Annual Maintenance Manual // XPLORER-NS

Annual Maintenance Manual // XPLORER-NS
Annual Maintenance Manual
X PLORER -NS
DOC0800400
Annual Maintenance Manual
// X P L O R E R -NS
Annual Maintenance Manual
X PLORER -NS
DOC0800400
Disclaimer
TE Instruments does not warrant the hardware will work properly in all environments and
applications, and makes no warranty and representation, either implied or expressed, with respect
to the quality, performance, merchantability, or fitness for a particular purpose.
TE Instruments has made every effort to ensure that this manual is accurate; TE Instruments
disclaims liability for any inaccuracies or omissions that may have occurred.
Information in this manual is subject to change without notice and does not represent a
commitment on the part of TE Instruments. TE Instruments assumes no responsibility for any
inaccuracies that may be contained in this manual. TE Instruments makes no commitment to
update or keep current the information in this manual, and reserves the right to make
improvements to this manual and/or to the products described in this manual, at any time without
notice.
If you find information in this manual that is incorrect, misleading, or incomplete, we would
appreciate your comments and suggestions.
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Copyright
The content of this manual is protected by copyright.
All efforts have been made to ensure the accuracy of the contents of this manual. However should
any errors be detected TE Instruments would greatly appreciate being informed of them.
The above notwithstanding TE Instruments can assume no responsibility for any errors in this
manual or their consequences.
For more information, check our website at www.teinstruments.com.
Any use of this manual other than, intended by the producer, is prohibited without the prior written
permission of TE Instruments.
© 2014, Copyright reserved by TE Instruments, Delft, The Netherlands
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Table of Content
Preface ................................................................................................................................................................. 6
Revision History ............................................................................................................................................... 6
Contact............................................................................................................................................................. 6
Warranty .......................................................................................................................................................... 6
Intended use .................................................................................................................................................... 6
Service and Maintenance................................................................................................................................. 6
Preamble.......................................................................................................................................................... 7
Pictograms ....................................................................................................................................................... 7
Safety Precautions ........................................................................................................................................... 7
Handling Precautions ....................................................................................................................................... 8
Introduction ......................................................................................................................................................... 9
Tools..................................................................................................................................................................... 9
Parts ................................................................................................................................................................... 10
Tests ................................................................................................................................................................... 10
XPLORER-NS ....................................................................................................................................................... 10
Inspection and Replacement ......................................................................................................................... 10
Preparation ................................................................................................................................................ 11
Furnace Compartment............................................................................................................................... 11
Electronics Compartment General............................................................................................................. 11
Electronics Compartment Nitrogen Detector ............................................................................................ 12
Electronics Compartment Sulfur Detector................................................................................................. 12
Conditioning Compartment ....................................................................................................................... 12
Tests ............................................................................................................................................................... 13
Liquids Module................................................................................................................................................... 14
Inspection and replacement .......................................................................................................................... 14
Tests ............................................................................................................................................................... 14
Solids Module..................................................................................................................................................... 15
Inspection and replacement .......................................................................................................................... 15
Tests ............................................................................................................................................................... 15
ARCHIE ............................................................................................................................................................... 16
Inspection and replacement .......................................................................................................................... 16
Tests ............................................................................................................................................................... 16
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NEWTON ............................................................................................................................................................ 17
Inspection and replacement .......................................................................................................................... 17
Tests ............................................................................................................................................................... 17
GLS ..................................................................................................................................................................... 18
Inspection and replacement .......................................................................................................................... 18
Tests ............................................................................................................................................................... 18
Parts ................................................................................................................................................................... 19
Furnace Compartment................................................................................................................................... 19
Explanation Furnace Exit Parts................................................................................................................... 19
Electronics Compartment .............................................................................................................................. 20
Conditioning Compartment ........................................................................................................................... 20
Nitrogen Detector .......................................................................................................................................... 20
Sulfur Detector............................................................................................................................................... 21
Liquids Module............................................................................................................................................... 21
Solids Module................................................................................................................................................. 21
ARCHIE ........................................................................................................................................................... 21
NEWTON ........................................................................................................................................................ 21
GLS ................................................................................................................................................................. 21
Annual Maintenance Report XPLORER-NS..................................................................................................... 22
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Preface
Revision History
Version
DOC0800400
Revision Date
November 2014
© 2014, Copyright reserved by TE Instruments, Delft, The Netherlands
Contact
Manufactured by:
TE Instruments
Voltaweg 22
2627BC Delft
The Netherlands
Distribution:
See the website www.teinstruments.com for your local distributor
Warranty
Information on warranty conditions are specified in the sales contract. Contact your local
TE Instruments representative for further information.
