Hydrogen Sulfide Analyzer User`s Operating

Hydrogen Sulfide Analyzer User`s Operating
Rev. 1.0
DEL MAR SULFURELITE™
Hydrogen Sulfide Analyzer
User’s Operating Manual
Serial Number XXXX
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Table of Contents
Section X Warranty .......................................................................Error! Bookmark not defined.
GENERAL INFORMATION ...................................................................................................... 7
OPERATING PRINCIPLES ..................................................................................................... 10
A
CHEMFILMTM Technology ................................................................................................. 10
B
SULFURELITETM Principle .................................................................................................. 10
INSTALLATION ........................................................................................................................ 13
C
Location ............................................................................................................................ 13
D
Input Power Requirements ................................................................................................ 13
E
Gas Sample Line Requirements ........................................................................................ 13
F
Exhaust Provision ............................................................................................................. 14
G
Humidifier ......................................................................................................................... 14
H
Alarm Connections ........................................................................................................... 14
I
Remote Recorder Connections ......................................................................................... 15
J
CHEMFILMTM Installation .................................................................................................. 15
MODULE FUNCTIONS ............................................................................................................ 18
K
Power Supply .................................................................................................................... 18
L
Touch Screen and Display ................................................................................................ 18
M
CPU ................................................................................................................................... 18
N
Sensor Unit........................................................................................................................ 18
O
Frequently Selected Options for SULFURELITETM ............................................................. 18
STARTUP AND OPERATING PROCEDURE ....................................................................... 22
P
Startup ............................................................................................................................... 22
Q
Shut Down ........................................................................................................................ 22
R
Touch Screen and Display Operation ............................................................................... 23
Normal Analyzer Display: ................................................................................................ 23
Configuration and Parameter Data Entry:......................................................................... 24
S
Parameter Selection .......................................................................................................... 24
T
Alarm Configuration ......................................................................................................... 25
Low Concentration Alarm: ............................................................................................... 26
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High Concentration Alarm:............................................................................................... 27
Diagnostic Alarm: ............................................................................................................. 28
U
Calibration Configurations................................................................................................ 29
Gas Calibration (Manual): ................................................................................................ 29
Gas Calibration (Manual) Running:.................................................................................. 30
Gas Calibration (Manual) Complete: ................................................................................ 31
Gas Calibration (Auto):..................................................................................................... 31
Gas Calibration (Auto) Configuration: ............................................................................. 33
AutoCal Start Time and Date:........................................................................................... 34
AutoCal Dwell Times: ...................................................................................................... 34
AutoCal Intervals: ............................................................................................................. 35
AutoCal Set-up: ................................................................................................................ 36
Gas Calibration (Auto) Running: ...................................................................................... 37
AutoCal Purge Screen: ...................................................................................................... 39
LED/Detector Calibration: ................................................................................................ 40
4-20mA Calibration Screen: ............................................................................................. 41
V
System Configurations ...................................................................................................... 42
Tape Advance Set-Up: ...................................................................................................... 43
Data Logger Set-Up: ......................................................................................................... 44
Installing and Removing the SD Card .............................................................................. 45
Data Logger Data Format ................................................................................................. 45
Modbus Address: .............................................................................................................. 46
Unit of Measure: ............................................................................................................... 47
4-20mA Loop Scale: ......................................................................................................... 48
W
System Information ........................................................................................................... 49
Display Configuration:...................................................................................................... 50
Instantaneous Response: ................................................................................................... 51
Number of Averages: ........................................................................................................ 52
Coefficient 1: .................................................................................................................... 53
Factory Reset: ................................................................................................................... 54
X
Clock Configuration.......................................................................................................... 55
System Clock: ................................................................................................................... 56
TROUBLESHOOTING ............................................................................................................. 58
Y
Typical Problems Encountered ......................................................................................... 58
Diagnostic Alarm .............................................................................................................. 58
Erratic Readings on the Display ....................................................................................... 60
Inoperable Alarm Relay(s) ................................................................................................ 60
Inoperable 4-20 mA Analog Output ................................................................................. 60
Unrolled ChemFilm™ in Bottom of Sensor Cabinet ........................................................ 60
Larger Than Normal Tape Advance ................................................................................. 60
Z
Component Checkout Procedures ..................................................................................... 61
1. Power Supply ............................................................................................................ 61
2. Optical Sensor ........................................................................................................... 62
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3.
