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Maintenance

CFPP Process Analyzer CFPP-4.2 03/2016

10.7.2 Measures in case of troubles

If the RCD has triggered immediately during commissioning, do the following steps:

Check whether the downstream working circuit and connected current-using
equipment are connected to earth.

Remove insulation faults or eventually available connections between neutral
conductor and the earth conductor on the load side.

If the above mentioned causes are impossible or if the RCD malfunctions replace the RCD.

A new RCD is available at BARTEC BENKE.

If the RCD is damaged it may not be repaired.

Summary of Contents for CFPP-4.2

Page 1: ...CFPP Process Analyzer CFPP 4 2 Operating Instructions 395778MDHEN A 03 2016 ...

Page 2: ...e operating instructions are subject to copyright laws This document may not be reproduced or transmitted neither whole nor in parts by any electronic mechanical or other means without prior written permission from BARTEC BENKE GmbH Nor is production of the entire instrument or individual components permissible on the basis of these operating instructions without our written approval ...

Page 3: ...rotective Equipment 18 2 8 Potential Dangers and Risks 18 2 9 In Case of an Accident or Emergency 22 3 Introduction 23 3 1 The CFPP Process Analyzer CFPP 4 2 24 3 2 Significance of the Cold Filter Plugging Point 25 3 3 Measuring Principle 25 4 Technical Data 27 5 Analyzer Description 31 5 1 Overview and Operating Elements 32 5 2 Type plates 34 5 3 Analyzer Components 35 5 3 1 Measuring unit enclos...

Page 4: ...1 Switching on the Analyzer 64 9 2 Operation 65 9 3 Switching off the Analyzer 65 9 3 1 Switching off in Normal Operation 65 9 3 2 Switching off in an Emergency 66 10 Maintenance 67 10 1 Safety during Maintenance 68 10 1 1 Qualification of Personnel 68 10 2 Measures after Maintenance 69 10 3 Maintenance and Inspection Plan 69 10 4 Checking the Protective Devices 70 10 5 General Visual Inspection 7...

Page 5: ...quid Level in the Sample Container 89 10 14 2 Adjusting the Liquid Level in the Sample Container 93 10 15 Reinstalling the Measuring Cell 94 10 16 Remove the cover of the measuring cell housing 97 10 17 Install the cover on the measuring cell housing 99 11 Troubleshooting 101 ...

Page 6: ...IV Contents CFPP Process Analyzer CFPP 4 2 03 2016 ...

Page 7: ...General 5 03 2016 CFPP Process Analyzer CFPP 4 2 1 General ...

Page 8: ...structions in these documents particularly the safety instructions in the operating instructions for analyzer components These operating instructions do not state the duties of the operating company which are stated in the applicable laws regulations and technical standards e g organizational measures explosion protection document regular checks etc For translations of these operating instructions...

Page 9: ...Safety 7 03 2016 CFPP Process Analyzer CFPP 4 2 2 Safety ...

Page 10: ...cing 2 2 Intended Use The CFPP Process Analyzer CFPP 4 2 is designed for determining in a fully automated process the temperature limit value for the filterability of liquid petrochemical products A sample stream and a calibration stream optional can be connected to the analyzer which operates online It is intended to monitor the quality of production in the process and also the compliance with ma...

Page 11: ...ch could result in death or serious injury if the safety instructions are not observed CAUTION indicates a potentially hazardous situation which may result in minor or moderate injury if the safety instructions are not observed ATTENTION indicates that the analyzer may be damaged or may malfunction if the safety instructions are not observed The signal words DANGER WARNING and CAUTION are used wit...

Page 12: ...stances which cause the explosive atmosphere may be gas mist or vapor but not dust IIC Gases and vapors which form an explosive atmosphere are classified by their explosion characteristics in the subgroups IIA IIB or IIC In this case gases and vapors of the subgroups IIC are permitted T4 Gases and vapors which form an explosive atmosphere are classified by their ignition temperature in the tempera...

Page 13: ...sification of potentially explosive areas in divisions 1 and 2 according to the frequency in which potentially explosive atmospheres arise In division 2 hazardous concentrations of combustible gases vapors and mist do not usually occur under normal operating conditions The device may be used in such areas Group A B C D Classification of gases vapors and mists into the groups A acetylene B hydrogen...