Any unauthorized modification of the software entails the invalidity of the guarantee and service
contract.
Intended use
The XPLORER is intended for fast accurate and precise analysis of Organic Halogens, Nitrogen and
Sulfur (depending on the exact configuration).
Service and Maintenance
For the highest level of performance and safety from your XPLORER instrument, proper attention to
maintenance is crucial. We recommend that all service and maintenance for the analyzer and
accessories should be carried out by TE Instruments trained and certified service engineers.
To ensure an optimum product performance we recommend an annual maintenance inspection by a
trained service engineer, the annual maintenance inspection is described in this document.
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Preamble
Before performing service on the XPLORER it is important to read this Maintenance Manual
thoroughly and completely. Non-observance of the instructions contained in this manual may entail
safety hazards.
Pictograms
In this Maintenance Manual pictograms are used as an optical signal to point out important
information.
Warning/Risk of
This symbol is used to indicate that non-compliance with
instructions or procedures may lead to physical injury or even
death or could cause damage to the instrument.
Electrical Hazard
Instructions preceded by this sign must be complied with
exactly. Failure to do so may result in physical injury.
Heat
This symbol is used to label potentially hot instrument surfaces.
Important note
This symbol is used to bring your attention to an important
annotation
Safety Precautions
The XPLORER analyzer and software must be used only by trained and skillful personnel.
It is essential that the following safety precautions required for servicing the XPLORER are carefully
read and observed.
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Handling Precautions
The XPLORER is an electromechanical instrument. There is a potential danger for the user of an
electric shock or physical injury if the instrument is not used according to the instructions given in
this manual.
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Follow all safety instructions printed on, attached to or
written for the analytical instrument
Observe all general safety precautions which apply to
electrical instruments
Never touch switches or power cord with wet hands
Non trained service engineer should not open the
housing of the XPLORER, please observe extra precaution when opening the cover of the XPLORER
Never use the instrument for another purpose than for
which it was developed
Carry out checks on the connection cables and tubings
for possible damage and leaks on a regular base
Never place a heavy object on top of the analyzer
Only authorized service personnel should perform service or
repairs required for this instrument.
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Always wear safety goggles, lab clothing and gloves
when dealing with acid and/or corrosive material and
chemicals
Don’t add water to an acid
The furnace temperature can reach a temperature of
1150 °C, the outer surface of the analyzer may become
hot
Cool down the furnace before removing the furnace
tube
Special Attention


8
Always use parts, consumables and accessories
developed and produced by TE Instruments.
Unauthorized parts, consumables and accessories can
affect the measurement, cause damage to the
instrument and can create a hazardous situation
Never use materials for a purpose other than that for
which they are intended
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Introduction
This Manual describes the checks and tests necessary as well as the parts recommended to replace
during an annual maintenance on the XPLORER and its accessories. The explanation how to perform
the tests and checks is provided during the Service Training at the factory of TE Instruments or
described in the Service Manual.
This manual contains a checklist which can be used at the customer site during the annual
maintenance and after the annual maintenance for conformation by both the customer and the
service engineer. TE Instruments encourages the use of the checklist.
Tools
Small vacuum cleaner
Digital multi meter (up to 1000 V)
Thermocouple (up to 1150 °C)
Thermocouple small (up to 750 °C)
Handheld digital flow meter
USB to mini-USB cable (to up-date firmware)
Tubing cutter
Tie-wraps small
Tie-wraps large
Go-no-go gauge small (NEWTON)
Loctite 242
PH 1 Screwdriver
PH 2 Screwdriver
Screwdriver flat head
Allen key 1.5 mm (set screw module pusher)
Allen key 2.0 mm
Allen key 2.5 mm
Allen key 3.0 mm (CFT boat cooling)
Wrench ¼”
Adjustable wrench
Socket wrench 5.5 mm
Cable cutter
Torx key no. 6
ARCHIE kit
9
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√
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GLS
NEWTON
ARCHIE
Solids Module
Liquids Module
XPLORER-NS
The XPLORER itself may require different tools than several accessories. The tools required for the
described part or accessory are noted below.
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Parts
The XPLORER itself may require different spare parts than several accessories. The spare parts
required for the described analyzer or accessory are noted in the chapter of that analyzer or
accessory. Please read all chapters and note the spare parts required for the complete
configuration.