4.
5.
6.
7.
Motor Drive .............................................................................................................. 62
Illumination Source ................................................................................................... 63
CPU ........................................................................................................................... 63
Display Assembly ..................................................................................................... 66
Relay(s) ..................................................................................................................... 66
Section VII
MAINTENANCE ............................................................................................... 68
A
Scheduled Maintenance .................................................................................................... 68
B
Non-Scheduled Maintenance ............................................................................................ 68
Section VIII
Section IX
REVISION TABLE ........................................................................................ 74
DRAWINGS ........................................................................................................ 76
Section X Warranty .................................................................................................................. 77
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CAUTION:
DO NOT adjust, except as part of a complete calibration
sequence, the following:
a.
b.
Sample flow
Sample pressure
Leave sample slipstream open at all times.
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Section I
General Information
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GENERAL INFORMATION
Del Mar Scientific’s SULFURELITETM precision series of analyzers provide on-line analytical
measurement of hydrogen sulfide (H2S) concentrations. Depending on the selected accessories,
the measurement concentration range varies from parts per billion up to percent levels.
The CHEMFILMTM technology provides specific, interference free, detection and measurement.
H2S detection and concentration analysis by the use of CHEMFILMTM are based on chemical factors
and physical constants, which confirm the unique analytical precision of the technology.
SULFURELITETM takes full advantage of microprocessor calculation precision. Data is acquired
with greater than 16-bit conversion resolution. Signal over sampling is applied for statistical
detection processing and accuracy correlation. An extensive set of mathematical algorithms is
executed with full floating point precision to calculate the concentration.
Local touch screen display provides easy operation selection and real-time analysis display.
Configuration selection is provided to meet varied user requirements.
* Engineering Units Displayed
* Diagnostic Alarm Settings
* Concentration Alarm Settings
Calibration options allow flexibility to match available resources with application requirements.
Diagnostic alarms are generated by software checks to provide system status and help with system
maintenance.
On-line reliability is built into Del Mar Scientific products at every level, from initial design to
final calibration and quality assurance testing. Operator confidence is gained through exceptional
on-line performance.
Careful design, strict manufacturing control and microprocessor technology, combined with the
proven detection principle, make these monitors the most accurate, versatile and reliable monitors
available for field installation.
All calibration constants and alarm set points are stored in random Flash memory on the processor.
Battery backup prevents loss of memory in the event of a power failure. The system is also
equipped with a real time clock and calendar. The system clock is required for auto calibration,
which allows the system to calibrate at user-selected time intervals.
The system also provides the means for calibrating a 4-20 mA loop, using an external-measuring
device, such as a current meter. The operator simply adjusts the displayed 4-20 mA current to
match the external measuring device.
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CAUTION: The specific start-up and shut-down sequence must be followed!
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Section II
Operating Principles
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OPERATING PRINCIPLES
A
CHEMFILMTM Technology
Measurement of H2S concentration by the use of CHEMFILMTM is based on physical
constants and chemical factors.
Mathematical formulations and field proven results demonstrate the calculation precision
that is achieved by the application of CHEMFILMTM technology.
Detection of H2S concentrations by the use of CHEMFILMTM is achieved by exposing the
film to a sample through an aperture in the sample flow system. The reaction of
photographic film to light is an analogy to the way that the chemically activated
CHEMFILMTM reacts to hydrogen sulfide.
This reaction has two characteristics that allow it to be applied with unique analytical
precision:
1. The reactants are colorless (white).
2. The product (lead sulfide) is colored.
3. In more than a century of use, H2S is the only reactant ever found that produces a
colored product.
