absorption signal from a laser diode absorption spectrometer Note that contamination of the mirrors results solely in lower overall signal. However, by tuning the laser off-resonance as well as on-resonance and normalizing the data, the technique self calibrates every scan resulting in measurements that are unaffected by mirror contamination.

  • Page 21: Getting To Know The Analyzer

    Introduction is at twice the modulation frequency (2f). Refer to Figure 1–4. below. This phase-sensitive detection enables the filtering of low-frequency noise caused by turbulence in the sample gas, temperature and/or pressure fluctuations, low-frequency noise in the laser beam or thermal noise in the detector. Normalized 2f Signal Peak...
  • Page 22 2-Pack Analyzer System LCD/KEYPAD SIGNAL WIRING SIGNAL WIRING ANALYZER A ANALYZER B ELECTRONICS ELECTRONICS ENCLOSURE ENCLOSURE ANALYZER POWER ANALYZER POWER INSTRUMENT AIR INLET (OPTIONAL) TEMPERATURE VAL GAS INLET INDICATOR (OPTIONAL) SAMPLE SUPPLY SAMPLE HEAT TRACE POWER CONDITIONING SYSTEM (SCS) SAMPLE RETURN HEATER POWER CHASSIS GROUND Figure 1–5 2-Pack analyzer architecture...
  • Page 23 Introduction TERMINAL BLOCK TB2, RELAY DRIVER AND 4-20 mA OUTPUT SIGNALS CONTROL BOARD STACK HYTEK TEMPERATURE CONTROLLER AC POWER SUPPLY SIGNAL CONVERTER RS-232 TO RS-485 BACKPLANE (OPTIONAL) ARM9 CONTROL BOARD COMPONENT STACK GROUND PROTECTIVE GROUND FUSES (F2. F1) ALARM/ SIGNAL RELAYS CUSTOMER GROUND...
  • Page 24 2-Pack Analyzer System TERMINAL BLOCK TB2, RELAY DRIVER AND 4-20 mA OUTPUT SIGNALS CONTROL BOARD STACK HYTEK TEMPERATURE CONTOLLER FUSE (F3) SIGNAL CONVERTER RS-232 TO RS-485 (OPTIONAL) BACKPLANE DC POWER SUPPLY ARM9 CONTROL BOARD STACK COMPONENT GROUND PROTECTIVE GROUND ALARM/ SIGNAL RELAYS FUSE (F1)
  • Page 25 Introduction ASSIGNABLE ALARM SIGNAL CONVERTER, GENERAL FAULT ALARM RS-232 TO ETHERNET COMMON SIGNALS FUSE (F4) 4-20 mA BOARDS Figure 1–8 Analyzer B HC12 electronics control board (AC) showing signal terminal block and alarm relays – Hardware Installation and Maintenance Manual...
  • Page 26 2-Pack Analyzer System ASSIGNABLE ALARM GENERAL FAULT ALARM COMMON SIGNALS FUSE (F5) 4-20 mA BOARDS Figure 1–9 Analyzer B HC12 electronics control board (DC) showing signal terminal block and alarm relays – 4900002256 rev. B 4-13-21...

  • Page 27: Fuses

    Introduction Fuses Fuses are located on the electronics control board, as shown in Figure 1–6 on page 1–11, Figure 1–7 on page 1–12, Figure 1–8 on page 1–13 and Figure 1–9 on page 1–14. The spare part kits for fuses are shown in Table 1–1 below and Table 1–2 on page 1–16 If you need to replace a fuse, use only the same type and rating of fuse as the original.

  • Page 28: Table 1-2 Fuse Specifications (Analyzer B)

    2-Pack Analyzer System Table 1–2 Fuse specifications (Analyzer B) Drawing Reference Voltage Description Rating Figure 1–8 120 VAC Miniature Fuse, 5 x 20 mm, 250 VAC Time Delay 0.8 A 240 VAC Miniature Fuse, 5 x 20 mm, 250 VAC Time Delay 0.8 A Figure 1–9...

  • Page 29: Potential Risks Affecting Personnel

    2 - S AFETY Potential Risks Affecting Personnel This section addresses the appropriate actions to undertake when faced with hazardous situations during or before service of the analyzer. It is not possible to list all potential hazards within this document. The user is responsible for identifying and mitigating any potential hazards present when servicing the analyzer.