During an Annual Maintenance several parts are checked or replaced. The exchange rate does not
always align with the Annual Maintenance. Some parts may require a replacement more than based
on one year, e.g. the septum of a liquids module. Other parts may require a replacement less than
based on one year, e.g. fast connectors of Argon and Oxygen (every 2 years). Indicated in this
manual are the exchange rates when taking into account the conditions in the pre-installation
manual and when normally used.
Tests
After replacing several parts, tests are carried out to verify the analyzer. The tests are noted after
the Required Spare Parts.
XPLORER-NS
The maintenance for the XPLORER Nitrogen (by chemiluminescence) and/or Sulfur (by fluorescence)
can be different for each analyzer, it depends on the accessories. Please refer to the correct chapter
for the configuration which will be serviced.
Inspection and Replacement
The XPLORER may be switched on at this moment and the furnace at temperature. When proceeding
ensure yourself that you are comfortable when working with the furnace heated up and that hot
parts can be safely stored without injuring people or creating a hazardous situation. When having
any doubts, cool down the furnace before proceeding.
When the cover of the XPLORER is opened take extra care of a
potential electrical shock.
Cool down the furnaces when a safe working place cannot be
guaranteed.
Inspection and replacement of parts is mentioned in the order a TE Instruments representative
would perform the annual maintenance.
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Preparation
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Remove the introduction module from the analyzer
Remove the furnace tube from the furnace
Open the main cover of the analyzer
Furnace Compartment
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Power off the XPLORER, remove the power cable and replace the fuse (6.3 A for 230 V and
10 A for 110 V), one per analyzer.
Remove dust in the furnace compartment.
Power on the XPLORER taking the safety precautions in mind.
Inspect the inside of the furnace, is the heating spiral intact and correctly positioned?
Inspect the wires and connections to the furnace (zone 1 and 2, heating wires and
thermocouple wires) for loose connections, repair when necessary.
Inspect the furnace tube.
Replace when it is damaged (cracked or glass chipped off) or mineralization is influencing
the performance of the analyzer/measurement.
Replace the O-ring of the furnace tube.
Inspect the furnace exits.
Replace when it is damaged (cracked or glass chipped off) or mineralization is influencing
the performance of the analyzer/measurement.
Explanation of different furnace exits is given in the overview Required Parts at the end of
the chapter XPLORER-NS
Inspect the thermocouples and replace every 2 years.
Check if the thermocouples are positioned well.
Replace the thermal switches every year.
Insert the furnace tube and check if the back of the tube closes correctly with the furnace
exit parts (springs correctly working?).
Electronics Compartment General
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
11
Inspect the ventilator in the back, the one for the cooling of the introduction and the two of
the power supply. When possible use compressed air to clean the ventilators from dust.
Check the speed and distance for the home and end position(s) of the boat driver.
Check the set screw in the module pusher (if applicable).
Check the status of the Perma Pure.
Inspect the quick connectors of the Argon and Oxygen (both female) in the frame and
replace every 2 years.
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Electronics Compartment Nitrogen Detector
During this chapter the XPLORER will have to be powered off. When working on an XPLORER-NS it is
advised to combine the chapter regarding the nitrogen and sulfur detector.
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Inspect the ventilator for the cooling of the nitrogen detector. When possible use
compressed air to clean the ventilators from dust.
Check the cooling of the nitrogen detector.
The base of the PMT should not be hot, the outside will actually not feel cool.
Check the heating of the nitrogen detector.
The reaction chamber should feel warm.
Power off the XPLORER and remove the power cable.
Replace the 2 inline filters.
Replace the ozonekiller(s), depending on the build 1 or 2 ozonekillers.
Open the reaction chamber of the detector (3 screws).
Inspect the reaction chamber window and red filter for dirt, clean with ethanol if necessary.
Inspect the capillary restriction in the nitrogen detector.
Assemble the reaction chamber back to the detector, the screws need to be fixed finger
tight.
Replace the vacuum pump every year.
Power on the XPLORER.
Electronics Compartment Sulfur Detector
During this chapter the XPLORER will be powered off. When working on an XPLORER-NS it is advised
to combine the chapter regarding the nitrogen and sulfur detector.
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Check the workings of the UV flasher lamp for correct flashing.
Check the workings of the UV-sensor (compare the current response with historic data).
Power off the XPLORER and remove the power cable.
Remove the lamp socket from the detector (2 screws).
Clean the 1st lens by using compressed air (or another gas).
Assemble the lamp socket.
Conditioning Compartment
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12
Open the filter housing and inspect the filter, clean or replace if necessary.
Inspect the 2 O-rings, replace if necessary.
