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48

7.5 O-rings replacement

CAUTION

C10.0076

Scalding/burns

Hot furnace / combustion tube / analyzer parts

−

Parts of the analyzer can be very hot.

•

Use heat protecting gloves.

CAUTION

•

V0062

Injuries in the form of cuts and other personal injuries

Danger from glass splitters
–

Injuries in the form of cuts can be caused by damaged sample flasks and
glass splitters.

•

Replace damaged sample flasks

•

Do not touch glass splitters with your hands

.

The O-rings are only replaced when they no longer adequately seal, due to severe damage or
aging. When removing the old O-rings, be sure that the sealing area of the fittings is not
damaged. Grooves where the old O-rings are installed must be cleaned to be completely free of
grease.
New O-rings should under no circumstances be greased before installing but only after
installation. Otherwise, the O-rings would turn with the glass tubes when trying to remove them
at a later stage.
It is recommended not to grease the upper O-ring of the moisture trap.

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Summary of Contents for CS-580A

Page 1: ...1 Manual Carbon Sulfur Analyzer CS 580A HELIOS REV0004 04 19 Translation ...

Page 2: ...2 Copyright Copyright by Eltra GmbH Retsch Allee 1 5 42781 Haan Germany ...

Page 3: ... 7 Operation Modes 26 5 8 Adjusting the gas flow 27 5 9 Temperature adjustment 28 5 10 Preheating the furnace 28 5 10 1 Configuration of preheating 28 5 10 2 BIOS configuration 29 6 Analysis 30 6 1 Working procedure 30 6 1 1 Procedure of carrying out analyses with autoloader optional 32 6 1 2 Procedure of carrying out analyses with manual loading of the sample 33 6 2 TIC determination optional 34 ...

Page 4: ...nction description 55 8 1 Measuring principle 55 8 2 Gas flow system 56 8 3 Infrared cell 59 8 4 Micro controller unit and PC Software 60 9 Ordering numbers 61 9 1 Analyszer front view 61 9 2 Rear side outside view 62 9 3 Bottom outside view 63 9 4 Left side inside view 64 9 5 Furnace side inside view 66 9 6 TIC module 67 10 Disposal 69 ...

Page 5: ... technical documentation is meant to be a tutorial and a reference The individual chapters are self contained Knowledge of the relevant chapters for the respective target groups defined according to areas is a prerequisite for the safe and correct use of the device This Operating Manual contains no repair instructions In the event of any faults or necessary repair work please contact your supplier...

Page 6: ...and corresponding content WARNING Type of danger personal injury Source of danger Possible consequences if the dangers are not observed Instructions on how the dangers are to be avoided We also use the following signal word box in the text or in the instructions on action to be taken WARNING Moderate or mild injury may result from not following these safety warnings We give you the following warni...

Page 7: ...e Source of property damage Possible consequences if the instructions are not observed Instructions on how the dangers are to be avoided We also use the following signal word in the text or in the instructions on action to be taken NOTICE ...

Page 8: ... 1 As the operating company you must ensure that the following applies to the persons working on the analyzer Operating personnel have been made aware of and have understood all safety regulations Operating personnel are familiar when starting work with all handling instructions and regulations that apply to the relevant target group for them Operating personnel have access at all times to the tec...

Page 9: ... Therefore use is permitted only in the laboratory by appropriately trained and instructed personnel All other applications are not permitted especially in the private sector 2 4 Improper use Private use is not permitted Repairs and modifications may only be carried out by Eltra GmbH or an authorized representative or by qualified service technicians 2 5 Explanation of signs and symbols Number Sym...

Page 10: ...least 10cm in order to avoid any damage during transport Especially the foam where the analyzer is put on is very important It should neither be too hard nor too soft When the foam is too soft the analyzer will practically touch the wood Fix the foam on the bottom of the wooden case by gluing The small loader with 36 trays can be packed in the wooden case together with the analyzer The bigger load...

Page 11: ...rovide an external fuse 20 ampere B type and a residual current device when connecting the mains lead to the mains in accordance with the regulations at the installation site Information about the required voltage and frequency of the device can be found on the type plate The data listed must be consistent with the existing power supply system The device may only be connected to the power supply s...