Page 14: ...re of an explosion inside the enclosure and to prevent the transmission of the explosion to the explosive atmosphere surrounding the enclosure Increased safety e An increased safety level is achieved by additional measures This eliminates the risk of incorrectly high temperatures and the risk of sparks or electric arcs inside and on the surface of electrical components which do not constitute an i...

Page 15: ...ions by their own ignition protection class Electrical equipment inside the measuring unit enclosure and the thermostat for the optional chiller are operated out of the control box in intrinsically safe electrical circuits Note The list with explosion proof components or subassemblies used and the corresponding certificates can be found in your customer folder The risk assessment shows that no add...

Page 16: ...sed by other analyzers and no other vapors or liquids can reach the analyzer through the vent drain system vent waste gas outlet drain waste liquid outlet It is not permissible to make any technical modifications to the analyzer without written authorization from BARTEC BENKE Any unauthorized modification can impair the safety of the analyzer and lead to accidents Use only spare parts supplied by ...

Page 17: ...Upper cover of Chiller for Liquids 9 Housing and front cover of Chiller for Liquids 10 Locks of control box 11 Warning label Opening the housing 12 Door of control box 13 Rear cover of Chiller for Liquids 14 Warning label Electrical equipment lightning symbol 15 Warning label Coldness 16 Locks of measuring cell housing 17 Measuring cell housing 18 Warning label Opening the housing 19 Cover of meas...

Page 18: ...ox and the cover 19 of the measuring cell housing must be closed during normal analyzer operation and locked by means of the locks 10 and 16 Even after the power is switched off the housings may be opened only after a waiting period of 5 minutes This is necessary because there may be components under electric charge and with high temperature i e potential ignition sources The waiting period allows...

Page 19: ...trical equipment respectively units with hot surfaces The warning label 15 indicates that the measuring cell housing contains actuated units with very cold surfaces Before opening the measuring cell housing wait always for warming up of the units in the measuring cell housing You must check the protective devices at regular intervals For further information please refer to chapter 10 4 The protect...

Page 20: ...further information please refer to the safety data sheet for the respective substance 2 8 Potential Dangers and Risks The analyzer conforms to the current state of the art However there is still a remaining risk The analyzer operates with electrical power DANGER Dangerous electric current If you touch components carrying electric current the electrical power can cause serious injury or death FOR ...

Page 21: ...er wait for at least 5 minutes before you open the control box to allow hot surfaces to cool down and electric charges to decrease If you want to open an Ex housing with the power switched on Make sure that there is no explosive atmosphere If you want to open an Ex housing with the power switched on First get a hot work permit from the operating company After finishing work close and lock the Ex h...

Page 22: ... spilled chemicals Also observe other possibly hazardous substance characteristics see safety data sheet can form an explosive gas mixture if in contact with air highly flammable caustic or can cause skin irritation Analyzer components contain pressurized liquids and gases CAUTION Pressurized liquids and gases Risk of injury FOR THIS REASON Before starting work on components carrying liquid or gas...

Page 23: ...tive gloves Do not remove or put out of operation a safety device The analyzer contents components out of plastic WARNING Danger of explosions due to static discharge Cleaning plastic surfaces with a dry cloth can result in static discharge Resulting sparks can ignite potentially explosive atmospheres FOR THIS REASON Always clean plastic surfaces with a moist cloth Note Detailed information for a ...

Page 24: ...upply fuse or main switch for the analyzer Close the manual shut off valves to stop the product streams connected to the analyzer The analyzer is now switched off CAUTION Switching off the analyzer by disconnecting it from the power supply can lead to lost data FOR THIS REASON Only use this procedure to switch off the analyzer in an emergency Suitable fire extinguishing agent Fire extinguisher wit...

Page 25: ...Introduction 23 03 2016 CFPP Process Analyzer CFPP 4 2 3 Introduction ...

Page 26: ... The analyzer carries out measurements according to the standards for measuring the CFFP in the laboratory The test filter corresponds to the test filter used in laboratory analysis The measuring cell is made of transparent material and allows you to observe the analysis process directly The control unit with integrated industry standard PC provides various possibilities for communication and conf...