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Tests
The tests described are to verify the correct functioning of some parts. When the parts are
exchanged the test is required to verify if the parts are functioning correctly. When the parts have
not been exchanged the tests is to verify the part is still working correctly or a change in setting is
required.
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13
Measure the temperature of both furnaces and correct if necessary.
Measure the flow of the argon and correct if necessary.
Measure the flow of the primary oxygen and correct if necessary.
Measure the flow of the collision flow (if applicable).
Measure the flow to the ozonator (if applicable).
Measure the total flow into the filter housing.
Perform a standard injection and inspect the peak shape and recovery.
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Liquids Module
The Liquids Module is used for the measurement of Total Nitrogen and Sulfur in petrochemical
products with a final boiling point of 420 °C.
The Liquids Module may be hot.
The Liquids Module should not be opened. When the Liquids Module requires service, contact the
Support Department of TE Instruments.
Do not open the Liquids Module without approval of the
Support Department of TE Instruments.
Inspection and replacement
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Inspect the status of the glass. Replace the whole Liquids Module when the glass is
damaged (cracked or glass chipped off).
Replace the septum.
Inspect the status of the screw cap.
Inspect the quick connectors of argon and oxygen, replace every 2 years.
Inspect the tubing of the argon and oxygen.
Tests
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14
Check the temperature of the Liquids Module, adjust if necessary.
Check if the Liquids Module closes properly and perform a leak test.
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Solids Module
The Solids Module is used for the measurement of petrochemical samples with a final boiling point
above 420 °C and for solid samples.
Inspection and replacement
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Inspect the status of the boat guiding tube.
Replace when damaged (cracked or glass chipped off). When the glass is dirty, clean with a
tissue (ensure the glass is at room temperature).
Inspect the status of the boat.
Replace when damaged (cracked or glass chipped off).
Clean the magnet holder when dirty.
Replace the O-ring of the module.
Inspect shutter and (when applicable) replace the septum in the injection port.
Inspect the quick connectors of the argon and oxygen, replace every 2 years.
Inspect the tubing of the argon and oxygen.
Tests
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15
Check if the Solids Module closes properly and perform a leak test.
Check the alignment at the injection and removal position (if applicable).
Also see the chapter regarding the NEWTON.
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ARCHIE
The ARCHIE sampler is used in combination with the Liquids Module or the Solids Module.
Inspection and replacement
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Inspect the syringe.
Inspect the glass of the wash and waste.
Inspect the tubing of the waste.
Check if the conditioned tray(s) are functional (when applicable).
Check the movement of the various axes (when powered off) for noise and heavy
movement, lubricate when necessary.
Tests
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16
Check the alignment of the sampler. Re-align when necessary.
Perform a test with a standard.
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NEWTON
The NEWTON is used in combination with the Solids Module.
The NEWTON should not be opened. When the NEWTON requires service, contact the Support
Department of TE Instruments.
Do not open the NEWTON without approval of the Support
Department of TE Instruments.
Inspection and replacement

Check the smoothness of the movement of the tray(s).
Tests
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17
Check the alignment of the sampler with the solids module. Re-align the combination of the
sampler with NEWTON when necessary.
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GLS
The GLS (Gas and Liquid Sampler) is used in combination with the Liquids Module.
Inspection and replacement
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Power off the GLS and remove the power cable.
Replace the fuse.
Inspect the quick connector gas connection.
Inspect the quick connector LPG connection.
Inspect the tubing.
Inspect the capillary of the LPG.
Replace the injection needle.
Inspect the inline filter for the LPG sampling and replace when necessary.
Inspect the ventilator.
Inspect the pressure reducer for gas.
Tests
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18
Perform a leak test.
Check the proper filling of the LPG loop
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Parts
Listed the parts mentioned in the above chapters for maintenance of the X PLORER Chlorine and its
accessories. Ensure you order the correct parts for the configuration to be serviced. Note that also
parts which only need to be checked are listed.
Furnace Compartment
Part Number
CON102000
CON104100
CON105100
CON106100
ELE800210
GLS101300
GLS101500
GLS101600
PRT100800
PRT103300
PRT114400
PRT700200
PRT700300
Description
Shutter O-ring big, for furnace tube
Standard furnace tube XPLORER (1 exit)
Collision Flow Tube XPLORER (2 exits)
Collision Flow Tube with boat cooling (2 exits)
Fuse 10 A T (for 110 V input)
Furnace exit collision flow inlet
Furnace exit perma pure single
Furnace exit perma pure collision
Thermocouple XPLORER series
Thermal switch, NC, 110 °C, 95 °C
Fuse 6.3 A T (for 230 V input)
Perma pure dryer
Inner tube pf perma pure dryer only
Action
Replace
Check
Check
Check
Replace
Check
Check
Check
Replace
Replace
Replace
Check
Check
during maintenance
every year
every 2 years
every year
every year
Explanation Furnace Exit Parts
The type of furnace exit part depends of the type of furnace tube used.