  • Page 30: Electrocution Hazard

    2-Pack Analyzer System Electrocution hazard 1. Shut off power at the main disconnect external to the analyzer. Complete this action before performing any service that requires working near the main input power or disconnecting any wiring or other electrical components. 2. Open enclosure door. If service must be performed with power engaged (gain adjustment, etc.): Note any live electrical components and avoid any contact with them.

  • Page 31: What Should Be Included In The Shipping Box

    What Should be Included in the Shipping Box The contents of the crates should include: • The SpectraSensors 2-Pack analyzer system • A document CD, which includes this manual and other system manuals and documents •...

  • Page 32: Inspecting The Analyzer

    2-Pack Analyzer System Ensure all equipment used for lifting/moving the analyzer is rated for the weight load. 19mm ” 1283mm ” 50-1/2 MOUNTING EARS 953mm (BOTH SIDES) ” 37-1/2 914mm ” 10mm [0.41”] Dia. Through (Type 4 PLCS) 724mm 19mm ”...

  • Page 33: Mounting And Installing The Analyzer

    Installation Mounting and Installing the Analyzer Installing the analyzer is relatively easy requiring only a few steps that, when carefully followed, will ensure proper mounting and connection. The steps are outlined in the following sections: • Hardware and tools for mounting and installation •...

  • Page 34: To Mount The Analyzer

    2-Pack Analyzer System To mount the analyzer The 2-Pack analyzer system is manufactured for wall installations. Refer to Figure A–1 on page A–5 for detailed mounting dimensions. When mounting the analyzer, be sure not to position the instrument so that it is difficult to operate adjacent devices. Allow three feet (1 m) of room in front of the analyzer and any switches.

  • Page 35: Protective Chassis And Ground Connections

    Installation Interconnection of the analyzer enclosure and cell enclosure shall be accomplished using wiring methods approved for Class 1, Division 2 hazardous locations as per the Canadian Electrical Code (CEC) Appendix J and the National Electric Code (NEC) Article 501, or methods described in the Standard IEC/EN 60079-0 and IEC/EN 60079-14.

  • Page 36: To Connect Electrical Power To Analyzer A

    2-Pack Analyzer System To connect electrical power to Analyzer A 1. Open Analyzer A (left side) electronics enclosure door. Take care not to disturb the electrical assembly inside. Hazardous voltage and risk of electric shock. Failure to properly ground the analyzer may create a high-voltage shock hazard.
  • Page 37 Installation 24 V AC CONNECTIONS DC CONNECTIONS Figure 3–2 AC and DC connections for the electronics control board terminal block in the Analyzer A electronics enclosure Connecting power to L1 also powers the solenoids, if included. To connect electrical power to Analyzer B 1. Open the Analyzer B (right side) electronics enclosure door. Take care not to disturb the electrical assembly inside.
  • Page 38 2-Pack Analyzer System Because the breaker in the power distribution panel or switch will be the primary means of disconnecting the power from the analyzer, the power distribution panel should be located in close proximity to the equipment and within easy reach of the operator, or within 10 feet of the analyzer.

  • Page 39: Field Interface Loads (Solenoid Valves)

    Installation Field interface loads (solenoid valves) The 2-Pack analyzer must be connected to a certified solenoid having a temperature code of T4, T5, or T6 at a maximum ambient temperature of   C (140 Connecting Electrical Power to the SCS Enclosure Heater Units with an enclosure heater will have an additional power connection through a conduit hub located at the bottom right of the sample conditioning...

  • Page 40: Application Of Conduit Lubricant

    2-Pack Analyzer System 3. Run conduit from the power distribution panel to the conduit hub on the lower right side of the heated enclosure labeled for power input. Refer to "Application of conduit lubricant". Conduit seals should be used where appropriate in compliance with local regulations.

  • Page 41: Connecting The Output Signals And Alarms

    Installation 1. Holding the fitting piece at one end, generously apply the STL8 lubricant on the male threaded surface (at least five threads wide) as shown in Figure 3–5 below. Figure 3–5 Applying conduit lubricant 2. Screw the female pipe thread onto the male fitting until the lubricated threads are engaged.