Page 27: ...le that is being cooled down in a defined way no longer flows through a standardized test filter In laboratory analysis the CFPP of a sample is determined according to the standards listed above The analyzer operates in accordance with these standards and carries out measurements automatically The sample is fed into a sample container and cooled down to a specific temperature It is then pulled thr...

Page 28: ...26 Introduction CFPP Process Analyzer CFPP 4 2 03 2016 ...

Page 29: ...Technical Data 27 03 2016 CFPP Process Analyzer CFPP 4 2 4 Technical Data ...

Page 30: ...54 Explosion Protection Marking II 2 G IIC T4 Gb EC Type Examination Certificate TÜV 09 ATEX 554793 Environmental conditions Ambient temperature operation 5 C 35 C storage 20 C 60 C Humidity 5 80 relative humidity non corrosive Sample Consumption approx 10 l h during purging approx 4 min 40 l h Primary pressure 1 bar 4 bar Temperature at inlet 15 C 40 C Viscosity max 50 cSt at inlet temperature Sa...

Page 31: ... VDC low 0 4 VDC reference potential 0 V ground Auxiliary power supply output 24 VDC max 0 8 A Signal outputs and inputs Analog output 1 CFPP measured value 2 Option product temperature in the measuring cell or next trigger point or temperature of the cooling bath or time between the last suction attempts Analog inputs Option 1 Cloud Point Digital outputs 1 system alarm 2 ready signal end of measu...

Page 32: ... inlets M20 M25 Weight and Dimensions Weight approx 400kg without optional equipment Dimensions B x H x T approx 1140 mm x 2030 mm x 710 mm Required space Right and left hand side approx 0 5 m free space supply air and exit air for Chiller for Liquids For option Chiller for Liquids you need free space on the left and on the right hand side according to specification Noise Emission Emission sound p...

Page 33: ...Analyzer Description 31 03 2016 CFPP Process Analyzer CFPP 4 2 5 Analyzer Description ...

Page 34: ...e plate 10 Signal junction box Ex e 11 Power supply box Ex e 12 Drain connection waste liquid outlet 13 Chiller for Liquids 14 Frame 15 Measuring cell housing Ex p 16 Measuring cell 17 Vacuum tank 18 Instrument air connection 19 Product inlet The measurement takes place inside the measuring cell 16 The Chiller for Liquids 13 combined with a heat exchanger and peltier elements in the measuring cell...

Page 35: ... unit It is required for the pressurization of the control box and the measuring cell housing The signal junction box 10 contains terminals for connecting the signal lines You operate the analyzer with the touch screen 4 and the pen 5 The overpressure control display 7 provides information on current operating states and parameter settings of the overpressure control system By means of the key swi...

Page 36: ...tion boxes Ex e Measuring cell housing Ex p Fig 5 2 Type plates examples for ATEX version and their position at the analyzer On the type plates you will find the most important information on explosion protection and safe operation of the analyzer as well as the analyzer s serial number Make sure that the type plate is always kept easily readable ...

Page 37: ...please refer to the supplied flow diagram Fig 5 3 Measuring unit enclosure open 1 Vacuum pressure gauge 2 Pressure switch for backflow detection 3 Metering valve injector 4 Pressure gauge for backflow detection 5 Pipe heater 6 Flow controller 7 Magnetic valves 8 Air service unit for injector and measuring cell 9 Air service unit for pressurized housings 10 Metering valve measuring cell 11 Vacuum i...

Page 38: ...ntroller 13 you can adjust the vacuum The vacuum pressure gauge 1 allows you to monitor the vacuum visually For the supply of the analyzer with always fresh product you can adjust a product flow through the bypass by using the flow controller 6 With metering valve 10 you can adjust a small air flow through the measuring cell Depending on the current process step the magnetic valves 7 connect the f...

Page 39: ...uring cell installed 1 Liquid sensor 2 Sample temperature sensor 3 Decondensation ring The sample temperature sensor 2 is screwed into the measuring cell body which is made of transparent plastic The liquid sensor 1 detects the sample that is sucked through the test filter Instrument air from the decondensation ring 3 prevents condensation or ice on the cold surface of the measuring cell ...

Page 40: ... communication Components for the overpressure control system of the housing I O board for processing internal and external digital and analog inputs and outputs Power supply units Transformers to adapt the power supply voltage for the analyzer Control components for the Chiller for Liquids Automatic circuit breakers motor protection switches and error relays filters and contactors Measuring trans...

