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SCS Overview Manual

–

Appendix B: Troubleshooting &

Maintenance

This chapter presents recommendations and solutions to common issues

related to sample conditioning system (SCS) operation. Contact Service if your

SCS does not appear to be hampered by one of these related problems. Refer

“Service Contact”

on page B-5.

For issues related to excessive gas sampling temperatures and pressures,

electrical noise and contamination, refer to the analyzer Hardware Manual.

Tools and Supplies

Some or all of the following supplies may be needed for troubleshooting and/or

repairs.

•

Lens cleaning cloth (Cole Parmer

EW-33677-00 TEXWIPE

Alphawipe

Low-Particulate Clean Room Wipes or equivalent)

•

Reagent-grade isopropyl alcohol (ColeParmer

EW-88361-80 or

equivalent)

•

Small drop dispenser bottle (Nalgene

2414 FEP Drop Dispenser

Bottle or equivalent)

•

Hemostat (Fisherbrand™ 13-812-24 Rochester-Pean Serrated

Forceps)

•

Bulb blower or dry compressed air/nitrogen

•

Torque wrench (3/16”, 7/16” fittings)

INVISIBLE LASER RADIATION

- The

sample cell assembly contains a low-power,

10 mW MAX, CW Class 3b invisible laser with

a wavelength between 750-3000 nm. Never

open the sample cell flanges or the optical

assembly unless the power is turned off.

The optical head has a seal and “WARNING” sticker to prevent

inadvertent tampering with the device. Do not attempt to

compromise the seal of the optical head assembly. Doing so will

result in loss of device sensitivity and inaccurate measurement

data. Repairs can then only be performed by the factory and are

not covered under warranty.

Isopropyl alcohol can be hazardous. Follow all safety precautions

when in use and thoroughly wash hands prior to eating.

Summary of Contents for SpectraSensors SS2100i-1

Page 1: ...table for Zone 1 Hazardous Location 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 time without prior notice ...

Page 2: ......

Page 3: ...lator 3 2 Sample flow controller 3 2 Sample dryer 3 3 Validation systems 3 3 Sample return vent 3 3 SCS heaters 3 3 To connect electrical power to the enclosure heater 3 3 Checking the SCS Installation 3 5 To perform SCS installation checks 3 5 Starting up the SCS 3 6 To prepare for SCS startup 3 6 To start up the field pressure reducing station 3 7 To start up the sample bypass stream on process ...

Page 4: ... Recalculating the System Constant Kp 4 6 To readjust the flow to the original factory sample flow setting 4 6 To recalculate the system constant 4 7 Connecting the Validation Gas Optional 4 8 To connect the validation source 4 8 Appendix A Specifications Appendix B Troubleshooting Maintenance Tools and Supplies B 1 To confirm the relief valve setting B 2 To replace the membrane separator B 2 To r...

Page 5: ...ler connections 3 4 Figure 4 1 Schematic of permeation tube 4 3 Figure 4 2 Typical sample system for differential measurement with permeation tube validation capability 4 4 TABLES Table A 1 Sample Conditioning System SCS Specifications A 1 Table B 1 Potential Instrument Problems and Solutions B 4 ...

Page 6: ...SS2100i 1 and SS2100i 2 Analyzer iv 4900002288 rev B 1 13 21 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 7: ... a moment to familiarize yourself with this user manual by reading the Table of Contents There are a number of options and accessories available for the SCS This manual has been written to address the most common options and accessories for a variety of analyte measurements Images tables and charts have been included to provide a visual understanding of the SCS and its functions Special symbols ar...

Page 8: ... Flammable Gases used in the processing of this analyzer may be extremely flammable Any work in a hazardous area must be carefully controlled to avoid creating any possible ignition sources e g heat arcing sparking etc Toxins SpectraSensors analyzers measure a variety of gases including high level H2S Follow all safety protocols governing toxic gases and potential leaks Inhalation Inhaling toxic g...