  • Page 42: To Connect Analyzer A Signal And Alarm Cables

    2-Pack Analyzer System The Concentra High Alarm (Analyzer A), Assignable Alarm (Analyzer B) and General Fault Alarm trigger SPDT relays located inside the respective analyzer electronics enclosures. The relays for the Concentra High Alarm and Assignable Alarm are configured to be normally de-energized with the dry contact changing state on alarm.
  • Page 43 Installation The external serial cable included in the shipping container is provided for service and troubleshooting purposes and is not intended for permanent installation. 4. Strip back the jacket and insulation of the current loop and serial cable just enough to connect to the mating terminal block, shown in Figure 3–6 below.

  • Page 44: To Connect The Analyzer B Signal And Alarm Cables

    2-Pack Analyzer System Table 3–1 Analyzer A input/output signal connections Terminal Description D-Conn Color Analyzer A Serial RX Pin-3 Black Analyzer A Serial TX Pin-2 COM Serial Ground Pin-5 Shield Analyzer A Current Loop + Analyzer A Current Loop - Analyzer B Current Loop + Analyzer B Current Loop - Digital Input...
  • Page 45 Installation 3. Pull the customer-supplied cables for the current loop and alarms through the conduit into the Analyzer B electronics enclosure. The external serial cable included in the shipping container is provided for service and troubleshooting purposes and is not intended for permanent installation.

  • Page 46: Changing The 4-20 Ma Current Loop Mode

    2-Pack Analyzer System Table 3–2 Analyzer B input/output signal connections Terminal Description D-Connector Color Analyzer A Serial RX Pin-3 Black Analyzer A Serial TX Pin-2 Analyzer A Serial Ground Pin-5 Shield Analyzer B Serial RX Pin-3 Black Analyzer B Serial TX Pin-2 Analyzer B Serial Ground Pin-5...

  • Page 47: To Change 4-20 Ma Board From Source To Sink (Analyzer A Or B)

    Installation To change 4‐20 mA board from source to sink (Analyzer A or B) 1. Disconnect power from the analyzer and open the electronics enclosure cover. Take care not to disturb the electrical assembly inside. 2. Locate the relay control board in the upper right of the electronics enclosure, as shown in Figure 1–6 on page 1–11 or Figure 1–7 on page 1–12 (Analyzer A) or Figure 1–8 on page 1–13 or Figure 1–9 on page 1–14 (Analyzer B).

  • Page 48: To Calibrate The Analog Output (Analyzer A)

    2-Pack Analyzer System To calibrate the analog output (Analyzer A) 1. Connect a calibrator and digital multi-meter into the circuit. 2. On the analyzer keypad, press #2 (Mode 2), the password (3142) and *. 3. Continue pressing the * key until the 4-20 mA Test parameter displays.

  • Page 49: To Test And Adjust 4-20 Ma Zero And Span (Analyzer A Or B)

    Installation 6. If desired, repeat by setting the 4-20 mA % Test parameter; R, to any value between 0 and 100 to confirm that the output, i, agrees with i=R(20 mA - 4 ma) + 4 mA. 7. When finished, reset the 4-20 mA % Test parameter to 101. 8.

  • Page 50: To Connect The Sample Supply Lines

    2-Pack Analyzer System SpectraSensors recommends using 1/4 in. O.D x 0.035 in. wall thickness, seamless stainless steel tubing. Refer to the system layout drawing in Appendix A for supply and return port locations. To connect the sample supply lines 1. First confirm that each sample probe is correctly installed at the process supply tap and that each sample probe isolation valve is closed.

  • Page 51: To Connect The Sample Returns

    Installation 10. Check all connections for gas leaks. SpectraSensors recommends using a liquid leak detector. Do not exceed 0.7 barg (10 PSIG) in sample cell. Damage to cell may result. To connect the sample returns 1. Confirm that the low pressure flare or atmospheric vent header shut- off valve is closed.

  • Page 52: To Connect The Pneumatic Valve Source (If Applicable)

    2-Pack Analyzer System To connect the pneumatic valve source (if applicable) 1. Determine appropriate tubing route from the customer supplied instrument air or nitrogen control gas source (3.4 barg [50 PSIG] minimum to 6.9 barg [100 PSIG] maximum) to the SCS. 2. Run stainless steel tubing from the customer supplied regulator (3.4 barg [50 PSIG] minimum to 6.9 barg [100 PSIG] maximum) to the pneumatic valve instrument air supply port.