Page 41: ...ry sampling point 5 Pressure gauge 2 Fine filter with bypass valves 1 Heat exchanger 8 Thermometer 13 Water separator coalescer 12 Flow meter for the water separator outlet 9 with connector for outlet Switching valve for validation product 11 with connector for validation product Flow meter for product 10 with connector for product outlet Control valve for cooling water 6 Shut off valves for cooli...

Page 42: ...ct which flows into the drain line of the analyzer for further processing The system consists mainly of a container a pump valves sensors and a separate control unit Automatic sampling The analyzer can be equipped with additional valves switches and sensors which allow automatic taking of samples The PACS process control software controls the sampling system which fills a sampling container with a...

Page 43: ...Transport Packaging and Storage 41 03 2016 CFPP Process Analyzer CFPP 4 2 6 Transport Packaging and Storage ...

Page 44: ...alyzer with tension belts to prevent it from toppling over Keep the analyzer upright while moving it Keep a safe distance If you want to move the analyzer without its packaging also note the following Only the lower frame is appropriate for lifting the analyzer To prevent the analyzer from slipping use intermediate layers of wood For moving the analyzer with a crane a ring screw is provided in the...

Page 45: ...e If it is necessary to store the system intermediately before installation the analyzer must be stored in its closed transport packaging In the storage area there must be no large temperature variations risk of condensation and no strong vibrations For details on permitted environmental conditions please refer to the chapter Technical Data 6 4 Packaging The analyzer is delivered in a packing unit...

Page 46: ...44 Transport Packaging and Storage CFPP Process Analyzer CFPP 4 2 03 2016 ...

Page 47: ...Installation and Disassembly 45 03 2016 CFPP Process Analyzer CFPP 4 2 7 Installation and Disassembly ...

Page 48: ...e even and level and capable of supporting the weight of the analyzer The analyzer building must be ventilated sufficiently and the analyzer must be well lit 7 1 2 Assembly of the Sample Conditioning System Optional Before making any pipe connections install a manual shut off valve on the product feed line into the sample conditioning system The shut off valve must be installed near the sample con...

Page 49: ...es 1 Connect the coolant lines to the connections 3 Connect the product feed line to the product inlet 2 Connect the product outlet 4 to the analyzer Connect the drain 5 to the drain The sample conditioning system is now installed and can be put into operation 7 1 3 Securing the Analyzer Adjust the analyzer vertically and horizontally and secure it to the floor with four fastening screws M 12 not ...

Page 50: ...ake sure there is sufficient ventilation Immediately clean up spilled chemicals The pipes to which the analyzer is connected contain pressurized liquids and gases CAUTION Pressurized liquids and gases Risk of injury FOR THIS REASON Before starting work on components carrying liquid or gas shut off the feed lines and ensure that they are depressurized Wear your personal protective equipment at leas...

Page 51: ...lied manufacturer s documentation Clean incoming pipes to remove any dirt particles and shavings Observe the minimum bending radius of the pipes Make the pipe connections according to the supplied layout drawing Check all connections for possible leaks The connections are now made The analyzer is now ready to be connected to the power supply 7 1 5 Electrical Connections The analyzer operates with ...

Page 52: ...he analyzer e g for signal transfer is supplied with power from the cabinet ensure that all capacities and inductivities are below the specified limits 6 Make sure that only screened cable is used for control connections Check the polarity of the signal cables To make the electrical connections proceed as follows Connect the analyzer to the local equipotential bonding using cable with at least 16 ...

Page 53: ...e it so that it cannot be switched on accidentally All work on the electrical system must be carried out by personnel qualified for electrical installation and explosion protection Do not remove or disable any protective devices Disconnect the analyzer completely from the power supply Secure to prevent the system from being switched on again Open the junction box Disconnect all cable connections a...

Page 54: ...e for the respective substances Make sure there is sufficient ventilation Immediately clean up spilled chemicals The pipes to which the analyzer is connected contain pressurized liquids and gases CAUTION Pressurized liquids and gases Risk of injury FOR THIS REASON Before starting work on components carrying liquid or gas shut off the feed lines and ensure that they are depressurized Wear your pers...