B
SULFURELITETM Principle
The block diagram on the following page shows how Del Mar Scientific’s SULFURELITETM
monitor utilizes a single optical sensor and light source to detect and measure the rate of
lead sulfide formation.
The single optical sensor used in the SULFURELITETM series functions as both a reference and
measurement optical sensor. At the beginning of each measurement cycle, the tape advances
to a new or unexposed portion of the tape. Instantly, as the tape stops, the optical sensor
value is measured and the resultant voltage level is stored in the microprocessor memory
section. A new optical sensor reading is compared to the stored information.
At this point, the microprocessor determines the level of H2S concentration by comparing
the two readings and displays the result on the digital display in engineering units as selected
by end user in the system configuration, such as, PPM or Grains by volume. Simultaneously,
the second reading is stored in the memory for later comparison to a third reading. The cycle
is repeated on an average of one reading every second, until the tape is too dark for further
accurate readings or until a tape advance occurs.
Effectively, a new zero or reference point is selected with each reading after the initial
period. Temperature drift is virtually eliminated, as it is confined to a time span of less
than 10 seconds.
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As the reading is displayed, it is used to actuate any alarms, if the level is above the alarm
set point, and drive the optional 4-20 mA loop or data logger.
Figure 0-1
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Section III
Installation
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INSTALLATION
Upon receipt, the instrument should be inspected for any damage that may have been sustained in
shipping. If the instrument has been damaged, it should be reported to Del Mar Scientific at once.
C
Location
The SULFURELITETM analyzers are designed for use in the following area classifications:
Non-hazardous
Class 1, Division 2
D
Input Power Requirements
The input power requirements for your particular analyzer vary depending on the input
power option ordered with the instrument. The following tables represent the input power
required at the possible voltage inputs. For best analyzer performance, Del Mar
Scientific recommends that analyzers NOT share a common DC power source with other
devices.
Input Voltage
110-120 VAC
230 – 240 VAC
12 VDC
24 VDC
Input Current
0.17 Amps AC
0.085 Amps AC
1.0 Amp
0.5 Amp
Notes
.5 Amps with
Cabinet heater
Max allowable
ripple is 200 mVp-p
Table 1
A ground rod must also be installed at each analyzer location. This ground should NOT
be shared with other instruments. The chassis, cabinet and/or back plate should be
grounded to the grounding rod.
E
Gas Sample Line Requirements
The input sample line should be made of stainless steel and not be more than 1/4" in
diameter. It is recommended that a slipstream be used to insure that a lengthy dead-end
sample line does not adversely affect response time.
A compression type 1/4" O.D. tube fitting is provided for the gas sample input to the
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analyzer.
F
Input Sample Pressure To Factory Supplied Regulator
20 – 3000 psig
Sample Pressure From Factory Supplied Regulator
15 psig
Input Sample Pressure (If No Factory Regulator Is Supplied)
15 psig
Sample Flow Meter
50 Elevation
Exhaust Provision
Sample gas is expelled through a compression type 1/4" tube fitting to atmosphere.
Always position the exhaust line in a downward configuration to prevent backpressure.
Use of a wind baffle (Part Number 030-0045-00) at the end of the exhaust line is
recommended. Any exhaust line must not be smaller than 1/4" O.D. and .032" wall
thickness.
NOTE: In making the exhaust connection, care must be taken to avoid creating either a
backpressure or a vacuum at the sensor head. The exhaust cannot be connected to a relief
or vacuum line.
G
Humidifier
The humidifier is located behind the hinged front panel and is accessible by opening the
panel. Remove the knurled fill plug and fill to within 1/4" of the fill line with the
humidifier solution (Part Number 305-0006-00), supplied with the instrument. Do not
over fill the humidifier, as it will not function properly when over filled. The capacity of
the humidifier is sufficient for approximately four weeks of operation under most
conditions. After filling, replace and hand tighten the knurled fill plug.
NOTE: The humidifier fill line is the etched mark on the side of the humidifier.
