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R6000S Operation Manual: Rev. G

Page 25 of 92

LOCK-OUT/TAG-OUT PROCEDURES

Follow all of your company’s lock-out/tag-out procedures at all times. Exercise caution at all times.

ACRONYMS

Acronym

Definition

ºC

Degrees Celsius

Cal

Calibration

CIF

Customer Interface

Cont.

Controller

Det

Detector

Det

Detector

Control Unit

EMI

Electromagnetic Interference

Furn.

Furnace

Gnd.

Ground

High-Voltage

HVPS

High-Voltage Power Supply

Identity -- Identification

Inst.

Instrument

JP(n)

Jumper connector on a printed circuit board

LCV

Leakage compensation valve

LED

Light emitting diode

Milliamperes

NEC

National Electrical Code

P/N

Part Number

P/S

Power Supply

PAC (L.P.)

Petroleum Analyzer Company

PAC IRIS

PAC Data System software for instrument

control and data management

PCB

Printed Circuit Board

Summary of Contents for R6000S

Page 1: ...R6000S Operation Manual Revision G www paclp com...

Page 2: ...ing the warranty of merchantability or fitness for a particular purpose At any time PAC may modify these materials its instruments or its programs without notice and subsequent versions of these mater...

Page 3: ...any means including electronic storage and retrieval or translation into a foreign language without prior agreement and written consent from the copyright owner All rights reserved The instructions g...

Page 5: ...Notices Cautions Warnings environmental information and other basic information Chapter 1 Introduction A general introduction to the R6000S detailing the basic theory of operation Chapter 2 Installati...

Page 7: ...ion 39 3 CHAPTER THREE OPERATION 43 3 1 Initial Startup Procedure 43 3 2 Calibrating the Analyzer 44 3 2 1 Set Zero 44 3 2 2 Set Span 45 3 2 3 Normal Operation 45 3 2 4 Temperature Controller Settings...

Page 8: ...ual Rev G 4 5 Fluorescence Chamber Lens Cleaning Procedure 63 4 6 PMT High Voltage Adjustment 64 4 7 Troubleshooting and Service Guide 64 4 7 1 Electrical Electronic Component Replacement 65 4 7 2 Tro...

Page 9: ...is equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instruction manual may cause harmful interference to radio communications Howeve...

Page 10: ...ntract If you have a separate agreement with your producer or importer such that you will take care of end of life disposal on your own please ensure an environmentally sound disposal according to the...

Page 11: ...signed or intended for use in other EMC environments The user of this system is obliged to properly use and install the system and to take all steps necessary to remove sources of interference to tele...

Page 13: ...ersonnel immediately voids all further warranty obligations of PAC PAC genuine consumables are sold on an as is basis and have no warranty beyond being shipped in good working order 3 Limited Warranty...

Page 14: ...expressly or impliedly modify extend alter or change any of the limited warranties expressed herein to BUYER 7 Procedure and Costs All limited warranty claims must be made in writing promptly followin...

Page 15: ...s after the issuance of a return authorization number will be subject to review Products may not be returned that are contaminated by radioactive materials infectious agents or other materials constit...

Page 16: ...the recipient as follows VISIBLE LOSS OR DAMAGE Note any external evidence of loss or damage on the freight bill or express receipt and have it signed by the carrier s agent Failure to adequately des...

Page 17: ...____________ Purchase Date ______________________________________ CONTACT US If you have any questions about your product contact us using the information below PAC L P 8824 Fallbrook Drive Houston TX...

Page 18: ...Dhabi 1 281 940 1803 33 231 264 300 49 9343 6400 65 6412 0890 31 10 462 4811 7 495 617 10 86 86 10 65072236 82 2 785 3900 66 2 627 9410 971 2 446 9671 Fax USA France Germany Singapore Netherlands Russ...

Page 19: ...exander sungurov paclp com Email to Asia Sales paclp com Email to Asia Sales paclp com Email to Asia Sales paclp com Email to Sales MiddleEast paclp com Service USA France Germany Singapore Netherland...

Page 20: ...SERIOUS INJURY WILL OCCUR IF NOT AVOIDED An electrocution hazard exists because severe electrical shock hazards exist when working around the high voltage and or 115 230 VAC components while power is...

Page 21: ...away from test areas Use standard safety procedures at all times Consult material safety data sheets MSDS for product safety storage and handling information POSSIBLE EYE OR FACE INJURY HAZARD DEATH...

Page 22: ...1010 Safety Requirements for Electrical Equipment for Measurement Control and Laboratory Use It is intended for indoor use only This instruction manual contains information Warnings and Cautions that...

Page 23: ...r each PAC supplied product and also reference the corresponding vendor supplied MSDS for each sample and standard utilized with the product Proper Use and Safety The R6000S analyzer is designed to be...