Page 55: ...Initial Operation 53 03 2016 CFPP Process Analyzer CFPP 4 2 8 Initial Operation ...

Page 56: ...nto operation and running it for approx 2 hours the following maintenance tasks must be carried out General visual inspection see chapter 10 5 Visual inspection in the measuring unit enclosure see chapter 10 6 Check liquid level in the sample container see chapter 10 14 Clean the test filter see chapter 10 13 Note If the residual current device RCD has triggered immediately during commissioning fo...

Page 57: ...tarting work read the safety instructions for example in the safety data sheet for the respective substances Wear your personal protective equipment at least wear protective goggles and protective gloves suitable for the respective substances Make sure there is sufficient ventilation Immediately clean up spilled chemicals The pipe that will be opened contains pressurized liquids CAUTION Pressurize...

Page 58: ...om the lines fully open the fastening screws Install a collecting container capacity at least 5 liters at the open end of the product feed line on the system side Carefully open the shut off valve of the product feed line and let the product drain into the collecting container Flush the product feed line with product until there are no more air bubbles Flush the product feed line for another 2 min...

Page 59: ...ed as follows Make sure that the pressure and temperature in the product feed line correspond to the specification in the layout drawing and the technical data Make sure that the product feed line is clean see chapter 8 2 Ensure that the vent drain system and the recovery system if installed are ready for operation Fig 8 2 Sample conditioning system example 1 Thermometer 2 Pressure gauge 3 Pressur...

Page 60: ...let of the water separator with the needle valve of the flow meter 5 see target value on the label If required adjust the pressure with the pressure regulator 3 Check the temperature on the thermometer 1 permitted temperature see supplied layout drawing and technical data The flow meter for the product outlet 6 can only be adjusted when the analyzer is switched on Feed in product see chapter 8 4 S...

Page 61: ...hat the product feed line is clean see chapter 8 2 Make sure that the sample conditioning system is ready for operation Ensure that the vent drain system and the recovery system if installed are ready for operation Open the shut off valve in the product feed line if it is not already open Make sure that the parameters correspond to the values specified in the supplied layout drawing and the techni...

Page 62: ...zer to the instrument air supply proceed as follows Make sure that the instrument air corresponds to the specifications see technical data Open the shut off valve of the instrument air line Open the measuring unit enclosure Fig 8 3 Open measuring unit enclosure 1 Vacuum pressure gauge 2 Pressure gauge for backflow detection 3 Air service unit for injector and measuring cell 4 Air service unit for ...

Page 63: ...abel The measuring cell and the injector for generation of the vacuum are supplied with instrument air Adjust the vacuum with the pressure controller 6 see target value on the label at the vacuum pressure gauge 1 Adjust a small air flow through the measuring cell with the metering valve 5 The air flow is important for the detection of the sample backflow The precise adjusting of the air flow you h...

Page 64: ...62 Initial Operation CFPP Process Analyzer CFPP 4 2 03 2016 ...

Page 65: ...Operation 63 03 2016 CFPP Process Analyzer CFPP 4 2 9 Operation ...

Page 66: ...ct and instrument air are adjusted correctly see chapter 8 Check the protective devices see chapter 2 5 Switch on the power using the separator for the power supply fuse or main switch for the analyzer The control box and the measuring cell housing are purged with instrument air loud noise 2 1 Fig 9 1 Overpressure control display 1 Touchscreen 2 Overpressure control display The remaining purge tim...

Page 67: ...cally with the first measurement The analyzer is now operating 9 2 Operation Generally analyzer operation is fully automated You can monitor the analysis process on the touchscreen You operate the analyzer with the pen and the touchscreen The supplied software manual describes in detail how to operate control and configure the analyzer and the analysis process 9 3 Switching off the Analyzer 9 3 1 ...

Page 68: ...the purging air supply The analyzer is now switched off 9 3 2 Switching off in an Emergency To switch off the analyzer as quickly as possible in an emergency Switch off the power using the separator for the power supply fuse or main switch for the analyzer Close the manual shut off valves to stop the product streams connected to the analyzer The analyzer is now switched off CAUTION Switching off t...

Page 69: ...Maintenance 67 03 2016 CFPP Process Analyzer CFPP 4 2 10 Maintenance ...