The filter (Part Number 240-0007-01) in the humidifier can be replaced by disconnecting
the sample input line located in the center of the humidifier. Remove the large, stainless
steel nut to which the filter is attached. The filter slips off the filter stem for easy
replacement. Carefully slip the replacement filter over the O-ring seal. Do not use any
other filter, as the wicking action of the filter is an important function of the humidifier.
When replacing the sample input line, be sure it is tightened sufficiently to insure that
leaks do not occur.
H
Alarm Connections
Alarm connections on all SULFURELITETM series instruments are made on Alarm Relay(s)
internal to the analyzer. Refer to the Installation and Wire drawing in Section IX -
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Drawings for location of these connections. Care should be taken to avoid exceeding the
maximum rating of these outputs, as damage to the control circuitry may occur. Follow
approved wiring methods when making the connections.
All inductive loads connected to mechanical relay outputs must have a
suppression diode installed across the load (at the load) to prevent backEMF from damaging the analyzer.
I
Remote Recorder Connections
Recorder connections on all SULFURELITETM series instruments are made on the Isolator
internal to the analyzer. Refer to the Installation and Wire drawing in Section IX Drawings for location of these connections. Care should be taken to avoid exceeding the
maximum rating of these outputs, as damage to the control circuitry may occur. Follow
approved wiring methods when making the connections.
Please note that the 2-wire, 4-20 mA signal, provided for external connection to a
chart recorder or other instrumentation, is self-powered.
J
CHEMFILMTM Installation
Refer to the “Assy, SulfurElite Front Panel” (020-0242-00) drawing in Section IX Drawings for identification of these components.
1. Press the “Hold” button on the top left corner of the display screen. The
button will indicate when the unit is in Hold.
2. Place a full roll of CHEMFILMTM on the supply hub. Leave approximately 10
inches of CHEMFILMTM loose.
3. Pull down on the spring-loaded pressure block. If you wish, you may place the
Tape Loading Tool (Part Number 220-0371-00) over the guide bolts at the
bottom of the pressure block to hold the detector open. Feed the loose end of
the CHEMFILMTM above the guide post then through the ½" slot in the detector
and pressure blocks until several inches of CHEMFILMTM extend through the
detector. Release the pressure block and pull about one inch of tape through
the detector head to verify that the tape is in the proper position between the
pressure block and detector block.
4. Place an empty cardboard spool on the take-up reel so that the notch on the
spool is engaged by the cap screw on the hub. Depress the pressure roller and
pass the CHEMFILMTM between the pressure roller and the capstan. Pull
several inches of tape through and then release the pressure roller. Secure the
CHEMFILMTM to the cardboard spool with a piece of tape. Slowly rotate the
take-up spool counterclockwise to remove as much slack as the take-up drive
will permit. The slip clutch action of the take-up drive will take up the
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balance of the slack when the analyzer is placed in operation.
5. Press the “Reset” button on the display screen. The analyzer will perform a
tape advance. Verify the CHEMFILMTM advances through the detector
properly.
6. Press the “Hold” button. This will place the analyzer back into normal
service. The “Reset” will NOT remove the “Hold” action.
Three mode settings control the behavior and use of your CHEMFILMTM tape in the
analyzer. These are:



Tape Advance Interval Time
Tape Advance Duration
Advance on Demand
Refer to these modes to understand how the analyzer consumes CHEMFILMTM.
NOTE: Your CHEMFILMTM is sensitive to moisture and environmental conditions.
It must be replaced after being open for 45 days. Del Mar Scientific can NOT
guarantee proper operation of your analyzer if the CHEMFILMTM tape has been out
of its package for more than 45 days.
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Section IV
Module Functions
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MODULE FUNCTIONS
The SULFURELITETM H2S analyzers have several optional modes of control and configuration.
These features are described in this section to familiarize operations personnel with the functions
of the system, and available options that may be added later.
K
Power Supply
The power supply accepts the input power and converts it to 24 VDC for the control
circuitry. Depending on the analyzer options, input power may be one of the following:


10-32 VDC
100-240 VAC
Insure that the correct input power and polarity is applied, or damage may occur.