Page 9: ...fuse closest to label PROTECTIVE EARTH GROUND Symbol indicates the connection point of the ground wire from the main power source FUNCTIONAL EARTH GROUND Symbol indicates grounding points intended primarily for troubleshooting INVISIBLE LASER RADIATION Avoid exposure to beam Class 3b Radiation Product Refer servicing to the manufacturer or qualified personnel Removing label from measurement cell o...

Page 10: ... the Endress Hauser Group in 2012 Manufacturer Address SpectraSensors Inc An Endress Hauser Company 11027 Arrow Route Rancho Cucamonga CA 91730 United States www spectrasensors com INVISIBLE LASER RADIATION The sample cell assembly contains a low power 10 mW MAX CW Class 3b invisible laser with a wavelength between 750 3000 nm Never open the sample cell flanges or the optical assembly unless the p...

Page 11: ...d associated with the product General understanding of inspection and maintenance requirements of IEC 60079 17 Familiarity with the particular techniques to be employed in the selection and installation of equipment in the standard Understanding of the additional importance of permit to work systems and safe isolation in relation to explosion protection Mitigating risks Refer to the instructions f...

Page 12: ... be performed with power engaged 1 Note any live electrical components and avoid any contact with them 2 Only use tools with a safety rating for protection against accidental contact with voltage up to 1000 V IEC 900 ASTF F1505 04 VDE 0682 201 Explosion hazard Any work in a hazardous area must be carefully controlled to avoid creating any possible ignition sources e g heat arcing sparking etc All ...

Page 13: ...nd corrected to ensure successful normal operation Typical SCS Component Overview All SpectraSensors tunable diode laser absorption spectroscopy TDLAS analyzers are designed for extractive sampling rather than in situ applications This allows for sample conditioning filtration temperature pressure and flow control to protect the optical components of the system and provides for ease of maintenance...

Page 14: ...nsors recommended sample transport tubing specifications Sample bypass flow control A sample flow control valve and flow meters are usually provided to maintain a flow of fresh sample to the SCS even during system shut down The flow control valve is typically a needle valve and should be closed very gently and carefully if used to shut off flow completely to avoid damaging the valve If the bypass ...

Page 15: ...ure 0 10 ppm H2O on page 4 1 Sample return vent Tunable diode laser absorption spectroscopy is inherently sensitive to sample pressure in the measurement cell so all SpectraSensors analyzers are calibrated for a range of sample pressures Most applications benefit from operation at low pressures instead of high pressures Sometimes the analyzer is designed to vent the sample to atmosphere or an atmo...

Page 16: ...power input Conduit seals should be used where appropriate in compliance with local regulations 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 or switch should be located in close proximity to the equipment and within easy reach of the operator An approved switch or circuit breaker ra...

Page 17: ... the flare vent is recommended SpectraSensors also recommends purging the sample transport line to confirm there is no dust particulates or liquids that were trapped during installation To perform SCS installation checks 1 If a sample probe is used with the system confirm that the sample probe is correctly installed at the process supply tap and that the sample probe isolation valve is closed 2 If...

Page 18: ...1 Confirm that all AC power switches for the analyzer and SCS are off 2 If applicable apply AC power to the electric traced sample transport tubing at the tracer control system 3 If used confirm that the sample transport line electric tracer temperature controller at the tracer control system is set to the temperature specified on the system drawings for your analyzer and that the sample supply tr...

Page 19: ...safe vent to ensure that dirt or liquids are not collected in the sample tubing 6 Reconnect the sample transport tubing and set the pressure or the regulator to the specified pressure 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 shut off v...

Page 20: ... not critical the pressure at the sample system should be within 5 PSIG of the specified supply pressure setpoint There may be a difference between the pressure readings at the sample tap and inside the SCS due to the pressure drop in the sample transport line under flowing conditions If the pressure at the SCS under flowing conditions is not sufficiently close to the specified setpoint it will be...

Page 21: ...m enclosure temperature does not exceed 65 C 4 Energize power to the analyzer controller and ignore any error messages that are seen on the display during the temperature stabilization period 5 Once the analyzer has been allowed to thermally stabilize be sure to enable Peak Tracking and any other software features as directed in the Firmware Operator s Manual Allow the system a minimum of 5 8 hour...