Page 70: ...er if unsuitable spare parts are used FOR THIS REASON Use only spare parts from BARTEC BENKE Other components may not meet the required safety standards particularly for explosion protection Warning No explosion protection due to using incorrect spare parts Some optional used spare parts are modified by BARTEC BENKE for a particular purpose The use of non modified original spare parts of the relat...

Page 71: ... overview Depending on the product quality solids and water content and on the environmental conditions during operation the actually required intervals may differ from the intervals stated below In case of malfunctions before the end of an interval shorten the intervals appropriately Document all inspections and maintenance work in suitable form Interval Inspection Maintenance daily Check the pro...

Page 72: ...ion box with cover 6 Lock for double bit key 7 Power supply box 8 Upper cover of Chiller for Liquids 9 Housing and front cover of Chiller for Liquids 10 Locks of control box 11 Warning label Opening the housing 12 Door of control box 13 Rear cover of Chiller for Liquids 14 Warning label Electrical equipment lightning symbol 15 Warning label Coldness 16 Locks of measuring cell housing 17 Measuring ...

Page 73: ...ent easily readable Control box 4 undamaged also visible outer components e g touchscreen no open bore holes or mounting cut outs door 12 is closed tightly and locked with both locks 10 Measuring cell housing 17 with rinsing tube undamaged also visible outer components no open bore holes or mounting cut outs cover 19 is closed tightly and fastened with four locks 16 Power supply box 7 undamaged no...

Page 74: ...e analyzer according to the following table The visual inspection can be carried out while the analyzer is operating Checks Remedy Error messages from the PACS process software see software manual Leakages remove immediately Ice forming on measuring cell ensure instrument air supply according to specification see chapter 4 ...

Page 75: ...can be carried out while the analyzer is operating The pressure target values are stated on the respective pressure gauges Fig 10 2 Visual Inspection Inside Measuring unit enclosure 1 Vacuum pressure gauge 2 Metering valve injector 3 Pressure gauge for backflow detection 4 Flow controller 5 Air service unit for injector and measuring cell 6 Air service unit for pressurized housings 7 Metering valv...

Page 76: ...injector and measuring cell Adjust pressure at air service unit 5 Check vacuum pressure 1 Adjust vacuum at pressure controller 8 If necessary readjust the metering valve 2 Check measuring cell pressure 3 for backflow recognition during process step Instrument Testing Adjust measuring cell pressure at needle valve 7 Leakages Remove Close the measuring unit enclosure The visual inspection is finishe...

Page 77: ... ignition sources Opening the control box can cause explosion of potentially explosive atmosphere FOR THIS REASON Avoid measures see chapter 2 Safety 1 Turn the Explosion protection key switch to the Off position 2 Open the control box 3 Activate the test button T once every six month at least if no other regional or application specific additional tests are specified The RCD must trigger 10 7 1 M...

Page 78: ...e downstream working circuit and connected current using equipment are connected to earth 2 Remove insulation faults or eventually available connections between neutral conductor and the earth conductor on the load side If the above mentioned causes are impossible or if the RCD malfunctions replace the RCD A new RCD is available at BARTEC BENKE If the RCD is damaged it may not be repaired ...

Page 79: ...is process must be running Note For a detailed description of the analysis process please refer to the software manual Wait for the process step Instrument Testing Observe the sample rising in the measuring cell 2 and check for visible dirt particles If dirt particles are visible clean the test filter see chapter 10 13 Wait for the process step Hot Flushing Watch the upper part of the measuring ce...

Page 80: ...oth to avoid static electricity discharge and sparks Do not clean the touchscreen with aggressive solvents or abrasives not with pressurized air or steam The touchscreen is a part of the control box with a protective function therefore it must not be damaged To clean the touchscreen proceed as follows Switch off the analyzer see chapter 9 3 This prevents you from operating the software accidentall...

Page 81: ...potentially explosive atmosphere Dismounting and installing the battery can cause sparks They can ignite potentially explosive atmosphere FOR THIS REASON Make sure that during all operations for changing the battery no potentially explosive atmosphere is present For changing the battery you must open the control box For it switch off the analyzer see page 65 Make sure that the power supply is swit...

Page 82: ...tteries can damage the box PC FOR THIS REASON For replacement use only batteries from BARTEC BENKE Note Information for changing the battery you find in the provided manual for the box PC Change the battery of the box PC Close the control box Switch on the analyzer see page 64 ...