Page 24: ...est when the lamp is nulled If the lamp is not correctly positioned more scattered light is produced in the fluorescence chamber Gas Quality Air and other gases supplied to the analyzer must be filter...

Page 25: ...orary window that contains options or information you can edit select or use Preventive Maintenance Maintenance performed or parts replaced on a routine basis to keep the product operating correctly a...

Page 26: ...following tools are a basic guide PERSONAL PROTECTION EQUIPMENT Consult your company s training standards for correct PPE usage The following PPE but not limited to should be used while operating or s...

Page 27: ...t Detector Det Detector CU Control Unit EMI Electromagnetic Interference Furn Furnace Gnd Ground HV High Voltage HVPS High Voltage Power Supply ID Identity Identification Inst Instrument JP n Jumper c...

Page 28: ...nds per square inch gauge R Resistor on a printed circuit board RLV Relief valve RTD Resistance temperature detector Sol Solenoid SoL Solenoid Number SSR Solid State Relay SW Switch TEC Thermoelectric...

Page 29: ...to carbon dioxide CO2 and water A membrane dryer located between the furnace and the detectors in the gas stream removes excess water The pyrolyzed and dried gas stream enters the Sulfur Fluorescence...

Page 30: ...mostly due to the aging of the UV lamp and to a lesser degree the aging of the PM tube the membrane dryer and any chemical changes that may happen to the fluorescence chamber coating due to reactions...

Page 31: ...e free for purge 80 100 psig Area Classifications Non Hazardous 1 4 Component Description Components used in the analyzers are described in the following sections 1 4 1 Controls and Indicators The fol...

Page 32: ...If R30 on the conditioning board is properly adjusted the value displayed will be equal to concentration The meter will display from 1999 to 1999 D Span Dial Used to adjust the detector s response cu...

Page 33: ...PAC L P All Rights Reserved 2015 Page 31 of 92 Detector Back View A Cover for fan filter B Terminal strip signal out C UV lamp fuse 2 amp D 115 volt fuse 3 amp E Power Input F Detector in G Detector...

Page 34: ...Furnace bypass switch E Sample regulator F Sample pressure gauge G Furnace temperature controller Sets and maintains furnace temperature H Power switch Turns ON or OFF all power used by the furnace mo...

Page 35: ...switch is in the calibrate position Zero position de energizes the solenoid valve Furnace Back View A System vent fitting B I O fuse C Sample vent fitting D Computer pin connection E Nitrogen sulfur...

Page 36: ...wed to cool below 1100 C before the alarm will unlatch and allow the furnace to heat Low Oxygen Pressure Alarm is provided when the oxygen pressure decreases below 28 psig Low Total Gas Flow Alarm is...

Page 37: ...on of the sample Zero Gas Carbon dioxide free of sulfur impurities Sample Gas The gas that is to be analyzed Sampling System Required to deliver 1000 cc min of zero span or sample gas when that stream...

Page 38: ...ly near the analyzer 2 2 1 Gas Fittings Perform the following steps to install gas fittings Figure 1 Compression Fittings 1 Insert tubing through nut 2 Slide ferrule set over tubing 3 Insert tubing wi...

Page 39: ...nstruments following figure on the back of the furnace module The inlet side of the scrubber tube is the Hopcalite black material if the scrubber tube is not marked Figure 3 Dryer In Furnace Detector...

Page 40: ...l shock and equipment damage or failure may result due to improper safety grounding Without a proper equipment ground for example a broken or faulty grounding conductor all normally grounded conductor...

Page 41: ...CUR IF NOT AVOIDED An electrocution hazard exists because severe electrical shock hazards exist when working around the high voltage and or 115 230 VAC components while power is applied HOW TO PROCEED...

Page 42: ...rnace operates at a temperature in excess of 1000 C and can serve as an ignition or burn source HOW TO PROCEED Ensure there are no explosive gases present in the working area of the furnace Ensure the...

Page 43: ...brane dryer if not already installed 10 Place the 1 4 1 8 right angle reducer with a Teflon ferrule on the 1 4 outlet tube of the pyrotube 11 Perform gas leak testing procedure POSSIBLE RELEASE OF HIG...

Page 45: ...erature controller for the detector will begin displaying 1 Displayed temperature will start decreasing to the set value of 10 C 2 If SV is not 10 C use the procedure in section 3 1 to set it to 10 C...

Page 46: ...are at the correct flow and pressure settings and that an adequate calibrating standard is available NOTE Make sure the instrument has been running for at least thirty 30 minutes after all settings h...

Page 47: ...Normally it is not necessary to reset any parameters but if it becomes necessary use the following procedure Complete details about any of these settings may be found in the temperature controller ope...