Page 22: ... off valves Refer to the analyzer system drawings 3 Allow any residual gas to flow out of the measurement cells The process sample at the sample tap is at a high pressure A pressure reducing regulator is located at the sample tap to reduce the sample pressure and enable operation of the SCS at a low pressure Use extreme caution when operating the sample probe isolation valve and field pressure red...

Page 23: ...cer if applicable and the sample system enclosure heater 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 ...

Page 24: ...hut off valve for the relief valve vent from the field pressure regulator 7 Close the sample supply shut off valve to the SCS 8 Leave the sample bypass flow meter control valve open 9 Close the low pressure flare or atmospheric vent header shut off valve for the effluent from the sample bypass 10 Turn off power to the analyzer The process sample at the sample tap may be at a high pressure A pressu...

Page 25: ...for long term shutdown or contact Service refer to Service Contact on page B 5 It is recommended to also disconnect the power completely from the analyzer to prevent potential damage from lightning strikes To purge the analyzer for shipment relocation 1 Refer to the procedure To isolate the process sample tap for long term shutdown on page 3 12 2 Disconnect the sample tubing at the inlet to the an...

Page 26: ... so that maintenance may be performed on a scheduled basis in order to prevent a failure that could take the system out of operation The SCS is designed for convenient removal and replacement of component parts Complete spare components should always be available In general if a problem or failure occurs the complete part should be removed and replaced to limit system down time Some components may...

Page 27: ...adings with the past readings to determine any variations Reading levels should remain consistent 5 If reading levels decrease check the filters To check the filter 1 Shut down the system following the procedure in Shutting Down the SCS on page 3 10 2 Inspect repair or replace the filter as required Refer to To replace the filter on page B 3 if required 3 Restart the system The system must be take...

Page 28: ...SS2100i 1 and SS2100i 2 Analyzer 3 16 4900002288 rev B 1 13 21 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 29: ...n be diluted using precision flow controllers to produce the desired concentration of trace moisture in the actual sample gas Permeation Validation for Trace Moisture 0 10 ppm H2O The concentration measured during calibration Cp is related to the certified permeation rate of the device Rp by a system constant Kp using the equation Kp Cp Rp This equation requires that the following conditions be me...

Page 30: ...o Figure 4 1 on page 4 3 for a schematic diagram of the permeation tube The moisture released is continuously mixed with the dry process gas at 3000 sccm during validation mode refer to settings for Mode 7 in the Firmware Operator s Manual This will result in a calibration mixture of Cp in parts per million ppm by volume as long as return pressure is at atmospheric pressure Due to the required con...

Page 31: ...rection carrying the mixed gas into the sample cell The concentration of pollutant obtained in ppm by volume may be computed using the following formula where C concentration of ppm in volume F carrier gas flow rate in ML minute at 1 atm and 25 C 77 F P permeation rate of the G CAL assembly in nanograms minute at the temperature of the G CAL environment temperature The entire flow system is mainta...

Page 32: ...only when the enclosure is at the specified temperature and sample flow rate After opening the sample system enclosure door to check settings allow at least 1 to 2 hours for the temperature to re stabilize before validating Figure 4 2 Typical sample system for differential measurement with permeation tube validation capability PERMEATION DRYER TUBE SAMPLE SUPPLY SAMPLE RETURN FLOW SHOWN IN THE OFF...

Page 33: ...tream of the dryer 2 While watching the cell flow meter allow all flow to come to zero 3 Block in the sample cell vent to prevent backflow into the cell and permeation device 4 Loosen the connections on the inlet and outlet of the permeation device 5 Remove the permeation device 6 Install the new permeation device carefully tightening the connections once in place 7 From the analyzer keypad press ...

Page 34: ...y 1 to 3 should be all on during the readjustment The sample system will require 5 8 hours to stabilize the temperature of the new permeation device SpectraSensors does NOT recommend validating the analyzer during the temperature stabilization period New permeation devices may take up to 21 days to fully stabilize the validation concentration It may be necessary to increase the Validation Allowanc...