Page 83: ...o this click Safe State in the PACS main window see software manual Product and instrument air can feed into the analyzer furthermore Product flowing through the analyzer is going on The vacuum injector is operated with instrument air With it a low pressure in the vacuum tank is produced continuously furthermore Emptying vacuum tank Fig 10 4 Vacuum tank with drain 1 Vacuum tank 2 Blind cap on drai...

Page 84: ...oduct by using the drain bottle Wait until no product is flowing The vacuum tank is emptied Note Only in the case of a fault a bigger amount of product accumulate in the vacuum tank The fault must be solved as soon as possible Contact for it BARTEC BENKE Close the drain professionally with the blind cape 2 Dispose the collected product professionally Make sure that the pressure in the vacuum tank ...

Page 85: ... 5 Measuring cell 1 Plug nipple for black pipe 2 Plug nipple for red pipe 3 Plug nipple for green pipe 4 Connectors for the temperature sensors 5 Connectors for the liquid sensor 6 Screws decondensation ring 7 Quick release coupling of the red pipe 8 Quick release coupling of the green pipe 9 Fixing screw 10 Union nut sample temperature sensor 11 Decondensation ring 12 Drain pipe Pull off the conn...

Page 86: ...otective equipment at least wear protective goggles and protective gloves suitable for the respective substances Make sure there is sufficient ventilation Immediately clean up spilled chemicals Note In order to remove the cover of the measuring cell housing it is not necessary to dismount the temperature sensors To protect the delicate temperature sensors please do not loose the screw connections ...

Page 87: ...mediately push them onto the two remaining plug nipples 3 2 on the underside of the measuring unit enclosure Pull off the quick release coupling of the drain pipe 12 and push the drain pipe slightly to the side Remove any leaked product Disconnect the holder of the decondensation ring from the frame by loosing the two screws 6 Remove the decondensation ring 11 Unscrew and remove the fixing screws ...

Page 88: ...measuring cell The measuring cell has now been removed Now you can clean the test filter or you can check the liquid level in the sample container see chapter 10 14 10 13 Cleaning the Test Filter If you have detected dirt particles while checking the test filter see chapter 10 8 you can now clean the test filter as follows Remove the measuring cell see chapter 10 10 Fig 10 7 Measuring cell Wait un...

Page 89: ...ple in the safety data sheet for the respective substances Wear your personal protective equipment at least wear protective goggles and protective gloves suitable for the respective substances Make sure there is sufficient ventilation Immediately clean up spilled chemicals Open the measuring unit enclosure Fig 10 8 Disassembling the sample container 4 Glass body 5 Red plastic ring Holding the meas...

Page 90: ...st filter 7 Filter assembly 8 Cylinder Remove the test filter while holding the filter assembly with one hand by its knurled part 7 Unscrew the cylinder 8 with the other hand Fig 10 10 Test filter 9 Test filter Remove the test filter 9 Clean the test filter and the sample container with a suitable detergent or solvent Disassembly and cleaning are now finished You can now reassemble the test filter...

Page 91: ...10 of the sample container To mount the sample container hold the red plastic ring 5 not the glass body 4 Reinstall the measuring cell see chapter 10 15 The test filter is now ready for operation You can now switch the analyzer back on see chapter 9 1 10 14 Checking Liquid Level in the Sample Container Note You can combine this task with the task Cleaning the Test Filter see chapter 10 13 10 14 1 ...

Page 92: ...ell upright so that no sample is spilled WARNING Hazardous substances product detergents or solvents and their vapors Serious injury or death can result from swallowing breathing in or skin contact with harmful substances FOR THIS REASON Before starting work read the safety instructions for example in the safety data sheet for the respective substances Wear your personal protective equipment at le...

Page 93: ...Process Analyzer CFPP 4 2 Fig 10 13 Disassembling the sample container 4 Glass body 5 Red plastic ring Holding the measuring cell upright remove the sample container To do this hold the red plastic ring 5 not the glass body 4 4 5 ...

Page 94: ... a note of it then adjust the liquid level see chapter 10 14 2 Empty the sample container and clean it The measuring cell can now be reassembled and reinstalled Check all O rings If there are signs of damage replace the O ring Fig 10 15 O ring sample container 10 O ring of the sample container 5 Red plastic ring Apply a small amount of mounting paste to the O ring 10 of the sample container To mou...

