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California Analytical Instruments 300 HFID Operation And Maintenance Manual

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OPERATION AND MAINTENANCE
MANUAL FOR MODEL 300 HFID/MHFID ANALYZER
C
A
alifornia
nalytical
I
I
nstruments,
nc.
1312 West Grove Avenue, Orange, CA 92865 - 714 974-5560 - Fax 714 921-2531
Website: www.gasanalyzers.com

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  • Page 1 OPERATION AND MAINTENANCE MANUAL FOR MODEL 300 HFID/MHFID ANALYZER alifornia nalytical nstruments, 1312 West Grove Avenue, Orange, CA 92865 - 714 974-5560 - Fax 714 921-2531 Website: www.gasanalyzers.com...
  • Page 2 INSTRUCTION MANUAL This manual describes the installation, calibration and operation of California Analytical Instruments, Inc. Model 300 HFID and Model 300M HFID Heated Total Hydrocarbon Gas Analyzer. To assure correct operation and accurate results, it is recommended that the user carefully read this document.

  • Page 3: Table Of Contents

    Pressure and Flow Rate ....................3-15 3.10. Sample Gas By-Pass Outlet (Vent) ................3-15 DESCRIPTION AND FUNCTION COMPONENTS ............. 4-16 4.1. Model 300 HFID/MHFID Analyzer Front Panel ............4-16 4.2. Model 300 HFID/MHFID Analyzer Rear Panel ............. 4-17 Major Internal Components ....................5-19 5.1.
  • Page 4 Section 1 Model 300 HFID/MHFID Analyzer 8.1. Main Circuit Board ......................8-34 8.2. Main Amplifier Board ....................8-34 8.3. Automatic Ignite Board ....................8-34 8.4. Diagnostic Board ......................8-34 8.5. EPC/Dual Temperature Control Board ................. 8-34 8.6. EPC Hydrogen/Cutter Temperature Control Board ............8-35 8.7.
  • Page 5 Figure 5-6 Model 300 HFID/MHFID Output Diagnostic Circuit Board......... 5-25 Figure 5-7 Model 300 HFID/MHFID EPC and Dual Temperature Control Board ....... 5-26 Figure 5-8 Model 300 HFID/MHFID EPC Hydrogen and CH4 Cutter Control Circuit Board..5-27 Figure 5-9 Model 300 Valve Driver Board................... 5-28 Tables Table 4-1 Connector for External Wiring..................

  • Page 6: Introduction

    Section 1 Model 300 HFID/MHFID Analyzer INTRODUCTION 1.1. Overview Thank you and congratulations! You have just purchased one of the most reliable gas analyzers in the world. Before using the analyzer, please familiarize yourself with its operation by reading this manual. If you have any questions, please do not hesitate to call California Analytical Instruments for assistance.

  • Page 7: Warranty Certificate

    Section 1 Model 300 HFID/MHFID Analyzer 1.5. Warranty Certificate Subject to the exceptions and upon the conditions stated below, California Analytical Instruments (CAI) warrants that the products sold under this sales order shall be free from defects in workmanship and materials for one year after delivery of the product to the original Buyer by CAI and if any such product should prove to be defective within such one year period, CAI agrees, at its option, either (i) to correct by repair or, at CAI’s election, by...

  • Page 8: Possible Explosion Hazard

    1.8. Fuel Requirements The CAI factory configures the Model 300 HFID/MHFID for either 100% Hydrogen or 40%/60% Hydrogen/Helium Fuel. Please make sure to use the CORRECT fuel. Use of INCORRECT fuel will DAMAGE the instrument and could cause an EXPLOSION.

  • Page 9: 1.10. Factory Qa Checkout Sheet

    Section 1 Model 300 HFID/MHFID Analyzer 1.10. FACTORY QA CHECKOUT SHEET FID SERIAL NUMBER: FACTORY AIR PRESSURE SETTING: FACTORY FUEL PRESSURE SETTING: FACTORY SAMPLE PRESSURE SETTING: Operations and Maintenance Manual 300HFID V7.0.doc...

