Model 4212 Pour Point Analyzer - ABB Group...Purge Air Alarm The analyzer contains circuits that...

��

4212-OSM C1: January 2002

OPERATION AND SERVICE MANUALModel 4212 Pour Point Analyzer

NOTICE

Material contained within this manual is proprietary information ofABB Inc.

and is to be used only for the purpose of understandingand operating this product.

Specifications are subject to change without notice.

©2002, ABB Inc.

For further information or assistance contact:

ABB Inc.843 North Jefferson Street

P.O. Box 831Lewisburg, WV 24901

General Information: Telephone (304) 647-4358Fax (304) 645-4236

Field Service: Telephone (304) 340-0508

Aftermarket Spares: Telephone (304) 647-1736Fax (304) 647-1837

Please include Sales Order Number, Tag Number,Analyzer Part Number and Serial Number

4212-OSM, C1 i

LIST OF EFFECTIVE PAGES—4212 Operation and Service Manual

Date of issue for each version of this manual:

A1 May 1998B1 June 1999B2 December 1999B3 October 2000B4 August 2001C1 January 2002

Revision status of each page in this manual:

Page No. Revision Status

All C1

The revision status is noted at the bottom of each page of this manual.

ii 4212-OSM, C1








4212-OSM, C1 iii

TABLE OF CONTENTS

Title Page

SECTION 1. INTRODUCTION

EQUIPMENT DESCRIPTION.............................................................................................. 1-1SPECIFICATIONS ............................................................................................................... 1-2

Range ............................................................................................................................ 1-2Performance .................................................................................................................. 1-2Sample Conditions at Analyzer...................................................................................... 1-2Connections .................................................................................................................. 1-2Utilities ........................................................................................................................... 1-2Air .................................................................................................................................. 1-3

AIR PURGE SYSTEMS ...................................................................................................... 1-3

SECTION 2. INSTALLATION

PREPARING FOR INSTALLATION ..................................................................................... 2-1Installation Tools and Equipment ................................................................................... 2-1Purge Air Alarm.............................................................................................................. 2-1

PLUMBING CONNECTIONS .............................................................................................. 2-2ELECTRICAL CONNECTIONS ........................................................................................... 2-2STARTUP ............................................................................................................................ 2-3

SECTION 3. OPERATION

CONTROLS AND INDICATORS ......................................................................................... 3-1Sample Interface ........................................................................................................... 3-1Controller Assembly ...................................................................................................... 3-2Local Keyboard ............................................................................................................. 3-2

OPERATING MODES ......................................................................................................... 3-3Automatic Mode ............................................................................................................ 3-3Manual Mode ................................................................................................................. 3-3

ADJUSTING THE OPERATING PARAMETERS................................................................. 3-3OPERATING PHASES ........................................................................................................ 3-4

Flush .............................................................................................................................. 3-4Settle ............................................................................................................................. 3-4Charge........................................................................................................................... 3-4Heat ............................................................................................................................... 3-4Cool ............................................................................................................................... 3-4Ready ............................................................................................................................ 3-5Unplug ........................................................................................................................... 3-5Standby ......................................................................................................................... 3-5Error .............................................................................................................................. 3-5

ALARMS.............................................................................................................................. 3-6Fast Loop Low Flow Error ............................................................................................. 3-6Filter Differential Pressure Error .................................................................................... 3-6Analyzer Low Flow Error ............................................................................................... 3-6Low Standard Level Error .............................................................................................. 3-6External Error ................................................................................................................ 3-6Low Difference Error ...................................................................................................... 3-6High Difference Error ..................................................................................................... 3-6

iv 4212-OSM, C1

TABLE OF CONTENTS (continued)

Title Page

Low Sample Error .......................................................................................................... 3-6Low Calibration Sample Error ........................................................................................ 3-7High Sample Error ......................................................................................................... 3-7High Calibration Sample Error ....................................................................................... 3-7Cool Time-Out Error ...................................................................................................... 3-7Low Sample Temperature Error ..................................................................................... 3-7

OUTPUTS ........................................................................................................................... 3-7Measuring Signals ......................................................................................................... 3-7Relay Outputs ................................................................................................................ 3-7Sample Temperature Sensor ......................................................................................... 3-8Printer Output ................................................................................................................ 3-8

INPUTS ............................................................................................................................... 3-8External Commands Inputs ........................................................................................... 3-8External Alarms and Warnings Inputs ............................................................................ 3-8

CONFIGURATION PARAMETERS ..................................................................................... 3-9Flush Time ................................................................................................................... 3-10Charge Time ................................................................................................................ 3-10Settle Time .................................................................................................................. 3-10Fill Time ........................................................................................................................ 3-11Ready Time .................................................................................................................. 3-11Unplug Time ................................................................................................................. 3-11Heat Time-Out .............................................................................................................. 3-11Cool Time-Out .............................................................................................................. 3-11Cooling Rate ................................................................................................................. 3-11Cooler Fail Level .......................................................................................................... 3-11Pour Point Range Minimum.......................................................................................... 3-11Pour Point Range Maximum......................................................................................... 3-11Calibration Range Minimum ......................................................................................... 3-11Calibration Range Maximum ........................................................................................ 3-11Flush Temperature Minimum ....................................................................................... 3-12Pour Point Offset ......................................................................................................... 3-12Calibrate Offset ............................................................................................................ 3-12Range Offset ............................................................................................................... 3-12Detector Threshold ...................................................................................................... 3-12Display Width............................................................................................................... 3-12Relay Outputs - Logical Inputs .................................................................................... 3-12Cooling Control Parameters ........................................................................................ 3-13Additional Parameters ................................................................................................. 3-13

SECTION 4. TECHNICAL DESCRIPTION

OPERATING PRINCIPLE.................................................................................................... 4-1SYSTEM OVERVIEW ......................................................................................................... 4-1SAMPLE INTERFACE......................................................................................................... 4-2ANALYSIS ASSEMBLY ....................................................................................................... 4-4CONTROLLER ASSEMBLY ................................................................................................ 4-5

Power Supply ................................................................................................................ 4-6Controller Electronics .................................................................................................... 4-7

VALVE OPERATION ........................................................................................................... 4-8X PURGE ............................................................................................................................ 4-8

X Purge Operation ......................................................................................................... 4-8

4212-OSM, C1 v

TABLE OF CONTENTS (continued)

Title Page

X Purge Override Option ............................................................................................. 4-10

SECTION 5. MAINTENANCE

PREPARATION FOR MAINTENANCE ............................................................................... 5-1USING THE LOCAL KEYBOARD ....................................................................................... 5-1TROUBLESHOOTING INSTRUCTIONS ............................................................................ 5-3CONTROLLER ASSEMBLY REPAIR .................................................................................. 5-3

Opening the Controller Assembly .................................................................................. 5-3Replacing Printed Circuit Boards ................................................................................... 5-3Closing the Controller Assembly.................................................................................... 5-5Replacing the Pressure Gauge ..................................................................................... 5-6Replacing the Pressure Regulator ................................................................................. 5-6

ANALYSIS ASSEMBLY REPAIR ......................................................................................... 5-7Opening the Analysis Assembly .................................................................................... 5-7Replacing the Cell Control Board .................................................................................. 5-7Replacing the Light Source Lamp ................................................................................. 5-7Replacing the Photodiode Detector ............................................................................... 5-8Removing and Reinstalling the Detector Cell ................................................................ 5-8

CONTROLLER ASSEMBLY ADJUSTMENTS..................................................................... 5-8Processor (CPU) Board ................................................................................................. 5-9Signal-Analog Outputs Board ...................................................................................... 5-10Acquisition Board ......................................................................................................... 5-11LCD VGA Controller Board .......................................................................................... 5-12Temperature Sensor Interface Board .......................................................................... 5-12Power Supply Board .................................................................................................... 5-14

ANALYSIS ASSEMBLY ADJUSTMENTS .......................................................................... 5-15

SECTION 6. REPLACEMENT PARTS

ORDERING INFORMATION ............................................................................................... 6-1ANALYSIS ASSEMBLY ....................................................................................................... 6-2CONTROLLER ASSEMBLY ................................................................................................ 6-3X PURGE ASSEMBLY ........................................................................................................ 6-4

vi 4212-OSM, C1

ILLUSTRATIONS

Figure Description Page

1-1 Pour Point Analyzer ....................................................................................................... 1-1

2-1 X Purge Assembly, Showing Alarm Connections ........................................................... 2-12-2 Plumbing Connections ................................................................................................... 2-22-3 Electrical Connections ................................................................................................... 2-3

3-1 Pour Point Analyzer ....................................................................................................... 3-13-2 Sample Interface Controls and Indicators ...................................................................... 3-13-3 Controller Assembly Controls and Indicators ................................................................. 3-23-4 Typical Configuration Parameters Table ...................................................................... 3-10

4-1 System Block Diagram .................................................................................................. 4-14-2 Sample Interface Flow Diagram..................................................................................... 4-34-3 Analysis Assembly Block Diagram ................................................................................. 4-44-4 Power Supply Block Diagram ........................................................................................ 4-64-5 Controller Electronics Block Diagram ............................................................................ 4-74-6 Valve Operation Table .................................................................................................... 4-84-7 X Purge with Cover Removed........................................................................................ 4-9

5-1 Operating Screen ........................................................................................................... 5-25-2 Printed Circuit Board Location ....................................................................................... 5-45-3 CPU Board Connections ................................................................................................ 5-55-4 Controller Assembly and Gauge Panel .......................................................................... 5-65-5 Processor Board Adjustments........................................................................................ 5-95-6 Signal-Analog Outputs Board Adjustments .................................................................. 5-105-7 Acquisition Board Adjustments ..................................................................................... 5-115-8 LCD VGA Controller Board Adjustments ...................................................................... 5-125-9 Temperature Sensor Interface Board Adjustments ...................................................... 5-135-10 Power Supply Board Jumper Location......................................................................... 5-15

6-1 Analysis Assembly ......................................................................................................... 6-26-2 Controller Assembly ....................................................................................................... 6-36-3 X Purge Assembly ......................................................................................................... 6-4

B4

4212-OSM, C1 1-1

SECTION 1. INTRODUCTION

EQUIPMENT DESCRIPTION

As shown in Figure 1-1, the Pour Point Analyzer consists of an X-Purge Assembly, aController Assembly, an Analysis Assembly, and a Sample Interface, mounted on a singlechassis intended for attachment to the floor. Since all the equipment is accessible from thefront of the chassis, the analyzer may be installed without rear access.