  • Page 53: Conditioning The Scs Tubing

    Installation 5. Connect the validation source tube to the SCS using the 1/4 in. stainless steel compression-type fittings provided. 6. Tighten all new fittings 1-1/4 turns with a wrench from finger tight. a. For connections with previously swaged ferrules, thread the nut to the previously pulled up position, then tighten slightly with a wrench.

  • Page 54: To Install The Heated Line Seal

    2-Pack Analyzer System To install the heated line seal The heat-shrinkable entry seal Model NUS-4X supplied by SpectraSensors provides a waterproof fitting where the heat trace bundle enters the SCS enclosure. This seal consists of a three-part assembly; a rigid plastic nylon nut, an O-ring and the heat-shrinkable molded area. Tools needed •...

  • Page 55: About The Scs

    4 - S AMPLE ONDITIONING YSTEM Personnel should have a thorough understanding of the operation of the 2-Pack analyzer and the procedures presented here before operating the sample conditioning system. The process sample at the sample tap may be at a high pressure. A pressure reducing regulator is located at the sample tap to reduce the sample pressure and allow operation of the sample conditioning system at a low pressure.

  • Page 56: Checking The Scs Installation

    2-Pack Analyzer System The membrane separator is a three-port device. When gas enters the separator inlet, only the vapors will pass through the membrane to the outlet. The outlet flow passes through a flow control valve and a flow meter to the analyzer. Blocked liquids or particles can be flushed from the separator housing out the bypass port.
  • Page 57 Sample Conditioning System 2. If a field pressure reducing station is used with the analyzer, confirm that the field pressure reducing station is installed properly at the sample probe. 3. Confirm that the relief valve at the field pressure reducing station has been set to the specified setpoint.

  • Page 58: Starting Up The Scs

    2-Pack Analyzer System 11. Confirm that the analyzer house atmospheric vent is properly installed, if applicable. 12. Confirm that all sample system tubing has been thoroughly leak checked. Starting Up the SCS After the SCS installation has been thoroughly checked, you are ready to begin preparing for initial SCS startup.

  • Page 59: To Start Up The Field Pressure Reducing Station

    Sample Conditioning System 2. Monitor the SCS enclosure thermometer during the warm-up period 5-8 hours to confirm that the sample system enclosure  temperature does not exceed 65 minimum of 5 to 8 hours Allow the system a (preferably overnight) to ensure stabilization. During this time, the system will emit a variety of alarms - this is normal.

  • Page 60: To Start Up The Sample Bypass Stream On Process Sample

    2-Pack Analyzer System To start up the sample bypass stream on process sample 1. Ensure the low pressure flare or atmospheric vent header shut-off valve is opened for the bypass flow effluent from the SCS. 2. Open the sample supply port shut-off valve. 3. Open the bypass flow meter metering valve to establish sample flow from the sample probe and set the metering valve to the specified value.

  • Page 61: Shutting Down The Scs

    Sample Conditioning System 4. Adjust the sample flow meter metering valves to the specified flows for the measurement cells. The adjustment setpoints of the analyzer flow meters and pressure regulators will be iterative and may require readjustment multiple times until the final setpoints are obtained. The analyzer system has been designed for the sample flow rate specified.

  • Page 62: To Isolate The Measurement Cell For Short-Term Shutdown

    2-Pack Analyzer System All valves, regulators, switches, etc. should be operated in accordance with site lock-out/tag-out procedures. To isolate the measurement cell for short‐term shutdown The analyzer can be isolated from the primary sample bypass section for short- term shutdown or maintenance of the analyzer while allowing the sample bypass flow to continue in a steady-state mode.

  • Page 63: To Isolate The Process Sample Tap For Long-Term Shutdown

    Sample Conditioning System 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. Although the pressure reducing regulator at the process sample tap is designed for “bubble-tight”...
  • Page 64 2-Pack Analyzer System The process sample at the sample tap may be at a high pressure. A pressure reducing regulator is located at the sample tap to reduce the sample pressure and allow operation of the SCS at a low pressure. Use extreme caution when operating the sample probe isolation valve and field pressure reducing regulator.

  • Page 65: To Purge For Shipment/Relocation

    Sample Conditioning System 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 66 2-Pack Analyzer System THIS PAGE INTENTIONALLY LEFT BLANK – 4900002256 rev. B 4-13-21...