Page 12: ...evice only to mains supply matching the values on the type plate 1 Device designation 2 Serial number 3 Year of manufacture 4 Voltage definition 5 Amps 6 Power 7 Manufacturer s address 8 Item number 9 Mains frequency 10 Protection type 11 Disposal label 12 CE mark Please quote the device designation 1 the serial number 2 of the device and the item number 7 if you have any queries ...

Page 13: ... the floor and any other surface being in the near of the analyser Make sure that the surrounding space of the analyser stays clear of any flammable material Always wear suitable clothing Keep the work environment clear of all materials that could catch fire WARNING Acceleration of fire oxygen rich atmosphere High purity oxygen carrier gas increased risk of fires Since the oxygen related risks hea...

Page 14: ...rtant to install the instrument on a stable place The balance should rest on a vibration free support Loader dimensions Version 36p 500x250x460mm Version 130p 900x500x460 Gas connections The supplied tubes carry a connector with G inner diameter Connections for compressed air The tubes supplied together with the analyzer carry a connector with G inner diameter ...

Page 15: ...mer samples this might lead to toxic fumes Personal health issues may arise Depending on the customer samples it is highly advisable to connect the system exhaust port to a lab ventilation system The connection to the exhaust system with and without connected hose is on top of the analyzer ...

Page 16: ...ep the work environment clear of all materials that could catch fire Do not store any items on top of the analyzer DANGER D2 0005 Mortal danger from electric shock Exposed power contacts High Voltage An electric shock can cause injuries in the form of burns and cardiac arrhythmia respiratory arrest or cardiac arrest Set the mains switch of the analyser to position 0 and pull the mains plug of the ...

Page 17: ...ir conditioned although it is best if the room temperature remains between 18 C and 30 C NOTICE Under no conditions the device should be placed in direct sunshine Avoid places exposed to the wind of air conditioners or to the wind blowing through open windows or doors ...

Page 18: ...e damaged Wear protective gloves and safety glasses when installing removing the reagent tubes 0 1 2 3 C S Analyser Auto sampler Air Power Inlet Gas P r e c l e a n i n g Carrier M o i s t u r e t r a p HELIOS 8 0 2 0 1 2 0 A i r 2 0 C 1 0 1 3 2 5 P a l h 2 0 0 5 0 3 0 0 A i r 2 0 C 1 0 1 3 2 5 P a l h 2 0 0 1 0 0 5 0 3 0 0 A i r 2 0 C 1 0 1 3 2 5 P a l h Inlet Lance 1 0 0 4 0 F i l t e r 1 2 3 4 ...

Page 19: ...on 3 Mains power switch 4 Compressed air gauge 5 Oxygen pressure gauge 6 Furnace inlet flow adjustment 8 Furnace inlet flow meter 9 Carrier gas flow meter 10 Lance flow meter 11 Lance flow adjustment 12 Furnace low inlet 13 Dust filter cartridge ...

Page 20: ...lame retardant environment Pay special attention to the table the floor and any other surface being in the near of the analyzer Always wear suitable clothing Keep the work environment clear of all materials that could catch fire Install the needed covers as given in the following chapters 5 3 1 Manual Setup If the Helios analyser was delivered without an autoloader system it is configured to be us...

Page 21: ...st or cardiac arrest Set the mains switch of the analyzer to position 0 and pull the mains plug of the mains socket DANGER D4 0005 Mortal danger from electric shock Damaged power cable An electric shock can cause injuries in the form of burns and cardiac arrhythmia respiratory arrest or cardiac arrest Never use a damaged power cable to connect the device to the main Check the power cable and the p...

Page 22: ... the balance 5 should be connected to the quad mains power socket 6 as shown in the figure Remark Before placing balance PC display and printer on the desk for connecting their power cables the loader should be attached to the analyzer and aligned Please refer to LOADER installation service and operation manual for the instructions on installation connection and alignment of the loader 35434 1 2 2...