Page 95: ...You can now switch the analyzer back on see chapter 9 1 10 14 2 Adjusting the Liquid Level in the Sample Container To adjust the liquid level proceed as follows Fig 10 16 Lock nut of the outlet pipe 1 Outlet pipe 2 Lock nut Loosen the lock nut 2 of the outlet pipe 1 with needle nosed pliers while holding the outlet pipe to keep it in position 1 2 ...

Page 96: ... 1 further out one turn corresponds to 1 25 mm Secure the outlet pipe with the lock nut while holding it in position By the same procedure adjust the bypass pipe 3 so that the distance from the outlet pipe is about 15 mm The liquid level is adjusted 10 15 Reinstalling the Measuring Cell CAUTION The transparent plastic of the measuring cell is not alcohol resistant it will be damaged by contact wit...

Page 97: ... black pipe 2 Plug nipple for red pipe 3 Plug nipple for green pipe 4 Connectors for the temperature sensors 5 Connectors for the liquid sensor 6 Screws decondensation ring 7 Quick release coupling of the red pipe 8 Quick release coupling of the green pipe 9 Fixing screw 10 Union nut sample temperature sensor 11 Decondensation ring 12 Drain pipe The correct mounting position can be checked by the ...

Page 98: ...not been loosed CAUTION The tips of the temperature sensors particularly the sample temperature sensor glass tip are very fragile and can bend or break if handled carelessly FOR THIS REASON Handle temperature sensors with great care Do not exchange temperature sensors Carefully slide the sample temperature sensor with glass tip into the screw connector Fig 10 19 Tightening screw connections Slight...

Page 99: ...d by a cover 3 At the bottom side of the cover a heat exchanger with peltier elements is located for the cooling of the measuring cell For changing the peltier elements you must remove the cover Fig 10 20 Measuring cell housing 1 Measuring cell 2 Screw connections of coolant lines 3 Cover 4 Locks 5 Measuring cell housing This is how to remove the cover Remove the measuring cell see page 82 To remo...

Page 100: ...ant prepare a cleaning cloth Open the screw connections Close the coolant lines with the blind plugs Open the four locks 4 of the measuring cell housing Note At the bottom side of the cover are located the heat exchanger with peltier elements and other electrical components The cover is connected to the measuring cell housing with a connecting cable via a plug connection at the bottom of the measu...

Page 101: ...e connector at the bottom of the measuring cell housing 5 Position the cover on the measuring cell housing Fix the cover on the measuring cell housing using the four locks 4 CAUTION Very cold components and coolant Risk of skin damage on direct contact FOR THIS REASON Wear protective gloves and protective goggles Close the screw connections 2 of the coolant lines To this remove the blind plugs Rei...

Page 102: ...100 Maintenance CFPP Process Analyzer CFPP 4 2 03 2016 ...

Page 103: ...Troubleshooting 101 03 2016 CFPP Process Analyzer CFPP 4 2 11 Troubleshooting ...

Page 104: ...er supply Fusing of overpressure control system is faulty Remove the cause of the malfunction Analyzer is switched off does not start a Display of overpressure control is present Overpressure control system has switched off the analyzer cannot start the analyzer Please refer to operating manual of the overpressure control system Internal fuses are faulty blown Remove the cause of the malfunction P...

Page 105: ... 5 3 adjust the vacuum by using the pressure controller if required A valve is out of order Replace the respective valve Drain and or vent is blocked Remove the cause of the malfunction A configured alarm has occurred Please refer to the software manual Liquid level in the sample container is incorrect Check liquid level see chapter 10 14 No heating of the heater Fuse or residual current circuit b...

Page 106: ... housing see chapter 10 16 A new completely converted cover with heat exchanger and peltier elements you obtain from BARTEC BENKE Fuse or residual current circuit breaker has blown Find and remove the cause of the malfunction Thermal fuse of peltier elements has blown Find and remove the cause of the malfunction Temperature of coolant is not deep enough Please refer to the manual Chiller for Liqui...

Page 107: ...Troubleshooting 105 03 2016 CFPP Process Analyzer CFPP 4 2 ...

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