Figure 1-1. POUR POINT ANALYZER

The Controller Assembly contains the power supplies, control electronics and the LCDscreen.

The Analysis Assembly contains the light source, measuring cell, photodiode detector, andthree temperature probes.

The Sample Interface contains:

• the sample in valve

• the calibration in valve

• the flowmeter for control of the sample flow, with associated needle valve

X PURGEASSEMBLY

CONTROLLERASSEMBLY

ANALYSISASSEMBLY

SAMPLEINTERFACE

1-2 4212-OSM, C1

• the flowmeter for control of the cooling water flow, with associated needle valve

• shutoff valves at the WATER INLET, the CALIBRATION INLET, and the SAMPLE INLET

The air pressure regulator and associated pressure gauge, which provide air for valveswitching, are located between the Controller Assembly and the Analysis Assembly.

SPECIFICATIONS

CAUTION

Specifications are subject to change without notice.

Range

Up to two ranges programmable from -50° C to +40° C. The second range can be dedicatedeither to auto-calibration on a standard or to a second measurement stream.

Performance

Precision: within the standard laboratory test, ASTM D97

Repeatability: ±1° C

Cycle Time: typically 40 to 50 minutes, depending on the application

Sample Conditions at Analyzer

Pressure: 0.5 to 2 bars g

Temperature: must be kept higher than 10° C above the pour point

Sample Flow Rate: about 15 to 20 liters/hour of continuous flow through the bypasscircuit

Ambient Temperature: the analyzer can be operated from 0° to 40° C, but thisdoes not correspond to the sample temperature limitation;therefore, it is recommended that the ambienttemperature be maintained between 20° and 35° C.

Connections

Sample Inlet/Outlet: 1/4-inch tube connection

Electrical: CENELEC

Utilities

Electrical: 115 V ±10%, 50 to 60 Hz; or 230 V ±10%, 50 to 60 Hz

Cooling Water: 30 to 60 liters/hour of clean water (maximum temperaturedependent on application and measuring range)

4212-OSM, C1 1-3

Air

Instrument air is required for valve actuation.

Pressure: 4 to 7 bars g

Consumption approximately 300 liters per hour

AIR PURGE SYSTEMS

If the analyzer will be in a Class I hazardous location, an air purging system must be installedto reduce the risk of explosion. Class I locations are those in which flammable gases orvapors are or may be present in the air in quantities sufficient to produce explosive orignitable mixtures.

1-4 4212-OSM, C1








4212-OSM, C1 2-1

SECTION 2. INSTALLATION

PREPARING FOR INSTALLATION

The analyzer should preferably be installed in a shelter with an ambient temperaturebetween 5 and 40° C. Since the construction and certification of the equipment authorizes itsinstallation near analyzers which use or analyze hydrogen, it is possible to install thesedevices in the same room. The sampling, air, and water needs and the electricalconsumption are specified in Section 1.

Installation Tools and Equipment

The following tools and equipment are required to install and check out the analyzer.

Tools: #2 Phillips screwdriver#1 Phillips screwdriver3/16-inch flat blade screwdriver1/8-inch flat blade screwdriver1 set of metric open-end wrenches6-inch adjustable wrench12-inch adjustable wrench1 set of metric hex key wrenches

Equipment: Leak testing solution (e.g., Snoop®)Flow meterStop watch (if not using a digital flow meter)Chart recorderMultimeter

Purge Air Alarm

The analyzer contains circuits that detect the loss of purge air to the analyzer and generatealarm signals to the customer. These purge alarm circuits comprise the automatic safetydevice required by certification agencies. The purge alarm connections are located in the XPurge Assembly, as shown in Figure 2-1. The customer has the responsibility to connect thepurge alarm to a visual or audible annunciator located in a constantly monitored area.

Figure 2-1. X PURGE ASSEMBLY, SHOWING ALARM CONNECTIONS

ALARMCONTACTS

2-2 4212-OSM, C1

PLUMBING CONNECTIONS

Connect the various inputs (WATER INLET, SAMPLE INLET, CALIBRATION INLET, and AIRINLET) to the Sample Interface as indicated in Figure 2-2 and verify each connection is tightand free from leakage.

Figure 2-2. PLUMBING CONNECTIONS

Connect the SAMPLE BYPASS VENT to the customer's sample return line. Connect theWATER OUTLET to a drain or a recirculation system as appropriate for the facility.

ELECTRICAL CONNECTIONS

CAUTION

All primary power and signal cables must be in conduit if the analyzer islocated in a hazardous area.

Connect the various electrical lines as indicated in Figure 2-3 and verify each cableconnection before placing the analyzer in operation.

AIR INLET

SAMPLEBYPASS VENT

SAMPLE INLET

CALIBRATION INLET

WATER INLET

4212-OSM, C1 2-3

Figure 2-3. ELECTRICAL CONNECTIONS

STARTUP

WARNING

Ensure that the cooling water is flowing through the detector cell prior toapplying power to the analyzer.

After verifying the various connections, apply power to the analyzer. Verify on the LCDscreen of the Controller Assembly that startup takes place without any error message (whichcould otherwise indicate a change of certain data files).

PowerFilter

TB61

InputPower

123456

CalibrationRequest

Standby(NO Contact)

Trend/Continuous 131415161718

13151719

Calibrationin Process

Calibration Signal4 - 20 mA isolated

Measuring Signal 4 - 20 mAisolated 750 ohm load

Output Valid

CONTROLLER ASSEMBLY

+

+-

-

NOTE: All relay contactsare voltage free.

RelayContacts

L1L2

GND

78

Error

Warning

RelayPCB

ConnectorRS-403-314 3

TB60

462

X PurgeUnit

1

1 These areexternally poweredrelay controls thatwill be connectedthrough anintrinsically safe(IS) barrier or othersuitable method ofprotection for thearea classification.

2-4 4212-OSM, C1

The LCD screen will indicate whether the analyzer is in "Manual" or in "Auto". If necessary,change to "Manual" to open the sample valve, by pressing the "M" key on the keyboard.

Before you run an analysis you should purge the air and fluid lines, to eliminate any trappedmatter that could later be harmful to the operation of the analyzer.

Test all connections with a leak detection solution (e.g., Snoop®).

Adjust the WATER INLET and SAMPLE INLET flows on the Sample Interface, using theassociated needle valve of the appropriate flow meter.

Adjust the purge air pressure to 40 psig using the pressure gauge and associated pressureregulator.

Change to "Auto" to start the first measurement cycle.

4212-OSM, C1 3-1

SECTION 3. OPERATION

CONTROLS AND INDICATORS

The Pour Point Analyzer's subassemblies are identified in Figure 3-1 and described in thefollowing paragraphs.

Figure 3-1. POUR POINT ANALYZER

Sample Interface

The controls and indicators for the Sample Interface are shown in Figure 3-2.

Figure 3-2. SAMPLE INTERFACE CONTROLS AND INDICATORS

X-PURGE

CONTROLLERASSEMBLY

ANALYSISASSEMBLY

SAMPLESYSTEM

WATER FLOW ADJUST

SAMPLE FLOW ADJUST

SAMPLE FLOWMETER

PRESSURE GAUGE

SAMPLE VALVE

CALIBRATION VALVE

WATER FLOWMETER

WATER VALVE

3-2 4212-OSM, C1

Controller Assembly

The controls and indicators for the Controller Assembly are shown in Figure 3-3.

Figure 3-3. CONTROLLER ASSEMBLY CONTROLS AND INDICATORS

Local Keyboard

For adjustment and service usage, a control keyboard can be connected to the analyzer bymeans of a connector on the Processor PCB in the Controller Assembly.

WARNING

Before opening any analyzer doors or covers, ensure the area is safe andhazard-free and will remain so the entire time the analyzer is open.

Connect the local keyboard as follows:

1. Turn the Controller Assembly front panel latches full counterclockwise with a 5/16-inch(or 8 mm) hex key wrench.

2. Open the Controller Assembly front panel.

3. Locate the cable with the open connector on the left side of the enclosure and connectthe keyboard cable to it.

4. The operating screen should appear on the display.

The following commands are available by one-touch keying:

M Manual: allows you to shift from automatic mode to manual mode.

N Next step: in manual mode, this key allows you to follow, step by step, thedifferent phases of operation of the apparatus.

S Standby: allows you to set the analyzer locally into STANDBY phase.

PROCESSOR PCB

POWERSUPPLY

PCB

SIGNAL-ANALOGOUTPUTS PCB ACQUISITION PCB

LCD VGACONTROLLER PCB

TEMPERATURESENSOR INTERFACE

PCB

RELAY PCB

CABLE FOR KEYBOARD

28 VDCPOWERSUPPLY

PRESSURE GAUGE REGULATOR

4212-OSM, C1 3-3

A Auto: allows you to return to the automatic mode from the manual mode.

C Calibration: when this key is activated, a calibration cycle will followimmediately after the end of the cycle in progress.

Q Quit: allows you to stop the program and return to DOS control.

Esc Escape: allows you to stop the program and display the configurationparameters.

OPERATING MODES

The analyzer has two operating modes: automatic and manual.

Automatic Mode

This is the normal (default) operating mode of the analyzer. Calibration, an operating optionin automatic mode, may be requested by the user by means of a local keyboard or byvoltage-free relays. During a calibration cycle, the calibration sample is admitted into theanalyzer by the calibration valve.

The control program of the analyzer operates a loop that refreshes data eight times eachsecond and stores a time count. All analog and digital inputs are monitored and analogoutputs are refreshed during each loop.

The operating cycle (or analysis cycle) is determined by the time required to perform ananalysis. The sequences within this cycle present different operating modes and states, asexplained in the following paragraphs.

Manual Mode

This may be selected using a local keyboard. Manual Mode is used when adjustingoperating parameters and when servicing the analyzer.