Page 23: ...ply The supplied additional devices have been already adapted to the interfaces when the analyzers are taken into operation in our company The plugs are all different from each other so that they cannot be interchanged The computer is already provided with operation system and with software for controlling the analyzer Please note As the balance transfers the weight to the PC its serial interface ...

Page 24: ...to the exhaust system The analyzer requires two gas connections oxygen and compressed air The necessary tubes for connecting the analyser to the oxygen and compressed air supplies are shipped with the analyzer Lay these hoses at least 5cm above the table surface Tube 1 connects the oxygen supply to the analyzer on the fitting of a pressure regulator This connection must be very secure considering ...

Page 25: ...ugh a connector with the compressor or compressed air supply For connecting the tube simply push it into the connector This connection must be also very secure considering that the pressure in the compressed air is 4 to 6 bar 60 to 90 psi 2 ...

Page 26: ... pump is enabled so that air and any moisture which has entered the gas flow system can be purged by the oxygen flow Keep it there for about 10 15 minutes before starting the first analysis To save time the purging can be started before the set temperature has been reached The slight influence of the oxygen flow on the temperature of the infrared cell is compensated At short working breaks like lu...

Page 27: ... meter 10 Lance flow meter 11 Lance flow adjustment 12 Furnace low inlet 13 Dust filter cartridge 0 1 2 3 C S Analyser Auto sampler Air Power Inlet Gas P r e c l e a n i n g Carrier M o i s t u r e t r a p HELIOS 8 0 2 0 1 2 0 A i r 2 0 C 1 0 1 3 2 5 P a l h 2 0 0 5 0 3 0 0 A i r 2 0 C 1 0 1 3 2 5 P a l h 2 0 0 1 0 0 5 0 3 0 0 A i r 2 0 C 1 0 1 3 2 5 P a l h Inlet Lance 1 0 0 4 0 F i l t e r 1 2 3...

Page 28: ...eeded During heating up to the set temperature the ceramic combustion tube is under high thermic stress This stress is increased with increasing speed of the heating up process For maximum service life of the combustion tube the furnace can be heated up slowly with a heating rate of 10 C min In order to avoid long waiting time until the furnace heats up the heating up of the furnace can be started...

Page 29: ...bles the start of the UNI software with every start of the PC The shortcut is deleted automatically when the preheating is deactivated 5 10 2 BIOS configuration In order to start the preheating before the work begins the BIOS has to be configured to start the PC automatically at the selected time The preheating starts automatically by starting the UNI software 1 Switch on your PC and enter the BIO...

Page 30: ...sk emanating from a sample during the analysis The analyser must be connected to an exhaust system The exhaust system must be in operation WARNING W4 0021 Fire hazard Risk of burns Hot parts crucibles reagents can fall down Ignition of tables floors or any other surface the hot part falls on Ignition of clothes and any other material Set up the analyser in a flame retardant environment Pay special...

Page 31: ...le accelerators and the sensitivity of the infrared cells will all be different The user of the device can receive from us free advice regarding the different methods involved for different materials In the following the procedures are described for the analysis of coal samples Before starting making analyses ensure the following The temperature of the analyzer is stable at least one to two hours ...

Page 32: ...sponding input field of the Analysis control window of the software This step is optional If no sample ID is required the entry may be omitted 6 Press the F7 Add button in the Loader window The sample weight and sample ID are transferred to the loader stack and memorized there 7 Take the crucible from the balance and put it on the loader on the first tray before the pick up position 8 Mark the F8 ...

Page 33: ... sample into the crucible Press the F4 Balance button in the Analysis control window of the software F4 on the PC keyboard to transfer the weight value from the balance to the PC The transfer function is performed regardless of how often the button is pressed This enables a correction of any falsely entered weight Enter the sample ID into the corresponding input field of the Analysis control windo...

Page 34: ...bustion tube analyzer parts Parts of the analyzer can be very hot Use heat protecting gloves 6 2 1 TIC module Due to the modular design of the CS 580 Helios the analyzer can be upgraded by a module for Total Inorganic Carbon TIC without further modification For the TIC determination the sample is treated with acid in the TIC module 6 2 2 TIC analysis The sample is treated with acid in an Erlenmeye...