  • Page 10: Features And Principles Of Operation

    The CAI Model 300 MHFID Heated Total Hydrocarbon Analyzer is exactly the same instrument as the Model 300 HFID, except that it contains a catalyst that may be switched in and out of the sample stream, with the front panel switch or via a contact closure, to analyze the methane content of the sample.

  • Page 11: Product Specifications Model 300 Hfid/Mhfid

    Section 2 Model 300 HFID/MHFID Analyzer 2.2. Product Specifications Model 300 HFID/MHFID ANALYSIS METHOD: Flame Ionization AIR REQUIREMENTS: Less than 1 ppm THC. Detector (FID) See Individual Sheet for Specific Flow Rates TOTAL RANGES: 0-3, 10, 30, 100, 300, 1,000, DISPLAY: 3½...

  • Page 12: Installation

    General The design of the instrument is for industrial applications. These installation instructions are for a typical site. Direct any questions regarding specific installation situations to Technical Service of California Analytical Instruments, Inc. 3.2. Site and Mounting NOTE: Observe the following precautions carefully: 1) Select a site free from direct sunlight, radiation from a high temperature surface, or abrupt temperature variations.

  • Page 13: Remote Range Operation

    Section 3 Model 300 HFID/MHFID Analyzer CAUTION: Electromagnetic interference (EMI) may affect the operation of the instrument. Do not install the instrument near electrical noise (such as high frequency furnaces, electric welding machines, etc.). A separate power line must be used If the instrument must be installed at such locations.

  • Page 14: Sampling System

    Section 3 Model 300 HFID/MHFID Analyzer 3.5. Sampling System The analyzer's sampling system consists of: 1) An internally mounted in line particulate filter 2) An internally mounted in line particulate filter 3) A sample pump and flow meter (optional) 4) A sample capillary that controls the sample flow rate to the sensor at 0.5 LPM.

  • Page 15: Sampling Requirements

    , HCI, etc. present in the sample gas will shorten the useful service life of the instrument. 2) Gas Temperature • The Model 300 HFID/MHFID is factory set at 190º C unless specified at other temperatures. 3.9. Pressure and Flow Rate An internal pressure regulator controls the burner air entering the instrument.

  • Page 16: Description And Function Components

    DESCRIPTION AND FUNCTION COMPONENTS 4.1. Model 300 HFID/MHFID Analyzer Front Panel Figure 4-1 Model 300 HFID/MHFID Analyzer Front Panel with CH Cutter 1) Digital Indicator (3 1/2 Digits): Displays analyzer output. 2) Digital Indicator (3 1/2 Digits): Displays diagnostic functions.

  • Page 17: Model 300 Hfid/Mhfid Analyzer Rear Panel

    Model 300 HFID/MHFID Analyzer 4.2. Model 300 HFID/MHFID Analyzer Rear Panel Figure 4-2 Model 300 HFID/MHFID Analyzer Rear Panel 1) Sample Gas Inlet: Feeds sample gas to the analyzer. Threaded ¼ Inch Tube. Fitting also contains a heated filter. 2) Sample Gas By-Pass Outlet (Vent): Exhaust for sample. Threaded ¼ Inch Tube.

  • Page 18: Table 4-1 Connector For External Wiring

    Section 4 Model 300 HFID/MHFID Analyzer Table 4-1 Connector for External Wiring 1. V Out Common 9. Zero Select 17. R1 ID/Control 25. Remote Range Control 10. Span Select 18. R2 ID/Control 26. Remote Range Common 3. 0- 10 VDC 11.