ADJUSTING THE OPERATING PARAMETERS

The operating parameters may be adjusted using a local keyboard. Normally theseparameters are set at the factory and are listed on the supplied Data Sheet. However, insome cases it may be necessary to adjust one or more parameters to compensate for sitevariations. If it is necessary to adjust any of the parameters, proceed as follows:

WARNING


1. Connect the local keyboard as described in "Local Keyboard."

2. The operating screen should appear on the display.

3. Press the Esc key. A list of sample streams (0 through 3) appears on the display.

4. Select the appropriate stream using the "up" and "down" arrow keys.

3-4 4212-OSM, C1

5. Press the Enter key.

6. In the parameters table, you can change any parameter by using the "up" and "down"arrow keys to select that parameter.

7. To change a parameter enter the desired number when the cursor is in that parameter'sfield.

8. When you have finished with the parameter table, press the Esc key.

9. Select Y (yes) or N (no) to save your changes.

10. Press Esc to return to the main screen and continue the analysis.

OPERATING PHASES

The analyzer has nine operating phases or states: flush, settle, charge, heat, cool, ready,unplug, standby, and error. During normal operation, the display will indicate the activephase.

Flush

During the FLUSH phase, the burette is purged and filled to the top of the overflow tube bythe fresh sample. The sample is usually that of the process to be controlled. In the case of acalibration cycle, it is the standard product. The duration of the FLUSH phase is a userprogrammable parameter. The duration setting is usually between 30 and 60 seconds.

Settle

During the SETTLE phase, the sample valve is closed so that the cell temperature and thedetector signal can stabilize. While the duration of this phase may be changed by means ofa user programmable parameter, it is usually set at about 30 seconds. During this time thevolume of the sample is kept at about 25 to 30 ml. (This volume is defined in the burette bythe adjustable overflow tube.)

Charge

During this phase, the amount of sample (25 to 30 ml) is transferred from the burette to thecup within the detector cell.

Heat

The sample is heated to 57° C (this temperature is user-programmable). Two heatercartridges are part of the detector cell. The COOL phase cannot begin until this temperatureis reached.

Cool

During the COOL phase, the thermoelectric elements are supplied as follows.

If the cell temperature is higher than the maximum value of the measure range,the supply is at its maximum value.

4212-OSM, C1 3-5

If the cell temperature is within the measure range but higher than the targetpoint, the cooling control is on.

If the cell temperature is lower than the target point, the cooling control is off.

In the first operating cycle, when there has been no previous detection, only thehigh cooling control is on.

The cooling rate is not measured or adjusted directly. A temperature ramp is generated as asetpoint and the cooling power is modulated at the output in order to minimize the differencebetween the ramp temperature and the effective temperature of the cell at the same time.

During the COOL phase, the output signal of the detector is controlled. If the optical detectorsignal varies by more than a threshold value, it is considered that a pour point has beenreached. When a pour point is detected, the COOL phase terminates and the analyzer isswitched to the READY phase.

If COOLER TIME-OUT is reached before detection of a pour point, the analyzer is switchedagain to the FLUSH phase and a warning is emitted (COOLER TIME-OUT).

The on and off cooling states, the cooler time-out, and the detection threshold may bechanged by user-programmable parameters. Typically, the detection threshold is 0.1 to 1.2Volts and the cooler time-out is 60 minutes.

If the difference between the ramp temperature and the effective cell temperature is higherthan 10° C, a cooling error is emitted and the following phase will be ERROR.

Ready

During the READY phase, the state relay is active/inactive (customer selected), the 4 to 20mA output signal is updated and any warning message on the display is deleted.

Unplug

During this phase, the heating cartridges are switched on to heat the sample and allow thecup within the detector cell to be drained. A new cycle starts with this sequence.

Standby

The STANDBY phase may be selected manually by means of a local keyboard or by logicinput from an external source. During STANDBY, the sample valve is open and the sampleflows through the cell to the sample return or not, depending on the parameter settings. Thetwo 4 to 20 mA signals then follow the cell temperature, allowing the calibration of thetemperature sensor to be verified and adjusted. Any stored pour point value is thencancelled, as well as any possible alarms or warnings.

Error

This phase corresponds to an operating error.

A lamp fault is detected by lamp current measurement. Accordingly, a low value maycorrespond to an open circuit and a high value to a short circuit. In the case of such an errordetection, this phase will be cancelled if the original conditions are reestablished. A looselamp leads to an error condition that will automatically trigger, for example on tightening. Thetransmission of the ERROR phase will follow the same mode.

3-6 4212-OSM, C1

However, a cooling error state may only be acknowledged by toggling to STANDBY phaseand back again.

ALARMS

Alarms do not usually degrade the operating cycle. An alarm will toggle the respective relayand issue a message on the printer, if it is connected. The possible alarms are describedbelow.

Fast Loop Low Flow Error

This error is emitted by a sample system flow relay; it indicates that the fast loop flow is lowerthan the set threshold.

Filter Differential Pressure Error

This error is emitted by a differential pressure relay to the terminals of the filter; it indicates anexcessively high loss of load, probably due to clogging of the filter cartridge.

Analyzer Low Flow Error

This error is emitted by a flowmeter warning relay; it indicates that during the FLUSH phase,the sample flow to the analyzer is insufficient. A delay is added to this function in order toabsorb the read fluctuation that may arise when the sample intake valve opens.

Low Standard Level Error

This error is emitted by a low level contactor on standard product reserve; it indicates thatthere is an insufficient quantity of product to run a calibration cycle. Since the calibration istriggered manually, there is no cycle inhibit when this error condition occurs.

External Error

This error is emitted by a voltage-free relay; it will be shown on the display, issued by theprinter and will actuate the alarm relay. This type of error may be used for any type ofinformation delivered by the system (temperature warning, for example).

Low Difference Error

This error is emitted when a pour point is detected with a value of more than 3° C below theprevious value.

High Difference Error

This error is emitted when a pour point is detected with a value of more than 3° C above theprevious value.

Low Sample Error

This error is emitted when a pour point of the input sample is detected with a value lowerthan the range start.

4212-OSM, C1 3-7

Low Calibration Sample Error

This error is emitted when a pour point of the standard (calibration) sample is detected with avalue lower than the range start.

High Sample Error

This error is emitted when a pour point of the input sample is detected with a value higherthan the range end.

High Calibration Sample Error

This error is emitted when a pour point of the standard (calibration) sample is detected with avalue higher than the range end.

Cool Time-Out Error

This error is emitted for a time-out higher than a predetermined value. When it is emitted,cooling halts and the analyzer switches to FLUSH phase instead of READY phase.

Low Sample Temperature Error

This error is emitted for an insufficient cell temperature increase after the HEAT phase of thecycle. Experience has shown that if this value is not reached, the repeatability and precisionof the measurements may be altered.

OUTPUTS

Measuring Signals

The two outputs of 4 to 20 mA are for the following:

• stored values of pour point measurements or cell temperature follow-up

• calibration signal

Relay Outputs

The NO or NC operating state may be modified by user programmable parameters.

Read Relay: This relay is activated when the pour point measurement signal is validated. Itis not activated when the signal is invalid, and its duration is programmable (usually twoseconds). At the same time the analog measurement signal is updated.

Calibration Relay: This relay is activated for the duration of each new calibration cycle.

Alarm Relay: This relay is activated if an alarm condition has been detected.Acknowledgment is automatic if the condition disappears.

Warning Relay: This relay is activated if a warning condition is detected. This error level canonly be acknowledged by manual intervention.

3-8 4212-OSM, C1

Sample Temperature Sensor

A Pt 100 probe with two-wire connection is placed upstream from the detector cell input.

Printer Output

The analyzer can also be connected to a serial printer through the RS232 COM 1 port. Thetransmission speed is 9,600 baud, 8 data bits, no parity, 2 stop bits. At the end of each cycle,the pour point value is reported, preceded by the date and the time. The report is completedby the identification of the cycle: “PRODUCT SAMPLE" or “CALIBRATION”.

If an error or warning condition arises, it will be reported on the printer.

INPUTS

External Commands Inputs

These inputs are for the terminal boards on which the normally closed relays will activate thefunction.

Calibration: After activation, this input will trigger a calibration cycle that will start at the endof the cycle in progress, if any. When a pour point is detected during a calibration cycle,the second 4 to 20 mA signal is updated instead of the first signal.

Measurement Memory/Follow-Up: After activation, this input will trigger each 4 to 20 mAanalog output in continuous follow-up mode. This mode permits verification of theproper settings of the electronics.

Standby: After activation, the analyzer is set into STANDBY phase and the sample runscontinuously through the cell, or does not run (customer selected).

After deactivation, the analyzer starts a new cycle in FLUSH phase.

This logical input may also be used to reinitialize the state of the analyzer. In this case,there is acknowledgment of the error messages and reinitialization of the calibrationvalues.

Selecting a Set of Parameters: There are four sets of user-programmable parameters. Theset used by the analyzer is determined by the state of two relays: Selection Relay 1 andSelection Relay 2.

SELECTION RELAY 1 STATE : 0 : 1 : 0 : 1 :SELECTION RELAY 2 STATE : 0 : 0 : 1 : 1 :SELECTED SET OF PARAMETERS : 0 : 1 : 2 : 3 :

External Alarms and Warnings Inputs

These six supplementary inputs each consist of one pair of terminals from which the state ofa relay (NO or NC according to the parameters set) permits the signalling of an externalalarm or warning state.

4212-OSM, C1 3-9

Fast Loop Low Flow: This alarm indicates that the flow value has dropped below apredetermined value on the detection sensor.

High Filter Differential Pressure: This alarm indicates that the pressurestat connected tothe terminals of the input filter has been triggered and that the filter is very probablyclogged.

Low Analyzer Flow: This alarm indicates that the flow in FLUSH phase is lower than apredetermined value.

Low Standard Level: This alarm indicates that the level of standard remaining in reserve isinsufficient to run a calibration cycle.

External Alarm: This alarm indicates that an external relay has been activated. It is alsopossible to protect the analyzer and its proper operation with one or more peripheralwarnings and transmit them to the control room as a general alarm.

External Warning: This warning stops the operation of the analyzer and is transmitted to thecontrol room.

CONFIGURATION PARAMETERS

The analyzer may be configured using the local keyboard, as described in "Local Keyboard."