Page 35: ...odule 2 CO2 outlet 3 Glass distributor 4 Connection to the furnace 5 Acid supply 6 50 ml glass flask 7 Heater with magnetic stirrer 8 Elevator with variable height 9 Glass flask with acid 10 TIC TC toggle switch ...

Page 36: ...and finally to the inlet 1 of the TIC module 5 Inside the TIC module this tube is connected to the input of the glass distributor 3 connection on top tube 4 6 The bottle of acid with dispenser 9 is placed to the right of the platform 8 and it is connected to the connection 5 of the glass distributor 7 The glass distributor 3 with the glass flask 6 is adjusted properly when the whole surface of the...

Page 37: ...d the analysis will be terminated 10 switch to TC mode with the TIC TC toggle 13 NOTICE The rotary speed of the stirrer should be kept low The rotary speed and the acid dosing should be done in a way to avoid sample particles being pushed up and stick on the inner glass surface The heater must be switched on Do not allow boiling or evaporation of the solution in the flask The table below shows app...

Page 38: ...t system must be in operation This chapter describes the operation modes for analysis of different sample materials For further materials contact the manufacturer NOTICE The maximum weights of the samples should not be exceeded 6 3 1 Coal Temperature 1350 C Weight 300mg 500mg Depending on the sensitivity of the IR cell and on the C and S content of the sample 6 3 2 Calcium Carbonate NOTICE Calcium...

Page 39: ...emperature 1250 C or higher Weight 300mg 6 3 5 Oil Asphalt and Rubber Temperature 1450 C Weight 80mg 100mg fuel oil and other thick oils Up to 50mg thin oil analysis 6 3 6 Wood Temperature 1300 C Weight 350mg Set the minimum analysis time to 50s Set the comparator level to 20mV ...

Page 40: ... the glass tube fill the bottom end of the tube with glass wool One should pay attention that the glass wool should be only as thick as necessary otherwise the gas flow can be choked Under no conditions should the amount of glass wool be less than that shown in the following schematics otherwise fine particles of magnesium perchlorate can pass through the glass wool layer blocking the hole of the ...

Page 41: ...41 NOTICE When replacing O rings never grease the new O rings before installation Otherwise the O rings will turn with the glass tube when trying to remove it 7 2 Cleaning ...

Page 42: ...ot touch glass splitters with your hands CAUTION C6 0081 Danger of bursting Defective reagent tubes may cause injuries in the form of cuts and other personal injuries Before installing the new reagent tubes check if they are damaged Wear protective gloves and safety glasses when installing removing the reagent tubes A DANGER W7 0017 Danger of toxication and personal injuries Some chemicals may cau...

Page 43: ...grease The components are refitted in reverse order NOTICE The dimensions for filling the glass tubes should be respected in all cases to secure proper analyzing and to avoid any damages of the device see chapter filling quantities When there is not enough glass wool in the lower end of the glass tube it is possible that dust of magnesium perchlorate can fall through and block the fitting below Th...

Page 44: ...icals may be suspended in the air and cause damage to eyes Always wear protective goggles when working with chemicals Please heed the safety data sheets for the chemicals used DANGER W8 0017 Danger of toxication and personal injuries Some chemicals may cause a fatal toxication or dangerous skin corrosion Refer to the material safety data sheet of the used substances Always wear the necessary perso...

Page 45: ...after being saturated it turns to light grey Please refer to chapter front panel illustration to identify the glass tubes on the analyzer Before filling the reagents into the glass tubes their lower end has to be stuffed using glass wool One should pay attention that the layer of glass wool should be pressed only as strongly as necessary otherwise the flow of gas could be choked Under no condition...