  • Page 19: Major Internal Components

    Major Internal Components 5.1. Model 300 HFID/MHFID Interior Layout Figure 5-1 Model 300 HFID/MHFID Interior Layout 1) Mother Board: Includes components for all power supplies and connector for the individual plug in boards. See Figure 6 for board locations. 2) Power Transformer: Converts line voltage to several lower AC voltages and delivered to the main circuit board.
  • Page 20 Section 5 Model 300 HFID/MHFID Analyzer 10) Methane Cutter: Removes ALL THC, except Methane. 11) Heated Sample Pump/Motor: Provides sample to Burner Assembly. 12) Fuel Proportional Control Valve: Regulates Pressure to Fuel Orifice. 13) Air Pressure Regulator: Regulates Pressure to Air Orifice.

  • Page 21: Main Circuit Board

    Section 5 Model 300 HFID/MHFID Analyzer 5.2. MAIN CIRCUIT BOARD Figure 5-2 Model 300 HFID/MHFID Main Circuit Board Amplifier Board Location: J12 Diagnostic Meter Connection: J11 Ignite Board Location: J16 Diagnostic Switch Connection: J8 Diagnostic Board Location: J7 Analog Meter Connection: J15...

  • Page 22: Main Amplifier Board

    Model 300 HFID/MHFID Analyzer 5.3. MAIN AMPLIFIER BOARD NOTE: Cover removed from high impedance section. Figure 5-3 Model 300 HFID/MHFID Amplifier Board 1. Input Connection: SMA Connector Signal Attenuator Adjust: R13 2. Amplifier Gain Adjust: R40 Filter Time Constant Adjust: R44 3.

  • Page 23: Burner Assembly

    Section 5 Model 300 HFID/MHFID Analyzer 5.4. Burner Assembly Figure 5-4 Model 300 HFID/MHFID Burner Assembly 1. Fuel Inlet 5. Collector Voltage Connection 1. Air Inlet 6. Burner Output Signal Connection 2. Sample Inlet 7. Burner Exhaust 4. Thermocouple Connection 8.

  • Page 24: Automatic Ignite Board

    Section 5 Model 300 HFID/MHFID Analyzer 5.5. Automatic Ignite Board Figure 5-5 Model 300 HFID/MHFID Automatic Ignite Board 1. Glow Plug: LED 1 Fuel Low Pressure Limit Adjust Pot: R20 2. Air Solenoid ON: LED 2 Air Low Pressure Limit Adjust Pot: R22 3.

  • Page 25: Diagnostic Board

    Section 5 Model 300 HFID/MHFID Analyzer 5.6. Diagnostic Board Figure 5-6 Model 300 HFID/MHFID Output Diagnostic Circuit Board 1. Fuel Pressure Zero Pot: R9 Burner TC Zero Pot: R51 2. Fuel Pressure Span Pot: R8 Burner TC Span Pot: R22 3.

  • Page 26: Epc And Dual Temperature Control Board

    Section 5 Model 300 HFID/MHFID Analyzer 5.7. EPC and Dual Temperature Control Board Figure 5-7 Model 300 HFID/MHFID EPC and Dual Temperature Control Board 1. Sample Pressure Cal Pot: R4 Oven Heater Indicator: LED2 2. Sample Pressure Adjust Pot: R30 Pump Heater Indicator: LED1 3.

  • Page 27: Epc Hydrogen And Ch4 Cutter Control Board Components

    Section 5 Model 300 HFID/MHFID Analyzer 5.8. EPC Hydrogen and Ch4 Cutter Control Board Components Figure 5-8 Model 300 HFID/MHFID EPC Hydrogen and CH4 Cutter Control Circuit Board Hydrogen Pressure Cal Pot: R4 Amplifier Offset Adjust: R45 Hydrogen Pressure Ignition Pot: R15...

  • Page 28: Valve Driver Board

    Section 5 Model 300 HFID/MHFID Analyzer 5.9. Valve Driver Board Figure 5-9 Model 300 Valve Driver Board Fuel Solenoid Connection: J1 Spare: J7 Burner Air Solenoid Connection: J2 AC Power Connection: J8 Zero Air Solenoid Connection: J3 Pump Heater Connection: J9...