Moreover, the parameters accessible to the user may be changed. There are four sets ofparameters (0 to 3). The set of parameters used by the analyzer is determined by the stateof two voltage-free remote-linked relays.

To access the configuration parameters:

1. While an analysis is running, press the Esc key on the keyboard (this stops theanalysis).

2. When the parameters menu appears, cursor down to the desired set of parameters andthen press the Enter key.

3-10 4212-OSM, C1

3. When the selected set of parameters appears (see Figure 3-4), you can change anyparameter by using the up and down cursor keys to select that parameter.

FLUSH TIME 30 S READY RELAY N/C 0CHARGE TIME 30 S ERROR RELAY N/C 0SETTLE TIME 30 S WARNING RELAY N/C 0FILL TIME 30 S CALIBRATE RELAY N/C 0READY TIME 2 S PRODUCT VALVE INVERT 0UNPLUG TIME 2 M PRINTER O/P ENABLE 0HEAT TIME OUT 10 M PROD VALVE IN STANDBY 0COOL TIME OUT 40 M SAMPLE TEMP ERROR 0COOLING RATE 5.2 °C/M FAST LOOP FLOW N/C 0COOLER FAIL LEVEL 15 °C FILTER PRESSURE N/C 0POUR POINT RANGE MIN -32 °C ANALYZER FLOW N/C 0POUR POINT RANGE MAX +10 °C CALIBRATE SAMPLE N/C 0CALIBRATE RANGE MIN -32 °C EXTERNAL WARNING N/C 0CALIBRATE RANGE MAX +10 °C EXTERNAL ERROR N/C 0FLUSH TEMP MIN +54 °C SAVE PCX 0POUR POINT OFFSET +0.0 °C ERROR GAIN 30CALIBRATE OFFSET +0.0 °C INTEGRAL GAIN 0RANGE OFFSET 32 °C DERIVATIVE GAIN 10DETECTOR THRESHOLD .2 V MAX COOLANT TEMP +24DISPLAY WIDTH 1400 S

Figure 3-4. TYPICAL CONFIGURATION PARAMETERS TABLE

4. To change a parameter, enter the desired number when the cursor is in that parameter'sfield.

5. When you have finished with the parameter table press the Esc key.

6. Select Y (yes) or N (no) to save your changes.

7. Press Esc to return to the main screen and continue the analysis.

Flush Time

The flush time may be selected in the range of 15 to 120 seconds. If the flush time is tooshort, it may give rise to low temperature warnings and/or precision and repeatabilityproblems. The flush temperature has to be set according to the application.

Charge Time

The charge time may be between 10 and 120 seconds. The optimal charge time dependsentirely on the sample viscosity.

Settle Time

This time may be selected from between 15 and 120 seconds. If the settle time is too short,it may give rise to false detection (too much sample in the detector cell cup).

4212-OSM, C1 3-11

Fill Time

This time may be selected from between 10 and 120 seconds.

Ready Time

This time may be set from 1 to 5 seconds.

Unplug Time

The unplug time may be set between 1 and 10 minutes. It should be set to allow the productto reach a viscosity compatible with atmospheric draining.

Heat Time-Out

The heat time-out may be set between 10 and 60 minutes in one-minute increments. Thistime should be selected to avoid false warnings.

Cool Time-Out

The cool time-out may be set between 10 and 60 minutes in one-minute increments. Thistime should be selected to avoid false warnings.

Cooling Rate

The cooling rate may vary from 0.1 to 9.9° C/minute. It should usually be set to 2° to 4° C/minute.

Cooler Fail Level

This value should be set between -32° C and +32° C in increments of 1° C.

Pour Point Range Minimum

This value should be set between -32° C and +32° C in increments of 1° C and be at least 8°C lower than the selected maximum pour point range value.

Pour Point Range Maximum

This value should be set between -32° C and +32° C in increments of 1° C and be at least 8°C higher than the selected minimum pour point range value.

Calibration Range Minimum

This is the same as Pour Point Range Minimum, but for the calibration samples.

Calibration Range Maximum

This is the same as Pour Point Range Maximum, but for the calibration samples.

3-12 4212-OSM, C1

Flush Temperature Minimum

This value should be set at +57° C.

Pour Point Offset

This offset may be adjusted across the range from -16 to +16° C. It is added to the celltemperature when a pour point is detected in order to obtain a value that will then be shown,transmitted and printed. This offset value is used to correlate the laboratory analysis valuewith the value indicated by the analyzer.

Calibrate Offset

This is the same as Pour Point Offset, but for the calibration samples.

Range Offset

The range offset may be between 0 and +40° C in increments of 1° C. This parameter allowsthe analyzer measurement range to be shifted to negative values.

Example:

If the typical range of the analyzer is -32° C to +32° C and a range offset of -32° C isselected, the resulting range will be -64° C to 0° C.

Detector Threshold

The detector threshold may be selected between 0 and 2.5 Volts in increments of 0.01 Volt.This allows acceptance of detection differences that could be linked to the nature of thesample.

Display Width

This may be set in increments of 1 second. Display Width allows you to reduce or increasethe period of time displayed in the graphics window of the display (like the time base rate onan oscilloscope).

Relay Outputs - Logical Inputs

Each of the relay functions may correspond to an open or closed contact when the relay is tobe activated. Each of the logical input functions may be controlled by opening or closing arelay, depending on the requirements of the site.

The following is a list of the relay outputs and logical inputs:

OUTPUTS INPUTSReady relay Fast loop flowError relay Filter pressureOperation warning relay Analyzer flowCalibrate relay Calibrate sample level

External warningExternal error

4212-OSM, C1 3-13

Cooling Control Parameters

In order to align the cooling control operation, three parameters are accessible to the user:proportional, integral and derived. Each parameter may be adjusted between 0 and 99.

The following procedure should be used:

1. Adjust the proportional parameter to 10 while the integral and derived parameters areset to 0.

2. Run the analyzer and change the proportional parameter until the characteristicdamping of the cell temperature displays ripples.

3. Progressively increase the derived parameter in order to reduce the observed ripples toa minimum.

4. When the damping has reached its maximum (minimum ripple), an offset is usuallyobserved between the target temperature and the cell temperature, with this offset risingas the cell temperature drops. This offset may be reduced by increasing the value of theintegral parameter.

Generally speaking, it is not advisable to try to eliminate completely all forms of ripple in thetemperature measurement, but rather to find the best possible compromise. The absence ofvariations of the same type on the 4 to 20 mA analog follow-up of the cell temperature willindicate a good compromise.

Additional Parameters

The user has access to two supplementary parameters that influence and force the operationof the analyzer:

Product valve in standby: determines whether this valve will remain open (1) or closed (0)in STANDBY phase.

Maximum coolant temperature: determines the maximum acceptable temperature of thecooling water at the outlet of the heat exchangers. If the temperature exceeds theselected value, the power to the thermoelectric coolers is shut off.

3-14 4212-OSM, C1








4212-OSM, C1 4-1

SECTION 4. TECHNICAL DESCRIPTION

OPERATING PRINCIPLE

The Pour Point Analyzer is used to measure the pour point of a liquid hydrocarbon sample.The pour point is defined as that temperature where the liquid sample shows no movementwhen the sample is cooled.

One of the main components of the analyzer system is the detector cell, which operates asan optical latch or switch. When there is movement (low viscosity) in the sample, no light isdetected and hence no output from the detector. When there is no movement (highviscosity), light is reflected to the photodiode detector via the light guide, producing anoutput. At the time an output is produced, the temperature is measured and defined as thepour point.

The remaining components of the analyzer system control and monitor temperature, cycletime, and operating states. In addition, the analyzer sends reports and operating status to thecontrol room via a printer, relay contacts, or a computer.

SYSTEM OVERVIEW

The Pour Point Analyzer consists of a Sample Interface, an Analysis Assembly and aController Assembly. Refer to the system block diagram in Figure 4-1 for the followingdiscussion.

Figure 4-1. SYSTEM BLOCK DIAGRAM

SAMPLEINTERFACE

Contact Closures

Printer Input

Recorder Input

Detector Signal

Sample Temperature

Coolant Temperature

Cell TemperatureANALYSIS

ASSEMBLYCONTROLLER

ASSEMBLY

Cooler Control Voltage

Sam

ple

Valv

e C

ontro

l

Cal

ibra

te V

alve

Con

trol

Air I

n

Sample InSample Return

Water In

Water Out

Sample In

Sample ReturnWater In

Water Out

Calibration In

Air Supply

Primary Power In

4-2 4212-OSM, C1

The Sample Interface provides the components to handle and control the sample input, thecalibration input, the cooling water input, and the instrument air input. The sample systemcontrols the sample flow rate, and whether the sample or the calibration input is sent to thedetector cell. The Sample Interface also controls the flow rate of the cooling water, coupledto the heat exchangers within the Analysis Assembly. The instrument air pressure is set by apressure regulator in the Sample Interface and is coupled to the Controller Assemblysolenoid valves, which provide valve control, and to the Analysis Assembly to provide purgeair.

The Analysis Assembly contains the detector cell and temperature probes to sense thesample, coolant, and cell temperatures, which are coupled to the Controller Assembly. Thecooler control voltage from the Controller Assembly is connected to the thermoelectriccoolers in the Analysis Assembly, which cool the detector cell. When the pour point isdetected, a signal is generated and sent to the Controller Assembly.

The Controller Assembly has two main subassemblies: the Power Supply and the ControllerElectronics. The Power Supply contains the power supplies that provide operating voltagesfor the Controller Electronics, the 28 Vdc power supply that provides the control voltage tothe thermoelectric coolers in the Analysis Assembly, and the solenoid valves to provide theair control for the sample and calibration valves. In addition, the Power Supply contains theterminal board connections for peripheral equipment, such as a printer and/or a recorder.The Controller Electronics provides the operating control for the analyzer through the internalCPU and associated circuitry, by establishing cycle times, operating states, solenoid valvecontrol, data handling, and data outputs for peripheral equipment. The Controller Electronicsalso accepts the detector signal for processing and monitors the three temperatures (sample,coolant, and cell).

SAMPLE INTERFACE

The Sample Interface components typically consist of three shutoff valves, two air activatedswitching valves, two flow meters with associated needle valves, a pressure indicator, acheck valve, and a combined assembly. The combined assembly consists of a pressureregulator and a pressure indicator. Refer to the Sample Interface flow diagram in Figure 4-2for the following discussion.