Page 46: ...ydroxide 90210 0 1 2 3 C S Analyser Auto sampler Air Power Inlet Gas P r e c l e a n i n g Carrier M o i s t u r e t r a p HELIOS 8 0 2 0 1 2 0 A i r 2 0 C 1 0 1 3 2 5 P a l h 2 0 0 5 0 3 0 0 A i r 2 0 C 1 0 1 3 2 5 P a l h 2 0 0 1 0 0 5 0 3 0 0 A i r 2 0 C 1 0 1 3 2 5 P a l h Inlet Lance 1 0 0 4 0 F i l t e r 35 15 65 4 2 1 20 90 25 90 25 1 5 1 2 1 ...

Page 47: ... part 2 2 Lift the glass tube 5 upwards tilt it to the side and pull downwards 3 Replace the magnesium perchlorate Anhydrone See chapter reagent tube replacing 4 Install the glass tube 5 in reverse order after greasing the lower O ring 5 Turn both screws 1 clockwise until the O ring 4 is properly pressed on the inner surface of the glass tube 5 Remark The O ring imprint on the whole circle length ...

Page 48: ... not touch glass splitters with your hands The O rings are only replaced when they no longer adequately seal due to severe damage or aging When removing the old O rings be sure that the sealing area of the fittings is not damaged Grooves where the old O rings are installed must be cleaned to be completely free of grease New O rings should under no circumstances be greased before installing but onl...

Page 49: ...stics The filtering material of a new cartridge is white Replace the dust filter cartridge when the filtering material shows coloration or at least every 500 analysis 1 Lift the dust filter cartridge 1 upwards 2 Tilt its low end to the front and pull downwards 3 Install a new cartridge by acting in reverse order Take care for the cartridge body to have the smaller diameter up and the bigger down 1...

Page 50: ...ries in the form of burns and cardiac arrhythmia respiratory arrest or cardiac arrest Set the mains switch of the analyzer to position 0 and pull the mains plug of the mains socket CAUTION C11 0076 Scalding burns Hot furnace combustion tube analyzer parts Parts of the analyzer can be very hot Wait before start working until the analyzer is cooled down ...

Page 51: ...it carefully in different directions until it becomes free Unscrew the 4 screws 13 by holding the ring 14 to prevent the combustion tube 12 from falling down Remove the ring 14 Remove the O ring 15 If this O ring and the combustion tube remained in the furnace after lifting the assembly 6 7 take care to prevent the combustion tube from falling down out of the furnace This can be done by keeping on...

Page 52: ...alyzer parts Parts of the analyzer can be very hot Wait before start working until the analyzer is cooled down Switch off the analyzer and disconnect the power plug Remove the cover panel 1 of the cabinet Unscrew 4 screws 2 on top Remove the tubes 3 4 and 5 from the upper furnace closure assembly 6 7 Remove the 4 screws 8 which hold the assembly 6 7 on the furnace Lift the assembly 6 7 in straight...

Page 53: ...rhythmia respiratory arrest or cardiac arrest Set the mains switch of the analyzer to position 0 and pull the mains plug of the mains socket The task of inserting replacing the heating elements may only be performed by a trained electrician or Eltra service personnel A CAUTION C13 0076 Scalding burns Hot furnace combustion tube analyzer parts Parts of the analyzer can be very hot Wait before start...

Page 54: ...oose the four nuts 7 and remove the two double clamps 8 Remove the four ceramic spacers 9 Apply the panel 6 in its original place and manually fix it with two nuts 5 diagonally to prevent it from falling down Unscrew the four screws 10 and remove the panel 11 Remove the two nuts 12 Loose the four nuts 13 and remove the two double clamps 14 Pull up the four heating elements 15 Reinstall in reverse ...

Page 55: ...pical combustion temperature is 1350 C Combustion is obtained by supplying oxygen which at the same time acts as carrier gas An electronic flow controller keeps the flow quantity at a constant level of 180 l h Dust traps and a moisture absorber ensure that a dry dust free gas mixture is supplied to the infrared cells The graphical representation of the detectors signals peaks is shown on the PC s ...

Page 56: ...56 8 2 Gas flow system ...

Page 57: ...ernal oxygen supply has no influence on the accuracy of the measurements A pressure switch 4 becomes conductive at around 1 bar 15 psi This information is passed to the software which energizes the valve 5 and starts the gas pump 22 as long as the pressure is higher than 1 bar This ensures that the pump runs only when sufficient pressure of oxygen is available so that no air enters the gas flow sy...