  • Page 29: Operation

    Section 6 Model 300 HFID/MHFID Analyzer Operation 1) Check that the external plumbing and wiring are connected correctly, as described in Section III of this manual. 2) Power On: Turn ON the power switch on the rear panel. The digital panel meters should illuminate.
  • Page 30 Section 6 Model 300 HFID/MHFID Analyzer 7) Zero Adjustment: a) After the one-hour warm-up period, flow zero gas through the instrument sample or zero inlet. b) Adjust the zero control on the front panel until the digital panel meter or recorder reading reads exactly zero.

  • Page 31: Start-Up Procedure

    Section 6 Model 300 HFID/MHFID Analyzer 6.1. Start-Up Procedure 1) Sampling System: Prepare and check the sample system. a) Check the sample pressure and by-pass flow and verify agreement with the factory QA Checkout sheet, (+/- 1.0 PSIG). b) Failure to meet the sample pressure may be due to a dirty filter. See Page 29 for replacement procedure.

  • Page 32: Functional Description

    7.1. Operating Principle The California Analytical Model 300 HFID Heated Total Hydrocarbon Analyzer uses the flame ionization detection-method of determination of total carbon (C) in a sample gas. The detector is a burner in which a regulated flow of sample gas passes through a flame...

  • Page 33: Flow System

    Section 7 Model 300 HFID/MHFID Analyzer 7.4. Flow System The basic function is to deliver highly regulated flows of sample, fuel, and air to the burner assembly. The air pressure regulator delivers the appropriate pressure to critical flow capillary. The control of the fuel is via a precision, electronically controlled proportional flow controller through a critical capillary.

  • Page 34: Electronics

    Section 8 Model 300 HFID/MHFID Analyzer ELECTRONICS 8.1. Main Circuit Board The main circuit board contains the instrument power supplies and edge connectors for the required control boards. A single transformer is used to allow operation form 110/220 VAC at 50/60 Hz. Change a small circuit board from the back panel of the instrument to convert from 110 to 220 VAC.

  • Page 35: Epc Hydrogen/Cutter Temperature Control Board

    Section 8 Model 300 HFID/MHFID Analyzer 8.6. EPC Hydrogen/Cutter Temperature Control Board This board, when fully populated, contains the circuitry required to temperature control the THC cutter, control the hydrogen solenoid, and provide pressure control for the hydrogen electronic control valve. To assure proper cutter operation, a small amount of burner fuel is introduced to the cutter and the solenoid is activated only when proper temperature and pressures are satisfied.

  • Page 36: General Information-Troubleshooting-Disassembly Procedures

    Section 9 Model 300 HFID/MHFID Analyzer GENERAL INFORMATION-TROUBLESHOOTING-DISASSEMBLY PROCEDURES 9.1. Oven Burner Assembly Filter Unit/Filter Removal 1) Shut off ALL gas flow. CAUTION: Burner may be hot if recently operational. 2) Remove power from the instrument. 3) Remove the sample line.

  • Page 37: Flow System/Fuel And Burner Air Supply

    Section 9 Model 300 HFID/MHFID Analyzer 9.4. Flow System/Fuel and Burner Air Supply. Capillary protection micro-screen metal filters are contained in the respective solenoid output fittings. If difficulty occurs during the lighting sequence, TEMPORARILY remove these filters when proceeding with diagnostic activity. It is necessary to replace contaminated filters.

  • Page 38: Troubleshooting Guide

    Section 10 Model 300 HFID/MHFID Analyzer TROUBLESHOOTING GUIDE SYMPTOM CAUSE REMEDY Downscale Electrical leakage in burner. Check Burner voltage. indication with flame out. Burner will not Air and/or Fuel Pressures Depress Ignite button, and with diagnostic switch ignite. improperly adjusted.

  • Page 39: Flow Diagrams And Schematics

    Section 11 Model 300 HFID/MHFID Analyzer FLOW DIAGRAMS AND SCHEMATICS Operations and Maintenance Manual 300HFID V7.0.doc 11-39...
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