4212-OSM, C1 4-3

Figure 4-2. SAMPLE INTERFACE FLOW DIAGRAM

The instrument air passes through the shutoff valve and is coupled to the combinationassembly, where the air pressure is regulated and indicated on the pressure indicator. Theoutput goes to the Controller Assembly to provide the control air via the solenoid valves tothe sample and calibration valves.

The calibration input passes through the shutoff valve and is coupled to the input of the airactuated calibrate valve. If the valve is open, the input is coupled to the junction at the outputof the sample valve, through the sample flowmeter to the detector cell in the AnalysisAssembly.

The sample input passes through the shutoff valve to the junction at the input of the samplevalve. When the sample valve is open, the sample passes through the flowmeter, where theflow rate is adjusted by the integral needle valve, and is coupled to the detector cell in theAnalysis Assembly. The sample pressure is measured on the pressure indicator at the inputto the flowmeter. When the sample valve is closed, the sample passes through the checkvalve to the sample return. This continuous sample flow insures that a fresh sample isavailable at all times.

The water input passes through the shutoff valve and the flowmeter, where the flow rate isadjusted by the integral needle valve, and is coupled to the heat exchangers in the AnalysisAssembly. The heat exchangers dissipate the heat from the thermoelectric coolers in theAnalysis Assembly.

WaterInput

WaterReturn

SampleReturn

SampleInput

SampleReturn

CalibrationInput

InstrumentAir

ToAnalysis

Assembly

ToControllerAssembly

SAMPLE INTERFACE

ControlAir

WaterInput

WaterReturn

SampleReturn

SampleInput

PI

PI

4-4 4212-OSM, C1

ANALYSIS ASSEMBLY

The Analysis Assembly contains the detector cell, three temperature probes, a Cell ControlBoard, two Heat Exchangers, and thermoelectric coolers. The detector cell consists of a lightsource, a mirror, a window, two light guides, a photodiode detector, two heater cartridges,and a slowly rotating cup within the cell body. Refer to the Analysis Assembly block diagram(Figure 4-3) for the following discussion.

Figure 4-3. ANALYSIS ASSEMBLY BLOCK DIAGRAM

The sample flows into the burette and fills to the level of the adjustable overflow tube,providing a volume of 25 to 30 ml. The burette is heated and vented to expedite the samplehandling and the flow into the detector cell. The sample return from the overflow tube is atatmospheric pressure and will flow continuously as long as the sample valve is open (FLUSHphase). The metered sample flows into the detector cell during the CHARGE phase whenthe control air from a solenoid in the Controller Assembly is applied to the gear drivenactuator, causing the valve between the burette and the detector cell to open, filling thesample cup. The sample remains in the slowly rotating sample cup during the analysis cycle.

During the analysis cycle, the cooler control voltage from the Controller Assembly is appliedto the thermoelectric cooler elements, driving the internal detector cell temperature down tothe pour point. As the temperature of the sample cup drops, the viscosity of the samplechanges from a low viscosity to a high viscosity substance. Prior to the cell temperature

LampVoltage

Regulator

24V FromPower Supply

Box Assy 12V Amp

To ControlBox AssyCELL CONTROL BOARD Detector

Output

CELL BOX ASSEMBLY

HE = Heat ExchangerTEC = Thermoelectric Cooler

PD = Photodiode DetectorLG = Light GuideLS = Light SourceTB = Thermal BlockM = Mirror

= Temperature Probe

LEGEND

HC = Heater Cartridge

SampleIn

SampleReturn

Cooler ControlVoltage from

Power Supply BoxAssy

Cooler ControlVoltage from

Power Supply BoxAssy

SampleReturn

Water Inlet fromSample System

Assy

WaterOutlet

To ControlBox Assy

PD

LS

HE

TECTECLG

M

Water

TB

HC HC

Motor

HE TB

LGTP

To ControlBox Assy Burette Gear Driven

Actuator

ControlAir

4212-OSM, C1 4-5

reaching the pour point, the viscosity of the sample is low and has no effect on the pendulumassembly. The pendulum assembly consists of a steel ball mounted on the end of theassembly, a mirror mounted on the pivot point of the assembly, and a temperature probemounted inside the assembly to measure the temperature of the steel ball. The pendulumassembly is suspended vertically over the sample cup, and slightly offcenter, with the steelball immersed in the sample.

The light beam from the light source (LS) is concentrated by the horizontally mounted lightguide (LG), strikes the mirror (M) and is reflected back toward the source. No light isreflected to the photodetector (PD) light guide (LG) during this time. Therefore there is nooutput from the detector cell. When the cell temperature drops near the pour point, theviscosity of the sample increases and the constantly rotating sample cup causes thependulum assembly to move slightly from the vertical position. At some point the pendulum(with its mirror) will be deflected enough to reflect some portion of the light beam toward thehorizontally mounted light guide (LG) and photodiode detector. The photodiode detector lightguide will pick up the reflected light and couple it to the photodiode detector (PD), whichproduces an output within the -5 to +5 Vdc range to the Controller Assembly, via the amplifieron the Cell Control Board.

When the detector cell produces an output that exceeds the preset threshold, thetemperature of the steel ball is retained in memory and defined as the pour point. When thepour point is reached, the cooler control voltage is shut off and power is applied to the heatercartridges in the thermal block. This raises the temperature of the sample cup, allowing thesample to be drained from the sample cup. This draining occurs when control air from asolenoid valve in the Controller Assembly is applied to the actuator at the bottom of thedetector cell, causing the actuator to open the valve on the bottom of the sample cup,releasing the sample to the sample return (at atmospheric pressure). The thermal block isused to provide a uniform temperature transfer to the sample cup during the cooling andheating cycles.

The detector cell is cooled by thermoelectric coolers (TEC), which have the propertyof transferring heat from one side of the element to the other upon application of theappropriate voltage. The cool side of each element is attached to the body of thecell and the warm side of the element is attached to the associated heat exchanger(HE). The water flowing through the heat exchangers dissipates the heat, allowingthe detector to cool.

The Cell Control Board contains an amplifier to boost the output of the photodiode detector(PD) and a threshold circuit to ensure that the detector output exceeds a preset level. Thethreshold circuit eliminates noise spikes, etc., prior to coupling the detected signal to theController Assembly. This board also contains a permanently controlled power supply for thelight source (LS) and a monitor circuit to determine any lamp malfunction (such as an opencircuit or an overcurrent condition). A lamp malfunction causes a logic signal to be generatedand coupled to the Controller Assembly.

Three temperature probes are installed in the Analysis Assembly to measure thetemperatures of the sample, the coolant and the detector cell. These signals are monitoredby the Controller Assembly.

CONTROLLER ASSEMBLY

The Controller Assembly consists of the Power Supply and Controller Electronicssubassemblies.

4-6 4212-OSM, C1

Power Supply

The Power Supply contains five solenoid valves, a Relay Board, a 28 Vdc power supply, anda Switched Mode Power Supply Unit. Refer to the Power Supply block diagram (Figure 4-4)for the following discussion.

Figure 4-4. POWER SUPPLY BLOCK DIAGRAM

The solenoid valves switch the air on and off to the air actuated valves of the SampleInterface and the actuators in the Analysis Assembly that control the filling and draining of thesample cup. The solenoid valves are switched by the presence or absence of 24 Volts onthe solenoid valve coil. This actuating voltage is supplied from the Relay Board to theappropriate solenoid valve. The Relay Board also provides contact closures to the remoteControl Room to indicate analyzer status. The Relay Board logic control and status inputsare derived from the Controller Electronics.

The 28 Vdc power supply provides the voltage for the thermoelectric cooler elements locatedin the Analysis Assembly during the cooling cycle of the analyzer.

The Switched Mode Power Supply Unit provides the voltage sources for the electroniccomponents in the Analysis Assembly, the Power Supply and the Controller Electronics. Thefollowing voltages are provided by the Switched Mode Power Supply Unit:

–5 Volts -12 Volts -24 Volts+5 Volts +12 Volts +24 Volts

Control fromControllerAssembly

COOLERCONTROL

BOARD

RELAYBOARD

120 VACInput

-5 VDC

+5 VDC

-12 VDC

+12 VDC

-24 VDC

+24 VDC

SWITCHEDMODE

POWERSUPPLY

UNIT

Status Inputsfrom Controller

Assembly

ContactClosures to

Control Room

Control Signalsfrom Controller

Assembly

SolenoidValve

SolenoidValve

SolenoidValve

SolenoidValve

Air Input fromSampleInterface

Air Control toSample Valve

Air Control toOptional Valve

Air Control toCalibration Valve

Air Control toOptional Valve

To AnalysisAssembly

Cooler Control Voltage

to Thermoelectric Coolers

POWER SUPPLY (p/o CONTROLLER ASSEMBLY)

SolenoidValve

Air Control toReset Status

4212-OSM, C1 4-7

Controller Electronics

The Controller Electronics consists of an internal computer (CPU) and associated interfacecircuitry mounted on PC compatible electronic boards. The major components include: theLCD screen, the Processor Board (CPU), the Signal-Analog Outputs Board, the AcquisitionBoard, the LCD VGA Controller Board, the Graphics Display Inverter Board (Inverter Board),the Temperature Sensor Interface Board, and the Interface Module. Refer to the ControllerElectronics block diagram in Figure 4-5 for the following discussion.

Figure 4-5. CONTROLLER ELECTRONICS BLOCK DIAGRAM

The Processor Board (CPU) contains two flash memories (unit D) and one static memory(unit E). This board has two serial input-output ports, configured as COM 1 and COM 2. TheCOM 1 port is normally connected to a serial printer and the COM 2 port can be connected toa computer.

The Signal-Analog Outputs Board can process eight analog outputs of 0 to 5 Volts. Theseoutputs are equipped with sample and memory circuits, which are refreshed eight times asecond. Two of these outputs are converted into 4 to 20 mA signals by Analog Device 2B22modules. Five of the other outputs are used to provide compensation to the detector signal,and to provide temperature compensation for the cell, the coolant, and the sampletemperatures.