  • Page 67: Appendix A: Specifications

    Appendix A: Specifications Table A–1 2-Pack: Analyzer A (H S) / Analyzer B (CO ) specifications Performance Refer to calibration report Concentration Repeatability Refer to calibration report S: <5 seconds Response Time : 1 second Periodic Scrubber Cycle Duration 90 seconds Application Data Environmental Temperature –20 °C to 60 °C (–4 °F to 140 °F)
  • Page 68 2-Pack Analyzer System Table A-1 Analyzer A (H S) / Analyzer B (CO ) specifications (Continued) Electrical & Communications (Continued) Analog Output: (4) Isolated 4-20 mA, 1200 ohms at 24 VDC maximum (concentration only) Serial Analyzer A (H S): RS-232 (all Communication parameters) and optional Ethernet Serial Analyzer B (CO...
  • Page 69 Specifications Table A–2 2-Pack: Analyzer A (H S) / Analyzer B (H O) specifications Performance Concentration Refer to calibration report Repeatability Refer to calibration report S: <5 seconds Measurement Update Time O: 1 second Periodic Scrubber Cycle Duration 90 seconds Application Data Environmental Temperature –20 °C to 50 °C (–4 °F to 122 °F) - Standard...
  • Page 70 2-Pack Analyzer System Table A-2 2-Pack: Analyzer A (H S) / Analyzer B (H O) specifications (Continued) Electrical & Communications (Continued) Analog Output: (4) Isolated 4-20 mA, 1200 ohms at 24 VDC maximum (concentration only) Serial Analyzer A (H S): RS-232 Communication (all parameters) and Ethernet Serial Analyzer B (H...
  • Page 71 Figure A–1 Outline and mounting dimensions, fixed mount, non-validation, 2-Pack analyzer system...
  • Page 72 Figure A–2 SCS schematic, fixed mount, non-validation, 2-Pack analyzer system...
  • Page 73 Figure A–3 SCS Bill of Materials, fixed mount, non-validation, 2-Pack analyzer system...
  • Page 74 Figure A–4 SCS schematic, fixed mount, non-validation, solenoid/air actuated valve option for 2-Pack analyzer system...
  • Page 75 Figure A–5 SCS schematic, fixed mount, non-validation, 1-pt air actuated valve/liquid knock-out option for 2-Pack analyzer system...
  • Page 76 Figure A–6 SCS schematic, fixed mount, non-validation, high H S purge option for 2-Pack analyzer system...
  • Page 77 Figure A–7 Power and signal wiring diagram, fixed mount, non-validation, 2-Pack analyzer system...
  • Page 78 Figure A–8 Power and signal wiring diagram, fixed mount, non-validation, optional analyzer electronics port for 2-Pack analyzer system...
  • Page 79 Figure A–9 Power and signal wiring diagram, fixed mount, non-validation, optional air-actuated valve for 2-Pack analyzer system...

  • Page 80: Spare Parts

    2-Pack Analyzer System Spare Parts Below is a list of spare parts for your customized analyzer with recommended quantities for 2 years of operation. Due to a policy of continuous improvement, parts and part numbers may change without notice. When ordering, please specify the system serial number (SN) to ensure that the correct parts are identified.
  • Page 81 Specifications Table A-3 Replacement parts for 2-Pack analyzer (Continued) Part 2 Year Description Number Quantity Pressure Sensor Options Relay, SPDT, D12VDC, 3 A/125 VAC 4500002002 Kit, Spares (O-rings, screws), Viton, 2-Pass Cell 0219900005 0219900011 Kit, Fuse, AC/DC Pressure Sensor, 30 PSIA, 5 V, 1/8 in. MNPT DIN4365 5500002041 NACE 6000002246...
  • Page 82 2-Pack Analyzer System Table A-3 Replacement parts for 2-Pack analyzer (Continued) Part 2 Year Description Number Quantity Sample Conditioning System (Continued) Temperature Controller, 120 VAC, Intertec 5300002004 TC CD E1 S J - 50C Temperature Controller (Division 1), Set at 60 °C, 5300002005 120 VAC, Intertec TCCD-E1-S-J-60C 5300002033...
  • Page 83 Specifications Table A-3 Replacement parts for 2-Pack analyzer (Continued) Part 2 Year Description Number Quantity Cables 0190217204 Cable, Power Supply Output, 14 in. Cable, Current Loop Board 0190217205 Cable, TE Cooler 0190217208 0210117206 Assembly, Cable, Signal Output and Terminal Block (TB2) Assembly, Cable, Power, Display, ARM9 6000002002 Assembly, Cable, RS-232, M-M, DSPL, Data 24.5...
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  • Page 85: Appendix B: Maintenance And Troubleshooting