Page 35: ... sccm reading is at ml min at STP Do NOT adjust the pressure regulator or needle valve without first consulting the Service department Refer to Service Contact on page B 5 Access to this parameter is gained through the Service password only Contact Service for password information Refer to Service Contact on page B 5 DO NOT CHANGE ANY OTHER PARAMETER Doing so may cause the analyzer to stop functio...

Page 36: ...gas source will need to be connected to the SCS To connect the validation source 1 Determine appropriate tubing route from the customer supplied validation gas source to the SCS 2 Run stainless steel tubing from the validation source regulated to the specified pressure to the Validation Gas supply port a Bend tubing using industrial grade benders check tubing fit to ensure proper seating between t...

Page 37: ...ant Sensitivity None for gas phase glycol methanol amines or mercaptans Electrical SCS Heater Voltage1 1 Supply voltage not to exceed 10 of nominal Transient over voltages according to Over Voltage category II 240 VAC 10 50 or 60 Hz SCS Heater Power 200 W Physical Specifications Enclosure IP66 NEMA 4X 304 or 316L stainless steel Dimensions 2 2 Dimensions may vary Consult the system drawings for yo...

Page 38: ...SS2100i 1 and SS2100i 2 Analyzer A 2 4900002288 rev B 1 13 21 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 39: ... 80 or equivalent Small drop dispenser bottle Nalgene 2414 FEP Drop Dispenser Bottle or equivalent Hemostat Fisherbrand 13 812 24 Rochester Pean Serrated Forceps Bulb blower or dry compressed air nitrogen Torque wrench 3 16 7 16 fittings INVISIBLE LASER RADIATION The sample cell assembly contains a low power 10 mW MAX CW Class 3b invisible laser with a wavelength between 750 3000 nm Never open the...

Page 40: ...ommends using a liquid leak detector To replace the membrane separator Use the following steps to replace a membrane separator 1 Close the sample supply valve 2 Unscrew the cap from the membrane separator If the membrane filter is dry 3 Check if there are any contaminants or discoloring of the white membrane If yes the filter should be replaced 4 Remove the O ring and replace the membrane filter 5...

Page 41: ...er cap 4 Remove the top O ring 5 Check if there are any contaminants or solid components blocking the metal filter 6 Drain any contaminants found and clean with isopropyl alcohol 7 Replace the top O ring 8 Place the filter cap back into position and tighten 9 Place the filter unit into the analyzer and tighten the base with the four screws 10 Check upstream of membrane for liquid contamination and...

Page 42: ...e filters or membrane separators Refer to To replace the membrane separator on page B 2 or To replace the filter on page B 3 Check and adjust the sample probe regulator Check for leaks Check the relief valve for proper setting Refer to To confirm the relief valve setting on page B 2 Check and clean the sample probe or the sample transport tubing Improper temperature in the SCS Check the wiring to ...

Page 43: ...information Diagnostic downloads using the procedures provided in the associated firmware manual or using AMS100 software from SpectraSensors Description of the problem or questions Access to the information above will greatly expedite our response to your Service request Disclaimers SpectraSensors accepts no responsibility for consequential damages arising from the use of this equipment Liability...

Page 44: ... writing of the defective product promptly after the discovery of the defect and within the warranty period Products may only be returned by Customer when accompanied by a return authorization reference number SRO issued by SpectraSensors Freight expenses for products returned by Customer will be prepaid by Customer SpectraSensors shall pay for shipment back to Customer for products repaired under...

Page 45: ...lcohol B 1 B 2 B 3 P Permeation Devices 4 2 Port Check gas supply 4 8 Sample supply 3 7 Power terminal box 3 4 3 5 Powering down the analyzer 3 13 Pressure regulator 3 1 3 6 3 7 3 10 3 12 S Sample bypass 3 7 3 9 3 10 3 11 3 12 Sample bypass stream Start up 3 7 Sample conditioning system SCS 3 1 Periodic maintenance 3 14 Preventative and demand maintenance 3 14 Sample probe 3 1 3 5 3 7 3 10 3 12 Se...

Page 46: ...SS2100i 1 and SS2100i 2 Analyzer Index 2 4900002288 rev B 1 13 21 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 47: ...www spectrasensors com contact 4900002288 Rev B ...

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