The Acquisition Board has eight 12-bit analog input (A/D Converter) channels, one dual-buffered 12-bit output (D/A Converter) channel, a 16-bit digital input (TTL compatible), and a16-bit digital output (TTL compatible).

The LCD VGA Controller Board provides the control interface to the LCD screen.

The Graphics Display Inverter Board (Inverter Board) provides power to the LCD screen.

PROCESSORBOARD(CPU)

LCD VGACONTROLLER

BOARD

LCDSCREEN

SIGNAL-ANALOGOUTPUTS

BOARDACQUISITION

BOARD

TEMPERATURESENSOR

INTERFACEBOARD

Temperature ProbeInputs from Analysis

Assembly

Detector Signal fromAnalysis Assembly

ControlVoltages to

Power Supply4 - 20 mAOutputs

CONTROLLER ELECTRONICS (p/o CONTROLLER ASSEMBLY)

INVERTERBOARD

4-8 4212-OSM, C1

The Temperature Sensor Interface Board contains three amplifier circuits used in conjunctionwith the three temperature probes in the Analysis Assembly to measure the cell, the coolant,and the sample temperatures.

The cell temperature probe amplifier converts the resistance variation of the temperatureprobe into an output signal of -5 to +5 Volts. This output signal represents a temperaturevariation of 64° C. Consequently, the cell temperature compensation signal allows thiscompensation value to be varied from 0 to 5 Volts, that is, from -32° C to 0° C. The normalcompensation value is usually adjusted to -32° C, which means that a temperature of 0° Ccorresponds to an output of 0 Volts.

The coolant and sample temperature probe amplifiers convert the resistance variation of thetemperature probe into an output signal of -5 to +5 Volts. These output signals represent atemperature variation of 64° C, compensated to 32° C, which means that a temperature of 0°C corresponds to an output of 0 Volts.

VALVE OPERATION

Figure 4-6 shows the valve operations for the Pour Point Analyzer. Where theHEATER or COOLER is shown as ON, they are actually under program controlexcept in UNPLUG where the HEATER is on all the time. When a calibration cycleis performed, the CALIBRATE VALVE is also CLOSED in HEAT, COOL, UNPLUGand READY in order to conserve calibration sample.

Figure 4-6. VALVE OPERATION TABLE

X PURGE

X Purge Operation

X Purge (see Figure 4-7) reduces risk by two levels and turns off the analyzer when an alarmoccurs.

ETATSECNEUQES ETATSECNEUQES ETATSECNEUQES ETATSECNEUQES ETATSECNEUQES STNENOPMOCLACIRTCELE/SEVLAV STNENOPMOCLACIRTCELE/SEVLAV STNENOPMOCLACIRTCELE/SEVLAV STNENOPMOCLACIRTCELE/SEVLAV STNENOPMOCLACIRTCELE/SEVLAV

TCUDORP TCUDORP TCUDORP TCUDORP TCUDORP *EGRAHC *EGRAHC *EGRAHC *EGRAHC *EGRAHC NIARD NIARD NIARD NIARD NIARD RELOOC RELOOC RELOOC RELOOC RELOOC RETAEH RETAEH RETAEH RETAEH RETAEH ROTOM ROTOM ROTOM ROTOM ROTOM

HSULF NEPO NEPO NEPO FFO FFO FFO

LLIF NEPO DESOLC NEPO FFO FFO FFO

ELTTES DESOLC DESOLC NEPO FFO FFO FFO

EGRAHC DESOLC NEPO DESOLC FFO FFO FFO

TAEH NEPO DESOLC DESOLC FFO NO FFO

LOOC NEPO DESOLC DESOLC NO FFO NO

YDAER NEPO DESOLC DESOLC FFO FFO FFO

GULPNU NEPO DESOLC DESOLC FFO NO FFO

YBDNATS LANOITPO DESOLC DESOLC FFO FFO FFO

RORRE NEPO DESOLC DESOLC FFO FFO FFO

rotautcaehtnoriatuohtiwCN*

4212-OSM, C1 4-9

Figure 4-7. X PURGE WITH COVER REMOVED

When you turn the power ON, X Purge begins monitoring the Controller Assembly air purgepressure. When the air purge pressure reaches the specified level, the X Purge starts atimed cycle. If the air purge pressure remains at the specified level during the timed cycle, XPurge will supply power to the equipment when it completes the timed cycle. If the air purgepressure drops before the X Purge completes the timed cycle, X Purge resets the timer andstarts over. It continues to reset the timer until the analyzer achieves and maintains thecorrect pressure for a complete timed cycle. The X Purge will not supply power to theanalyzer until it sucessfully completes the timed cycle.

The X Purge cycle time depends totally on the application, but it may vary with analyzerconfiguration and condition. Refer to the analyzer label or Data Package for specific purgespecifications. Once X Purge applies power to the analyzer, power continues to the analyzeras long as the Controller Assembly maintains air purge pressure.

X Purge removes power from the analyzer when the Controller Assembly air purge pressuredrops below specifications. It locks out power to the analyzer and activates an alarm. Theanalyzer has connections available to the customer for connecting the purge alarm to avisual or audible annunciator located in a constantly monitored area.

In order to re-start the analyzer after an X Purge alarm, you must first correct the cause ofthe drop in pressure. Then turn the power OFF at the circuit breaker for at least ten secondsand turn the power back ON. This starts a new X Purge timed cycle, which it must completebefore it will supply power to the analyzer. If you do not correct the cause and cannotachieve and maintain pressure, the X Purge will not complete the cycle and will not supplypower to the analyzer.

When X Purge removes and locks out power to the analyzer after a drop in ControllerAssembly purge air pressure (or before pressure has initially attained the specified level),you can use Override to provide power to the analyzer for troubleshooting or maintenancepurposes. Override does not cancel the X Purge power lockout but temporarily overrides it.

OVERRIDEPUSHBUTTON

ALARMCONTACTS

REMOTEOVERRIDE

POWER IN

4-10 4212-OSM, C1

X Purge Override Option

WARNING

Before you enable X Purge Override to override its control of power tothe analyzer, ensure the area where the analyzer is located is safe andhazard free, and remains so for the entire time the X Purge housing coveris removed.

CAUTION

Override must not be left on during regular operation of the analyzer.

Use the X Purge Override Option only for start up, troubleshooting, and maintenance. Donot leave it on during regular operation of the analyzer. Override requires a well-lighted areato function. A light sensor inside the X Purge housing allows you to enable Override afteryou remove the X Purge housing cover. When you replace the cover, the light sensorcancels Override.

The following steps describe how to use the override function.

1. Ensure the area is safe and well-lit.

2. Remove the X Purge housing cover and press the Override button (see Figure 4-7) toapply power to the analyzer.

NOTE

CENELEC versions of the X Purge have a set screw in the lid that mustbe removed before the housing cover can be removed.

3. Perform the necessary maintenance and troubleshooting.

4. When you have completed the maintenance and troubleshooting, replace the X Purgehousing cover (and the CENELEC set screw).

5. To cancel Override safely and properly and to reset X Purge, turn the supply power OFFat the circuit breaker outside the analyzer (for at least ten seconds) and then turn powerON again.

6. With X Purge reset, the air purge timed cycle begins in the Controller Assembly.

When you use Override during start-up, it overrides the X Purge control of power to theanalyzer, but the air purge timed cycle continues. Once the Controller Assembly haspressurized and X Purge completes its timed purge cycle, the analyzer will have power fromthe X Purge. If you replace the housing cover without turning the power off at the circuitbreaker, the analyzer will still have power because of X Purge.

If the Controller Assembly pressure drops during Override use and if the timed cycle iscomplete, the X Purge will lock out its power to the analyzer. Since Override bypasses the XPurge, the analyzer will still have power. If you cancel Override by replacing the housingcover without turning off the power at the circuit breaker, the X Purge power lock out willcause the analyzer to be without power. To restart X Purge, you must correct the cause of

4212-OSM, C1 4-11

the drop in pressure, then turn power OFF (for at least ten seconds), and then ON again.The X Purge must complete its timed cycle before the analyzer will receive power.

NOTE

The remote control feature of the Override option is not available on CSAcertified analyzers.

The X Purge housing has terminals for connecting a remote control override (see Figure 4-7), except in CSA certified analyzers. The customer is solely responsible for connecting andmaintaining the remote control switch. This remote control is only to be used during start-up,maintenance and troubleshooting. The customer must ensure the remotely controlledoverride is removed when start-up, maintenance and troubleshooting is completed.

4-12 4212-OSM, C1








4212-OSM, C1 5-1

SECTION 5. MAINTENANCE

PREPARATION FOR MAINTENANCE

This section of the manual provides a series of routine maintenance procedures whichshould be performed on a periodic basis to reduce failures and to enhance the equipmentoperational stability. Removal and replacement instructions are included for printed circuitboards and detector cell components. The latter portion of this section will includeadjustments, DIP switch positions, and jumper connectors, when printed circuit boards arereplaced.

The following tools and equipment are required to perform this maintenance.

Tools: #2 Phillips screwdriver#1 Phillips screwdriver3/16-inch flat blade srewdriver1/8-inch flat blade screwdriver1 set of metric open end wrenches6-inch adjustable wrench12-inch adjustable wrench1 set of metric hex key wrenches1 pair of tweezers

Equipment: Leak testing solution (e.g. Snoop®)Flow meterStop watch (if not using a digital flowmeter)Potentiometric recorder (two channels)Decade resistance boxSerial printerMultimeter (Fluke 80 series or equivalent)Pump to provide continuous circulation of the sampleSample container (approximately half full) with an output connection (tubing to the bottom of the container) and an input connection for a sample return

USING THE LOCAL KEYBOARD

Most of the maintenance procedures will require connecting the local keyboard to allow theanalyzer to be set to various operating states.

WARNING


To connect the local keyboard proceed as follows:

1. Turn the Controller Assembly front panel latches fully counterclockwise with a 5/16-inch(or 8 mm) hex key wrench.


5-2 4212-OSM, C1

3. Locate the cable with the open connector (on the left side of the enclosure) and connectthe keyboard cable to it.

4. The operating screen should appear on the display (see Figure 5-1).

Figure 5-1. OPERATING SCREEN

NOTE

In the following procedures, if there is no keyboard activity for 30seconds, the display will revert to the operating screen.