Page 48: ...Furnace Detector 2nd Block Parameter Furnace Detector 3rd Block Para meter Furnace Detector NAnu OFF OFF P 5 5 P n1 0 2 S b OFF OFF 20 240 SG L 980 980 ProG N A N A d 60 60 SG H 100 FS 100 FS LACH 0...

Page 49: ...t at the factory In the event the full scale range needs to be changed the following steps should be taken 1 Set zero span switch to SPAN a When the output has stabilized adjust span dial for an outpu...

Page 51: ...intenance Intervals Component replacement should be performed according to the following schedule Preventive Maintenance Table Routine Maintenance Performed by lab technician etc Interval Done Pyrotub...

Page 52: ...o the power source Also follow any required lock out tag out procedures your company policy requires To prevent electrical shock hazard DO NOT operate this equipment in rain or wet conditions HOT SURF...

Page 53: ...lfur detector module needs replacement 1 Turn the power switch to the OFF position and remove the power cord from the detector module ELECTROCUTION HAZARD DEATH OR SERIOUS INJURY WILL OCCUR IF NOT AVO...

Page 54: ...ved 11 Recalibrate the instrument 12 Resume normal operation 4 2 2 Photomultiplier Tube Removal and Replacement Perform the following steps to replace the sulfur or nitrogen detector PMT 1 Turn the po...

Page 55: ...HAZARD DEATH OR SERIOUS INJURY WILL OCCUR IF NOT AVOIDED An electrocution hazard exists because severe electrical shock hazards exist when working around the high voltage and or 115 230 VAC components...

Page 56: ...rd exists because severe electrical shock hazards exist when working around the high voltage and or 115 230 VAC components while power is applied HOW TO PROCEED Avoid hazard by turning off the unit wi...

Page 57: ...he new or repaired reaction chamber assembly 9 Recalibrate the instrument 10 Resume normal operation 4 2 5 UV Lamp Nulling Procedure In the event that the UV Lamp has been serviced or moved the follow...

Page 58: ...ar appropriate UV eye protection 8 Depress the Auto Zero button to bring the Level Meter to zero 9 Loosen the UV lamp housing null adjustment screw on the housing bracket 10 Slowly move the UV lamp ho...

Page 59: ...e the UV lamp housing by loosening the null adjustment screw and sliding the housing off of the slide bracket on the collimating lens assembly 5 Remove the defective UV lamp from the lamp housing by l...

Page 60: ...ED Avoid hazard by turning off the unit with the ON OFF switch and remove the power connection or power cord from the unit to the power source Also follow any required lock out tag out procedures your...

Page 61: ...rd DO NOT operate this equipment in rain or wet conditions 2 Use the Sulfur Detector Assembly Removal and Replacement procedure Section 4 2 1 to remove the detector 3 Loosen the two securing screws an...

Page 62: ...ement procedure Section 4 2 1 to remove detector 3 Loosen the two securing screws and carefully remove the aluminum heat transfer assembly and gasket from the top of the detector housing 4 Carefully l...

Page 63: ...bserve the rotometer ball a If the ball drops to zero there are no significant leaks in this section of the system Go to Step 9 b If the ball doesn t drop to zero after one to two minutes there is a l...

Page 64: ...light leak s 3 Set the detector sensitivity to X50 4 Press the Auto Zero button and allow the baseline to settle to the zero point 5 Locate the light leak s using a strong light source i e flashlight...

Page 65: ...ence filter 4 Remove the four screws securing the fluorescence lens assembly 5 After noting the location carefully remove the lens 6 Carefully clean all lenses interference filter stainless steel inse...

Page 66: ...any required lock out tag out procedures your company policy requires To prevent electrical shock hazard DO NOT operate this equipment in rain or wet conditions 5 Turn the High Voltage switch to the O...

Page 67: ...ATH OR SERIOUS INJURY WILL OCCUR IF NOT AVOIDED An electrocution hazard exists because severe electrical shock hazards exist when working around the high voltage and or 115 230 VAC components while po...

Page 68: ...ble Replace Main Power Supply or cable Defective UV Power Supply PCB Replace PCB No Power To Detector Defective detector power supply or cable Replace power supply or cable if output is not as specifi...

Page 69: ...Check output signal DCV to solid state relay Replace temperature controller as needed Over Temp Circuit is latched Remove power form Furnace Module for 10 seconds Furnace Overheating Shorted Thermoco...

Page 70: ...ce HVPS cable No High Voltage See symptom Erratic or Low Baseline following pages UV 12 VDC PS defective or output is shorted Check for shorted 12DCV output and remove short or replace supply Defectiv...