For the standard furnace tubes (CON104100) the following exit is used:
GLS101500 – Furnace exit perma pure single – colored green in the picture
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For the collision furnace tubes (CON105100 and CON106100) the following exit is used:
GLS101600 – Furnace exit perma pure collision – colored blue in the picture
GLS101300 – Furnace exit collision flow inlet – colored green in the picture
Electronics Compartment
Part Number
PRT103100
PRT103200
PRT104300
PRT111200
Description
Quick connector female, white (argon)
Quick connector female, blue (oxygen)
Fan including wiring introduction module
Fan including wiring backside XPLORER
Action
Replace every 2 years
Replace every 2 years
Check
Check
Conditioning Compartment
Part Number
PRT700100
PRT701200
Description
Particulate filter (frit)
Ring RX Silicon
Action
Check
Check
Nitrogen Detector
Part Number
PRT700700
PRT900100
PRT900750
20
Description
In-line filter, 25 micron
Ozon killer
Vacuum pump XPLORER
Action
Replace every year
Replace every year
Replace every year
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Sulfur Detector
Part Number
PRT700500
Description
Xenon flash lamp
Action
Check
Liquids Module
Part Number
CON101400
PRT101500
PRT105100
PRT151900
Description
Septum 12 mm, 10 pieces
Quick connector male, blue (oxygen)
Quick connector male, white (argon)
Screw cap
Action
Check
Replace every 2 years
Replace every 2 years
Check
Solids Module
Part Number
CON100100
CON100101
CON101400
CON101900
PRT101500
PRT105100
Description
Slider boat for small sampler cups
Slider boat for small sample cups winged
Septum 12 mm, 10 pieces
Shutter O-ring small, boatguiding tube
Quick connector male, blue (oxygen)
Quick connector male, white (argon)
Action
Check
Check
Check
Replace during maintenance
Replace every 2 years
Replace every 2 years
Description
Injection syringe ARCHIE
Wash vial, ARCHIE
Waste duct, ARCHIE
Action
Check
Check
Check
ARCHIE
Part Number
PRT400100
PRT400200
PRT400300
NEWTON
For an Annual Maintenance of the NEWTON parts are not required.
GLS
Part Number
ELE800200
?
PRT121900
PRT600600
PRT801500
PRT802000
21
Description
Fuse 2.0 A T (for 230 V input)
Fuse 4.0 A T (for 110 V input)
Furnace needle coupler
POX purge needle 81 mm PS5 (set of 3)
GLS Capillary ¼”
GLS liquids particle filter
Action
Replace
Replace
Replace
Replace
Check
Check
every
every
every
every
year
year
year
year
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Annual Maintenance Report XPLORER-NS
Information XPLORER Nitrogen and/or Sulfur
Serial Number:
TEIS Software Version:
Furnace Temperatures
Setpoint furnace 1:
Setpoint furnace 2:
Measured:
Measured:
Flows
Setpoint argon:
Setpoint primary oxygen:
Collision flow:
Ozonator flow (only for the XPLORER-N or -NS):
Total flow calculated:
Leak test:
☐ Passed ☐ Failed
Nitrogen Detector
Heating:
Cooling:
Standard test, concentration:
☐ Passed
☐ Passed
Sulfur Detector
Heating:
Standard test, concentration:
☐ Passed
☐ Failed
☐ Failed
Measured:
☐ Failed
Measured:
Liquids Module
Serial Number:
Setpoint heating:
Closes properly:
Leak test:
☐ Passed
☐ Passed
☐ Failed
☐ Failed
Solids Module
Closes properly:
Leak test:
☐ Passed
☐ Passed
☐ Failed
☐ Failed
ARCHIE
Serial Number:
Calibration correct:
☐ Passed
☐ Failed
NEWTON
Alignment correct:
☐ Passed
☐ Failed
22
Measured:
Measured:
Measured:
Measured:
Measured:
Measured:
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GLS
Serial Number:
Leak Test:
☐ Passed
☐ Failed
Used Parts
Comments
Date:
Name customer:
Name Service Engineer:
Signature:
Signature:
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