5. The following commands are available by one-touch keying:

M Manual: allows you to shift from automatic mode to manual mode.

N Next step: in manual mode, this key allows you to follow, step bystep, the different phases of operation of the analyzer.

S Standby: allows you to set the analyzer locally into STANDBY phase.

A Auto: allows you to return to automatic mode from manual mode.

C Calibration: when this key is activated, a calibration cycle will followimmediately after the end of the cycle in progress.

Q Quit: allows you to halt the program and return to DOS.

01/26/99 08:35:36 COOL 162 AUTO 600

PARAMETER SET 0PROCESS SAMPLE POUR POINT -3.7 CCALIBRATE SAMPLE POUR POINT -32.0 CCELL TEMPERATURE +38.0 CWATER TEMPERATURE +0.0 CSAMPLE TEMPERATURE +0.0 C

PROCESS 4-20 O/P No 1 14.8 mACALIBRATE 4-20 O/P No 2 4.0 mADETECTOR SLOPE +0.0 VDETECTOR THRESHOLD 0.0 V

Trend/ConTStandbyCal RequestLamp FailFast LoopFilterFlowCal SampleExt WarningExt ErrorParams LSBParams MSBHoldDCDDSRCTS

ReadyErrorWarningCal StatusSample ValveCalib ValveCharge ValveDrain ValveMotorRange ErrorCooler TOCooler FailCoolerHeaterCal Ack.CommsPrinterSave PCX

4212-OSM, C1 5-3

TROUBLESHOOTING INSTRUCTIONS

Most troubleshooting should begin at the display. Periodic observation of the normal displayshould make abnormalities rather easy to spot. For example, if the temperature trace is notfollowing the desired line, it probably indicates a need to readjust the cooling rate parametersor a failure in the cooling circuit.

When power to the analyzer is turned OFF (or an inadvertent shutdown occurs), a three-waysolenoid valve automatically shuts off sample and calibration flow to the analyzer.

CONTROLLER ASSEMBLY REPAIR

WARNING


Opening the Controller Assembly

To access the printed circuit boards and other components in the Controller Assemblyperform the following steps:

1. Turn the Controller Assembly front panel latches fully counterclockwise with a 5/16-inch(or 8 mm) hex key wrench.


Replacing Printed Circuit Boards

The five printed circuit boards of the Controller Assembly are located inan eight slot backplane in the following order from left to right:

Processor Board (CPU)Spare slotSignal-Analog Outputs BoardAcquisition BoardLCD VGA Controller BoardSpare slotTemperature Sensor Interface BoardSpare slot

CAUTION

Remove power from the analyzer before attempting printed circuit boardreplacement.

To protect printed circuit boards from damage, use a properly groundedanti-static wrist strap when handling all circuit boards.

5-4 4212-OSM, C1

Replace any of the printed circuit boards in the Controller Assembly in thefollowing manner (see Figures 5-2 and 5-3 for location and cabling):

Figure 5-2. PRINTED CIRCUIT BOARD LOCATION

1. Open the Controller Assembly front panel as described in "Opening the ControllerAssembly."

2. Disconnect any cables to the selected board and remove the board.

4. Compare the removed board to the replacement board.

a. If any DIP switches are installed on the removed board, ensure that the positions ofthe switches on the replacement board match those of the removed board.

b. If any jumpers are installed on the removed board, ensure that the jumpers on thereplacement board match those of the removed board.

FOR DETAILS ONCPU BOARD

CONNECTIONS,SEE FIGURE 5-1B

BACKPLANE BOARD

CPU

BO

ARD

SIG

NAL

-AN

ALO

G O

UTP

UTS

BO

ARD

AC

QU

ISIT

ION

BO

AR

D

VGA

CO

NTR

OLL

ER B

OAR

D

TEM

P S

ENSO

R IN

TER

FAC

E BO

ARD

Spare

Spare

Spare

CN1

CN5

CN4

CN3

CN3

CN4

CN1

CN1

CN3

1 2 12P2

4

3

2

1PCL-711 S

DISPLAY

P8P9

POWERSUPPLY

24V

GND

4212-OSM, C1 5-5

Figure 5-3. CPU BOARD CONNECTIONS

4. Install the replacement board.

5. Reconnect cables, using Figures 5-2 and 5-3 as guides.

6. If you have completed all work inside the Controller Assembly, close and secure theController Assembly as described in "Closing the Controller Assembly."

Closing the Controller Assembly

To close the Controller Assembly perform the following steps:

1. Ensure all circuits boards are installed and the PCB holding bracket is in place.

2. Close the Controller Assembly front panel.

3. Tighten the panel latches.

KEYBOARDCONNECTOR

MOUSECONNECTOR

PRINTERCONNECTOR

5-6 4212-OSM, C1

Pressure Gauge Regulator

Replacing the Pressure Gauge

The pressure gauge is located on the panel between the Controller Assembly and theAnalysis Assembly (see Figure 5-4). You can access the gauge from underneath the panel.

Figure 5-4. CONTROLLER ASSEMBLY AND GAUGE PANEL

1. Disconnect the line from the back of the gauge.

2. Loosen the screws on the plate that secures the gauge to the panel and then removethe plate.

3. Remove the gauge from the panel.

4. Insert the new gauge through the hole in the panel.

5. Install the plate that secures the gauge to the panel.

6. Tighten the screws holding the gauge and plate to the panel.

7. Reinstall the line on the back of the gauge.

Replacing the Pressure Regulator

The regulator is located on the panel between the Controller Assembly and the AnalysisAssembly (see Figure 5-4). You can access the regulator from underneath the panel.

1. Disconnect the lines from the back of the regulator.

2. Remove the regulator adjusting knob.

3. Remove the nut securing the regulator to the panel.

4. Remove the regulator from the panel.

5. Remove the adjusting knob from the new regulator.

6. Insert the new regulator through the hole in the panel.

7. Fasten the nut securing the regulator to the panel.

4212-OSM, C1 5-7

8. Install the adjusting knob on the regulator.

9. Reinstall the lines on the back of the regulator.

ANALYSIS ASSEMBLY REPAIR

Opening the Analysis Assembly

WARNING


The following steps describe the removal and replacement of various components of theAnalysis Assembly.

1. Remove the power from the analyzer and close the WATER INLET, the SAMPLE INLET,and the AIR SUPPLY shutoff valves.

2. Loosen the hex socket head locking screw on the Analysis Assembly cover and removethe cover.

Replacing the Cell Control Board

1. Disconnect the detector coaxial cable from the Cell Control Board.

2. Remove the four nuts securing the cover on the Cell Control Board and remove thecover.

3. Disconnect the wires from the terminal board on the Cell Control Board.

4. Unscrew the four hex head standoffs and remove the Cell Control Board.

5. Install the replacement board in the reverse order of removing the board.

Replacing the Light Source Lamp

CAUTION

Do not touch the lamp with bare fingers.

1. Unscrew the lamp retaining cap from the lamp holder.

2. Remove the lamp with a pair of tweezers.

3. Install the new lamp with a pair of tweezers.

4. Reconnect the lamp retaining cap to the lamp holder.

5-8 4212-OSM, C1

Replacing the Photodiode Detector

CAUTION

Do not touch the photodiode detector with bare fingers.

1. Unscrew the optical detector cable assembly from the photodiode holder.

2. Disconnect the other end of the optical detector cable assembly fron the Cell ControlBoard and remove the cable from the unit.

3. Connect the replacement optical detector cable assembly to the Cell Control Board.

4. Connect the other end of the replacement optical detector cable assembly to thephotodiode holder.

Removing and Reinstalling the Detector Cell

It will be necessary to remove the complete detector cell from the Analysis Assembly toreplace the thermoelectric coolers, the cell temperature probe, or any other internalcomponents. Remove the detector cell as follows:

1. Unscrew the optical detector cable assembly from the photodiode holder.

2. Disconnect the cable to the lamp holder of the light source.

3. Disconnnect the wiring to the heaters.

4. Disconnect and remove the coolant lines to the detector cell.

5. Disconnect the external heating and cooling wiring at the terminal board mounted on thedetector cell assembly.

6. Remove the four hex socket head screws that secure the back plate and remove thedetector cell.

7. Place the detector cell on a clean work surface.

8. Remove the nuts and washers securing the insulating blocks to gain access to thethermoelectric cooling elements and the heater cartridges.

9. Reinstall the detector cell in the reverse order of removal.

CONTROLLER ASSEMBLY ADJUSTMENTS

Some adjustments may be required periodically to compensate for component aging and toset different system parameters. Open the Controller Assembly front panel as described in"Opening the Controller Assembly."

WARNING


4212-OSM, C1 5-9

Processor (CPU) Board

There are two different Processor (CPU) boards used in the analyzer. When you replace aCPU board you must use the same type of board—the boards are not interchangeable.

When you replace the old type CPU board (832Z011-00), you set DIP switch S1 (see Figure5-5 for location) to meet the system requirements. If in doubt, set the switch to the samepositions as those on the removed board.

Figure 5-5. PROCESSOR BOARD ADJUSTMENTS

DIP switch S1 selections are as follows:

SwitchPosition Function Action

S1-1 On-Board Serial Port 1 Disable ON to disable(This switch overriden by Feature Setup selection) OFF to enable

S1-2 On-Board Serial Port 2 Disable (see Note) ON to disable(This switch overriden by Feature Setup selection) OFF to enable

S1-3 On-Board Parallel Port Disable (see Note) ON to disable(This switch overriden by Feature Setup selection) OFF to enable

S1-4 Console Mode Enable ON to enable(This switch enables console mode on Serial Port 1) OFF to disable

S1-5 Not Used

S1-6 Boot Disk ON to boot from solidstate disk device SSDO

OFF to boot as specified inthe Feature Setup Program(FSETUP.EXE)

SWITCH S1

NEW CPU BOARD (3617856-1)OLD CPU BOARD (832Z011-00)

5-10 4212-OSM, C1

The new CPU board (3617856-1) has no switches or adjustments.

Signal-Analog Outputs Board

The Signal-Analog Outputs Board has four potentiometers that are used to set the 4 to 20mA current values (see Figure 5-6).