    Appendix B: Maintenance and Troubleshooting This section presents recommendations and solutions to common problems, such as gas leaks, contamination, excessive sampling gas temperatures and pressures, and electrical noise. Contact Service if your analyzer does not appear to be hampered by one of these related problems, refer to “Service Contact”...

  • Page 86: Excessive Sampling Gas Temperatures And Pressures

    2-Pack Analyzer System designed to withstand some contamination, it is recommended to always keep the sampling lines as contamination free as possible. Refer to “Cleaning the Sampling Lines” on page B-3. Excessive Sampling Gas Temperatures and Pressures The embedded software is designed to produce accurate measurements only within the allowable cell operating range (refer to Appendix A).

  • Page 87: Relief Valve Setting

    Maintenance and Troubleshooting Relief Valve Setting The relief valve is pre-set at the factory at 50 PSIG and should not require adjustment. Refer to the system drawings in Appendix A. Improper adjustment in the field could prevent the proper operation of the relief valve and/or sample conditioning system. Contact Service for questions or issues, refer to “Service Contact”...

  • Page 88: Tools And Supplies

    2-Pack Analyzer System Do not attempt to clean the cell mirror until you contacted Service and have been advised to do so (refer to “Service Contact” on page B-31). The sample cell assembly contains a low-power, 10 mW maximum, CW Class 3b invisible laser with a wavelength between 750 to 3000 nm.
  • Page 89 Maintenance and Troubleshooting 0.1 m CELL 0.8 m CELL 8 m/28 m CELL Figure B–1 Measurement cell types The stainless steel mirrors are used with 0.1 m and 0.8 m measurement cells only. The stainless steel mirrors have been identified with either an “X” engraved on the outside bottom of the mirror or a groove around the rim of the mirror.

  • Page 90: To Clean The Mirrors

    2-Pack Analyzer System b. If the bottom surface is rough or engraved, or a groove on the side of the mirror is detected, a stainless steel mirror is being used. Do not attempt to replace a glass mirror with a stainless steel mirror or system calibration may be adversely affected.
  • Page 91 Maintenance and Troubleshooting The sample cell assembly contains a low-power, 10 mW maximum, CW Class 3b invisible laser with a wavelength between 750 to 3000 nm. Never open the sample cell flanges or the optical assembly unless the power is turned off. Always handle the optical assembly by the edge of the mount.

  • Page 92: To Replace The Stainless Steel Mirror

    2-Pack Analyzer System To replace the stainless steel mirror If your system has been configured with a stainless steel mirror in the 0.1 m or 0.8 m measurement cell, use the following instructions for replacing the mirror. If stainless steel mirrors are replacing another version of mirror in the field, such as glass, the analyzer may need to be returned to the factory for re-calibration to ensure optimal cell function.