Page 58: ...lls is shown on the upper flow meter 20 on the front side of the analyzer The displayed value must be at constant 180 l h The attenuator 21 makes the pulsing flow of the pump 22 smooth The flask 23 is a silencer for the pump exhaust ...

Page 59: ...ain narrow band infrared radiation to pass This narrow band must correspond to the IR wavelength for which the gas to be detected has its maximum absorption capability The intensity of the radiation after the filter thus corresponds to the concentration of a specific gas in the path The beam finally strikes a solid state infrared sensor giving an electrical signal corresponding to the intensity of...

Page 60: ... case the combustion takes longer the integration is prolonged Then the detector signal is compared to a comparator level The integration continues as long as the IR output signal is higher than the comparator level When it comes down below this level the integration is stopped Should the IR signal remain above the comparator level the analysis is interrupted by a set maximum time Then the integra...

Page 61: ... reagent tube holder 36710 Lower reagent tube connector 48067 Lower reagent tube connector 48069 Upper reagent tube connector 70320 O ring 72010 Pressure gauge 2 5 bar for oxygen 72020 Pressure gauge 10 bar for compressed air 78017 Mains power switch As a moisture trap instead of the narrow reagent tube 09090 further reagent tubes with a larger filling quantity for magnesium perchlorate are availa...

Page 62: ...I 1 4 15268 Pump control boart PC1 35490 Pump support 15270 Gas pump 35325 Attenuator volume 35336 Attenuator volume 35456 Blower 60234 Pneumatic valve 60522 Fitting 90 60552 Adjustable restrictor 77032 Circuit breaker 77140 Mains power filter 77145 Mains power filter 77460 Switch ...

Page 63: ...63 9 3 Bottom outside view Part Nr Description 11035 Cooling fan 11492 Oxygen pressure regulator ...

Page 64: ...Bu1 77051 35533 77052 11480 1 0 5 2 1 5 A i r 2 0 C 1 0 1 3 2 5 P a l h 15083 11490 36284 36284 26320 26320 36914 MD50 35779 78051 FD15 Digital I O Loader Power temp control Analog I O Microcontroller board UNI 2 1 Part No 18468 Regulating valve PC Pump control 24VDC 78052 16114 35779 18468 FD37 06441 ...

Page 65: ...er supply 18468 Microcontroller board UNI2 26320 Insulator 35536 2 2 way valve 24VDC 35779 Power temperature control cable 36284 Heating element connector 36798 Transformer 36904 Temperature control board TH 44 36914 Thermocouple 36915 Power temperature control board 60353 Piston sensor 77051 Thyristor block 77052 Solid state relay 78051 Pump control cable 78052 USB cable for PC interface 78072 Cu...

Page 66: ...e insulation 35462 Upper plate 35512 Ceramic plate 35540 Combustion tube 35541 Ceramic lance 35542 Pedestal 36284 Heating element connector 36289 Heating element clamp 70150 O ring 70427 O ring 70428 O ring 77501 Heating elements 4pcs 77505 Ceramic spacer 90150 Crucible ...

Page 67: ...67 9 6 TIC module 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 ...

Page 68: ...ss flask 90090 7 Heater with magnetic stirrer 71070 8 Support with variable height 38400 9 O ring 9 3 70230 10 Lower moisture trap connector 11045 11 Geared mechanism 38850 12 Glass stopper connection to the furnace 38227 13 Glass stopper connection to the acid supply 38220 14 Glass support 38340 15 Dispenser Assimat 71065 16 Acid bottle 71060 17 Bottle support 38677 ...

Page 69: ... business to business area to which this product is classified may no longer be disposed of with municipal or household waste To document this the devices are provided with the disposal label Fig 1 Disposal label Since the disposal regulations worldwide and also within the EU may differ from country to country the supplier of the device should be consulted directly in case of need This labelling o...

Page 70: ...Copyright Copyright by Eltra GmbH Retsch Allee 1 5 42781 Haan Germany ...

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