Figure 5-6. SIGNAL-ANALOG OUTPUTS BOARD ADJUSTMENTS

If necessary, the 4 mA and 20 mA current values can be adjusted using thesepotentiometers. In these procedures the analyzer is ON and in STANDBY and the cover isremoved from the Controller Assembly.

Adjusting the Measuring Analog Output

1. Connect a milliammeter in series with terminals 84 (+) and 85 (-).

2. Connect a keyboard to the CPU Board and exit from the application program bypressing the Q key (Quit). The prompt letter D will be displayed.

3. Type TESPROG and then press the ENTER key. A screen will appear which showsvarious options.

4. Using the left/right arrow key, select the Edit Menu and the DIGITAL-ANALOG mode.

5. First set the voltage level of MOD1 (Trend Channel) to 0.00 volts and adjust RV-2 for anoutput current of 4 mA.

6. Change the voltage level to 5.00 volts and adjust RV-1 for an output current of 20 mA.

7. Verify that the output current value is 12 mA when the voltage is set to 2.5 volts.

Adjusting the Calibration Analog Output

1. Connect a milliammeter in series with terminals 86 (+) and 87 (-).

VR4 VR3 VR2 VR1

4212-OSM, C1 5-11

2. Connect a keyboard to the CPU Board and exit from the application program bypressing the Q key (Quit). The prompt letter D will be displayed.

3. Type TESPROG and then press the ENTER key. A screen will appear which showsvarious options.

4. Using the left/right arrow key, select the Edit Menu and the DIGITAL-ANALOG mode.

5. First set the voltage level of MOD2 (Calibrate Channel) to 0.00 volts and adjust RV-4 foran output current of 4 mA.

6. Change the voltage level to 5.00 volts and adjust RV-3 for an output current of 20 mA.

7. Verify that the output current value is 12 mA when the voltage is set to 2.5 volts.

Acquisition Board

The Acquisition Board has a six-position DIP switch SW1 used to set the base address of theboard and a connector link to select the output (see Figure 5-7).

Figure 5-7. ACQUISITION BOARD ADJUSTMENTS

JP1SW1(SW1-1 at left; ON at top)

5-12 4212-OSM, C1

Perform the following adjustments with the power OFF.

Jumper orSwitch Position Action

JP-1 -5 VoltsSW1-1 OFFSW1-2 ONSW1-3 ONSW1-4 ONSW1-5 OFFSW1-6 ON

There are also five potentiometers on this board. They are set at the factory and should notrequire adjustment thereafter.

LCD VGA Controller Board

There are two controls (VO and VEE) located on the LCD VGA Controller Board in theController Assembly (see Figure 5-8). The VO control is used to adjust the intensity of thecursor. The VEE control is not used in this application.

A ribbon cable connects this board to the Graphics Display Inverter Board (located on theinside of the Controller Assembly door).

Figure 5-8. LCD VGA CONTROLLER BOARD ADJUSTMENTS

Temperature Sensor Interface Board

In these procedures, the analyzer is ON and in STANDBY and the Controller Assembly frontpanel is open. For ranges down to -30° C use the parameter editing mode to set the RANGEOFFSET to 32° C. This sets the CELL TEMPERATURE range at -32° C to +32° C. Figure5-9 shows the location of the adjustments on the Temperature Sensor Interface Board.

VEE VO

4212-OSM, C1 5-13

Figure 5-9. TEMPERATURE SENSOR INTERFACE BOARD ADJUSTMENTS

Adjusting the Sample Temperature Circuit

The temperature range for the SAMPLE TEMPERATURE is from 0° C to +64° C.

1. Connect a resistance box in place of the sample temperature sensor (terminals 5 and 6of terminal board TB4) and adjust the value to 100 ohms.

2. Measure the voltage at the terminals of the resistance box and adjust RV-9 to obtain avoltage of 300 mV. This corresponds to a current setting of 3 mA.

3. Adjust the resistance box value to 112.44 ohms.

4. Adjust RV-3 to obtain a sample temperature reading on the Controller Assembly display(SAMPLE TEMP.) of +32° C.

5. Adjust the resistance box to a value of 100.39 ohms.

6. Adjust RV-6 so that the sample temperature reading on the Controller Assembly display(SAMPLE TEMP.) is +1° C.


8. Verify that the sample temperature reading on the Controller Assembly display(SAMPLE TEMP.) is +63° C.

Adjusting the Coolant Temperature Circuit

The temperature range for COOLANT TEMPERATURE is from -32° C to +32° C.

RV-9

RV-8

RV-7

RV-6

RV-5

RV-4

RV-1

RV-2

RV-3

5-14 4212-OSM, C1

1. Connect a resistance box in place of the coolant temperature sensor (terminals 8 and 9of terminal board TB4) and adjust the value to 100 ohms.


3. Adjust RV-2 to obtain a water temperature reading on the Controller Assembly display(WATER TEMP.) of 0° C.


5. Adjust RV-5 so that the water temperature reading on the Controller Assembly display(WATER TEMP.) is -31° C.


7. Verify that the water temperature reading on the Controller Assembly display (WATERTEMP.) is +31° C.

Adjusting the Cell Temperature Circuit

1. Ensure that the RANGE OFFSET is -32° C.

2. Connect a resistance box in place of the cell temperature sensor (terminals 11 and 12 ofterminal board TB4) and adjust the value to 100 ohms.


4. Adjust RV-1 to obtain a cell temperature reading on the Controller Assembly display(CELL TEMP.) of 0° C.


6. Adjust RV-4 to obtain a cell temperature reading on the Controller Assembly display(CELL TEMP.) of -31° C.


8. Verify that the temperature reading on the Controller Assembly display (CELL TEMP.) is+31° C.

NOTE

This procedure is for analyzers with a basic CELL TEMPERATURE rangeof 0° C to +64° C. The RANGE OFFSET parameter may be used to shiftthe range down a maximum of 64° C (i.e., a RANGE OFFSET OF 1° C willprovide a range of -1° C to +63° C and a RANGE OFFSET of 32° C willprovide a range of -32° C to +32° C).

Power Supply Board

There is one jumper on this board (see Figure 5-10). Insert this jumper so that you can readthe system's input voltage value (115V or 230V) on the jumper tab.

4212-OSM, C1 5-15

Figure 5-10. POWER SUPPLY BOARD JUMPER LOCATION

ANALYSIS ASSEMBLY ADJUSTMENTS

The only adjustment in the Analysis Assembly is VR-1 on the Cell Control Board. This is afactory adjustment and should not require adjustment on site.

POWER JUMPER

5-16 4212-OSM, C1








4212-OSM, C1 6-1

SECTION 6. REPLACEMENT PARTS

ORDERING INFORMATION

This section provides a listing of operator-level replacement parts, with part number anddescription. For a full listing of available replacement parts, see the "Recommended SpareParts List" which is in the Data Package provided with the analyzer.

CAUTION

Since the particular application defines the component parts specific toany given system, refer to the “Recommended Spare Parts Lists” in theanalyzer's Data Package to obtain the full and correct part number for thedesired part or assembly.

Include the following information, found in the Data Package and on the analyzer nameplate,in any communication concerning replacement parts or components:

• ABB Process Analytics Model Number of the analyzer

• ABB Process Analytics Customer Order Number

• Analyzer Part Number (P/N) and serial number

• Cell serial number

• For serial numbered subassemblies such as PC boards, include the serialnumber and the part number (including dash number and revision letter) for thesubassembly in the request

• Applicable references from the “Recommended Spare Parts List” of the DataPackage, included with each analyzer

• Description of part

Contact Aftermarket Spares for specific instructions and include a complete description of thecomponent, analyzer, symptoms and problems. Please address your requests as follows:

ABB Inc.Attention: Aftermarket Spares843 North Jefferson StreetP.O. Box 831Lewisburg, WV 24901

Telephone: (304) 647-1736Fax: (304) 645-1837

6-2 4212-OSM, C1

ANALYSIS ASSEMBLY

Description Part Number

Cell Control Board 832Z053-00Detector Cell Assembly 842A003-1Lamp, Filament 832Z064-00-1Fuse, 10A 250V (5mm x 20mm) 832Z055-10A

Figure 6-1. ANALYSIS ASSEMBLY

DetectorCell Assembly

Cell ControlPCB

4212-OSM, C1 6-3

CONTROLLER ASSEMBLY


Power Supply PCB, Modified 840D012-00Acquisition PCB 832Z016-00Graphics Display Inverter PCB 832Z017-00 (on back of door)Relay PCB 832Z037-00Cooler Control PCB 832Z042-10LCD VGA Controller PCB 832Z013-00Fuse, 1.6A 250V (5mm x 20mm) 3615086-15Pressure Gauge, 0 to 100 psig 44726-4Regulator, 0 to 40 psig 3616975-2Power Supply, 28 Vdc 832Z012-20Processor PCB (application dependent—see Data Package)Signal-Analog Outputs PCB (application dependent—see Data Package)Temperature Sensor Interface PCB (application dependent—see Data Package)

Figure 6-2. CONTROLLER ASSEMBLY

PROCESSOR PCB

POWERSUPPLY

PCB

SIGNAL-ANALOGOUTPUTS PCB ACQUISITION PCB

LCD VGACONTROLLER PCB

TEMPERATURESENSOR INTERFACE

PCB

RELAY PCB

CABLE FOR KEYBOARD

28 VDCPOWERSUPPLY

PRESSURE GAUGE REGULATOR

6-4 4212-OSM, C1

X PURGE ASSEMBLY


X Purge PCB, NEC/CEN 115V 3528938-222X Purge PCB, NEC/CEN 230V 3528938-232X Purge PCB, CSA 115V 3528938-242X Purge PCB, CSA 230V 3528938-252

Figure 6-3. X PURGE ASSEMBLY

X PURGE PCB

ABB Inc.843 N. Jefferson StreetLewisburg, WV 24901 USA

Office: (304) 647-4358FAX: (304) 645-4236

Business Unit–Analyticalwww.abb.com/analytical

0107

��

Model 4212 Pour Point Analyzer - ABB Group...Purge Air Alarm The analyzer contains circuits that...

Documents

Transcript of Model 4212 Pour Point Analyzer - ABB Group...Purge Air Alarm The analyzer contains circuits that...