  • Page 93: Pressure Sensor Replacement

    Maintenance and Troubleshooting 7. Obtain the new stainless steel mirror. Refer to Figure B–3 below. Figure B–3 Stainless steel mirror - mirror side up 8. Check the O-ring. a. If a new O-ring is needed, apply grease on fingertips and then to the new O-ring.
  • Page 94 2-Pack Analyzer System • 7/8 in. wrench • 9-64 in. Allen wrench • Flat-head screwdriver • Phillips-head screwdriver • Metal pick • Military grade stainless steel PTFE tape (or equivalent) • Dry nitrogen • Isopropyl alcohol Isopropyl alcohol can be hazardous. Follow all safety precautions when in use and thoroughly wash hands prior to eating.
  • Page 95 Maintenance and Troubleshooting MOUNTING BRACKET CELL INLET OPTICAL CABLE (8/28 m CELL) HARNESS THERMISTOR CABLE PRESSURE SENSOR CABLE CELL OUTLET MOUNTING BRACKET Figure B–4 SCS cabinet interior 11. Dismount the cell from the bracket by removing the four securing screws (two on top, two on the bottom) using a 9/64 in. Allen wrench.
  • Page 96 2-Pack Analyzer System 12. Holding the cell firmly with one hand, use a 7/8 in. wrench to remove the old (to be replaced) pressure sensor as shown in Figure B–6 below. Figure B–6 Removing the old pressure sensor Turn the 7/8 in. wrench counterclockwise to loosen the pressure sensor until it is able to be removed.
  • Page 97 Maintenance and Troubleshooting 14. Check for any debris if you suspect debris has fallen into the measurement cell. Refer to “Cleaning the Mirrors” on page B-3 to check for debris. 15. Check for tape fragments inside the cell and remove with a swab as shown in Figure B–8 below.
  • Page 98 2-Pack Analyzer System Figure B–10 Replacing pressure sensor 19. Hand tighten the pressure sensor clockwise into the opening until no longer moving freely. 20. Holding the cell in place, turn the sensor clockwise with a 7/8 in. wrench until tight. Two or three threads on the pressure sensor should still be visible.

  • Page 99: To Replace The Pressure Sensor On A 0.8 M Or 0.1 M Cell

    Maintenance and Troubleshooting 23. Remount the cell to the mounting brackets using a 9/64 in. Allen wrench with the pressure sensor facing out towards the cabinet door. 24. Reconnect the cell inlet and cell outlet using a 9/16 in. wrench. 25.
  • Page 100 2-Pack Analyzer System 1. Remove the cell from the bracket by removing the four securing screws (two on top, two on the bottom) using a 9/64 in. Allen wrench. Place the measurement cell on a clean, flat surface with the pressure sensor facing up.
  • Page 101 Maintenance and Troubleshooting 3. Remove excess seal tape from the flange opening and threads and check threads for galling. Refer to Figure B–14 below. Figure B–14 Removing excess seal tape from flange Contact Service to arrange for a repair if the threads show signs of galling indicating a possible leak.
  • Page 102 2-Pack Analyzer System 7. Hand tighten the pressure sensor turning it counterclockwise into the flange until no longer moving freely. Refer to Figure B–16 below. Figure B–16 Replacing pressure sensor 8. Using the 9/16 in. wrench to hold the flange in place, turn the sensor clockwise with a 7/8 in.

  • Page 103: Periodic Scs Maintenance

    Maintenance and Troubleshooting 12. Reinstall cell inlet and cell outlet using a 9/16 in. wrench. 13. Reconnect the thermistor. 14. Connect the new pressure sensor harness and cable to the circular connector. 15. Reconnect the optical cable harness. 16. Close the door to the SCS enclosure. 17.

  • Page 104: Preventive And On-Demand Scs Maintenance

    2-Pack Analyzer System If loading of a filter is observed, the filter should be cleaned and the filter element replaced. Refer to “To check the filter” on page B-21. After observation for some time, a regular schedule can be determined for replacement of filter elements.

  • Page 105: Scs Status Check

    Maintenance and Troubleshooting SCS status check These steps should be performed only if there is a suspected problem with the analyzer. Performing this check will cause reading errors for up to 4 hours while the enclosure temperature stabilizes. 1. Open the SCS door. 2.

  • Page 106: To Replace The Filter

    S flows through the scrubber (gas composition) and how often (switching frequency). Thus, scrubber lifetime is very application specific. The SpectraSensors 2-pack analyzer system predicts the remaining scrubber capacity by using the actual H S concentration measurements and dry cycle...
  • Page 107 Maintenance and Troubleshooting 4 ppmv, 2” Scrubber 100 ppmv, 3” Scrubber DAYS Figure B–18 Predicted scrubber lifetime based on average H S load The powder material in the scrubber efficiency indicator changes color from turquoise to dark grey if there is any H S breakthrough, as shown in Figure B–20 on page B–25.