Page 71: ...t greater than 200mv or odor from Sulfur chamber Clean Fluorescent chamber and sample system No High Voltage High Voltage switch is OFF Check position of High Voltage switch Fuse is blown Check fuses...

Page 72: ...em Clean or replace Fluorescent Chamber or sample system tubes as necessary Contaminated or defective membrane dryer Replace Membrane Dryer Change in Detector Gain Reset Detector gain setting Defectiv...

Page 73: ...ine Off Scale PMT voltage too high Adjust PMT voltage Contaminated gas supply Replace gas supply Contaminated pyrotube transfer tubes or fluorescence chamber Clean or replace pyrotube transfer tubes o...

Page 74: ...d correct Unstable gas regulator Replace regulator High voltage power supply is unstable Use high voltage adjustment procedure to monitor high voltage for stability Replace if necessary Defective PMT...

Page 75: ...UV Lamp PMT Voltage Change Replace or adjust PMT Abnormal ambient temp change Stabilize ambient temperature Light leakage Use light leak test to find leaks and repair as needed Defective PMT or Coole...

Page 76: ...ut Replace UV Lamp PMT Voltage Change Replace or adjust PMT HV Abnormal ambient temp change Stabilize ambient temperature Light leakage Use light leak test to find leaks and repair as needed Defective...

Page 77: ...eak Use gas leak test to find leaks and repair as needed Detector Module Will Not Zero auto zero light lit Detector is contaminated Inspect and clean as needed Sample system is contaminated Clean samp...

Page 78: ...as needed No detector electronics response Cause a light leak in the detector to determine operation of electronics Defective Supply Check all supply outputs and replace defective supply Membrane Drye...

Page 79: ...onnect Detector Furnace B42134 R1 Component Ident Front Panel Sulfur Detector Section B42160 R3 Component Ident Base Panel Sulfur Detector Section B42165 D Component Ident Rear Panel Sulfur Detector S...

Page 81: ...PAGE 79 OF 92 INTERCONNECT DIAGRAM R6000S REF B42175 R3 TP 1 1...

Page 82: ...PAGE 80 OF 92 FLOW DIAGRAM INTERCONNECT DET FURNACE REF B42134 R1 TP 1 1...

Page 83: ...PDalbello JBE PAGE 81 OF 92 COMPONENT IDENT FRONT PANEL SULFUR DET SECTION REF B42160 R3 TP 1 1...

Page 84: ...LL DGA QM SR DA PAGE 82 OF 92 COMPONENT IDENT BASE PANEL SULFUR DETECTOR SECTION REF B42165 D TP 1 1...

Page 85: ...P Dalbello JBE PAGE 83 OF 92 COMPONENT IDENT REAR PANEL SULFUR DETECTOR SECTION REF B42166 R3 TP 1 1...

Page 86: ...MK DA QM SR PAGE 84 OF 92 ASSY SULFUR DETECTOR W COOLER REF B42025 N TP 1 1...

Page 87: ...LL DGA QM SR PAGE 85 OF 92 WIRING DIAGRAM SULFUR DETECTOR 110 120VAC REF B42146 F TP 1 1...

Page 88: ...LL QM JK PAGE 86 OF 92 WIRING DIAGRAM SULFUR DETECTOR 220 230VAC REF B42145 E TP 1 1...

Page 89: ...PDalbello JBE PAGE 87 OF 92 COMPONENT IDENT FRONT PANEL FURNACE OPTIONAL FURN BYPASS REF B42159 R4 TP 1 1...

Page 90: ...PAGE 88 OF 92 COMPONENT ASSY BASE PANEL FURNACE SECTION OPTIONAL FURNACE BYPASS REF B42161 R5 TP 1 1...

Page 91: ...PDalbello JBE PAGE 89 OF 92 COMPONENT IDENT REAR PANEL FURNACE SECTION REF B42162 R3 TP 1 1...

Page 92: ...PAGE 90 OF 92 FLOW DIAGRAM FURNACE SECTION WITH OPTIONAL FURNACE BYPASS REF B42163 R1 TP 1 1...

Page 93: ...SOL 2 SOL 3 SEE NOTE 3 SEE NOTE 4 SEE NOTE 4 SEE NOTE 4 SEE NOTE 4 SEE NOTE 4 SEE NOTE 4 SEE NOTE 4 SEE NOTE 4 SEE NOTE 4 BK DA PR PAGE 91 OF 92 WIRING DIAGRAM FURNACE SECTION 110 120VAC REF B42143 C...

Page 94: ...PDalbello JBE PAGE 92 OF 92 WIRING DIAGRAM FURNACE SECTION 220 230VAC REF B42144 R3 TP 1 1...

Page 95: ...Petroleum Analyzer Company LP Web site www paclp com For a complete list of contact information refer to the Contacts section of this publication...

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