  • Page 108: To Replace The Scrubber And Scrubber Efficiency Indicator

    2-Pack Analyzer System Figure B–19 Scrubber and scrubber efficiency indicator If scrubber replacement is necessary, follow the procedure below. Replacement scrubbers, scrubber efficiency indicators, and other replacement parts can be ordered by the part numbers listed in Appendix A. All valves, regulators, switches, etc. should be operated in accordance with site lock-out/tag-out procedures.
  • Page 109 Maintenance and Troubleshooting BEFORE BREAKTHROUGH AFTER BREAKTHROUGH Figure B–20 H S scrubber efficiency indicator before and after breakthrough 5. Tighten all new fittings 1-1/4 turns with a wrench from finger tight. For connections with previously swaged ferrules, thread the nut to the previously pulled up position, then tighten slightly with a wrench.

  • Page 110: Disposal Of Used Scrubbers

    2-Pack Analyzer System Disposal of Used Scrubbers  Depleted H S scrubbers and scrubber indicators contain predominantly Copper (II) Sulfide [CAS# 1317-40-4] with some remaining Copper (II) Oxide [CAS# 1317-38-0] and basic cupric carbonate [CAS# 12069-69-1], each of which are odorless dark powders that require few special precautions other than avoiding contact with the internal substances, keeping the scrubber tightly sealed and protecting the contents against humidity.
  • Page 111 Maintenance and Troubleshooting Table B-1 Potential analyzer issues and solutions (Continued) Symptom Response Laser Power Low Alrm Capture diagnostic data and send the file to SpectraSensors (see “To read diagnostic data with HyperTerminal” in the Firmware Manual). Possible alignment problem. Contact Service for service information.
  • Page 112 2-Pack Analyzer System Table B-1 Potential analyzer issues and solutions (Continued) Symptom Response Front panel display is not lit and no Check connections on the display characters appear (Continued) communication and power cables. Strange characters appear on front panel Check connections on the display display communication cable.
  • Page 113 Maintenance and Troubleshooting Table B-1 Potential analyzer issues and solutions (Continued) Symptom Response Reading seems to always be high by a Capture diagnostic data and send the fixed amount file to SpectraSensors (see “To read diagnostic data with HyperTerminal” in the Firmware Manual).

  • Page 114: Packing

    2-Pack Analyzer System Table B-1 Potential analyzer issues and solutions (Continued) Symptom Response Serial output is displaying garbled data Make sure the computer COM port is set for 19200 baud, 8 data bits, 1 stop bit, no parity, and no flow control. Serial output is providing no data Make sure the analyzer is operating in Mode 1 and readings are being...

  • Page 115: Storage

    Maintenance and Troubleshooting 7. Allow all residual gas to dissipate from the lines. 8. Close any valves controlling the sample flow effluent to the low pressure flare or atmospheric vent. 9. Disconnect power to the system. 10. Disconnect all tubing and signal connections. 11.

  • Page 116: Service Repair Order

    All returns should be shipped to: SpectraSensors, Inc. An Endress+Hauser Company 11027 Arrow Rte. Rancho Cucamonga, CA 91730-4866 United States of America Renewity returns Returns can also be made inside the USA through the Renewity system.

  • Page 117: Index

    NDEX Numerics 4-20 mA current loop 3–11 Electric traced tubing 4–3 4–4 Electric tracer 4–4 Electrical noise B–1 B–2 Enclosure Electronics 3–4 O 3–11 Absorption profile 1–7 O/CO 3–5 3–7 3–12 3–14 3–15 AC connection terminal block 3–7 Acetone B–3 S 3–5 3–6 3–8...
  • Page 118 2-Pack Analyzer System Port Pneumatic valve air or N supply 3–22 Hardware 3–3 Pressure relief vent 3–21 Heated enclosure 3–10 Sample return 3–21 Sample supply 3–20 4–6 Power input requirements 3–4 Power terminal box 3–9 3–10 Pressure regulator 4–1 4–4 4–5 4–6 4–7...
  • Page 119 Index Trace gas measurement (mixed background) 1–9 Tracer 4–4 Tunable diode laser (TDL) 1–5 Tunable diode laser absorption spectroscopy (TDLAS) 1–5 Valves Isolation 4–1 4–2 4–7 4–10 Metering 4–4 4–6 4–8 4–10 Relief 4–3 4–5 4–8 4–9 4–10 Sample probe isolation 3–20 4–4 4–5 Sample supply shut-off 4–9...
  • Page 120 2-Pack Analyzer System This page intentionally left blank – Index 4900002256 rev. B 4-13-21...
  • Page 121 4900002256 Rev B www.spectrasensors.com/contact...

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