L
Touch Screen and Display
The display module with touch screen is the primary operator interface. The display
shows the current concentration during normal operation or mode status during
configuration. All operator selectable parameters are made via the touch screen by
selecting the appropriate mode. A listing and description of modes and instructions for
changing parameters can be found in Section V – Part C.
M
CPU
The CPU performs analyzer calculations, displays H2S concentration, and outputs various
signals.
N
Sensor Unit
The sensor unit consists of the optical sensor, illumination source and the motor.
O
Frequently Selected Options for SULFURELITETM
Data Logger
A SD Card based data logger
is available to record concentration, date, time, and
alarm status. The data is an easily readable CSV
format and can be read from any standard PC or
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laptop with an appropriate adaptor and software.
4-20 mA Isolated Output
Alarm Relay(s)

Provides 4-20mA isolated outputs.
Diagnostic Alarm
This option provides a
mechanical relay contact output, in the event of one
of the following fault conditions:







Tape breakage
Out of tape
Motor failure
Optical sensor failure
Illumination source failure
Auto Calibration failure(if Installed)
Processor failure

Low Concentration Alarm This option provides
mechanical relay contact outputs in the event that
the concentration equals or exceeds the selected
value.

High Concentration Alarm This option provides
mechanical relay contact outputs in the event that
the concentration equals or exceeds the selected
value.
Cabinet Heater
A 115/220 VAC, 50-watt heater,
with thermostat control integrated into the cabinet
that maintains operating temperature and provides
freeze protection of the humidifier solution.
Pressure Regulator
A 0-3600 PSIG input with a 0-25
PSIG output and pressure gauge used to control
sample pressure to the analyzer. Materials of
construction have been selected for H2S service.
Sample Filter(s)
This option provides protection for
the analyzer from moisture and particulate
contamination. A low dead end volume provides a
minimal sample transport delay. Materials of
construction have been selected for H2S service.
This option provides customer
connection fittings and valves to provide input of
calibration gas without disconnection of sample
Calibration Tap
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line.
Auto Calibration
This option provides the software,
contact outputs, solenoid valves, tubing and
customer connections for automatically calibrating
the analyzer at user selected time intervals.
Modbus
This option offers the ability
to communicate with the analyzer using the popular
Modbus ASCII protocol. The analyzer uses RS-485
serial communication for the Modbus interface.
Additional options may be available. Consult the factory for details and pricing information.
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Section V
Start-Up and Operating Procedure
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STARTUP AND OPERATING PROCEDURE
The initial start-up of any SULFURELITETM instrument is very simple, but the few steps involved
must be followed for proper operation. If, during the start-up procedure (or at any other time), the
instrument does not function properly, refer to Section VI - Troubleshooting for help in correcting
the problem.
P
Q
Startup
1.
Turn on main power to the unit.
2.
Install the CHEMFILMTM sensing tape as described in Section III, Part H.
3.
Fill the humidifier assembly with solution as described in Section III, Part E.
4.
Verify pressure and flow settings as stated in Section III, Part C.
Shut Down
1.
Turn off main power to unit.
2.
Turn off gas flow to the analyzer.
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R
Touch Screen and Display Operation
Information display and data entry is performed through the touch screen.
Normal Analyzer Display:
During normal analyzer operation the display shows the current time, date and concentration
data, as new values become available. The display also shows the buttons for system
configuration. The screen will also show if the analyzer is in hold mode by showing “ON” on
the Hold button. The screen will also show if the analyzer is in an alarm state by changing the
color of the concentration value. Green indicates the concentration is below all alarm set points.
Yellow indicates the concentration is above the low alarm set point. Red indicates the
concentration is above the high alarm set point
Hold:
Pressing the “Hold” button freezes all outputs.
System:
Pressing the “System” button brings up the Analyzers Information. See section H.
System Information.
Alarm:
Pressing the “Alarm” button brings up the alarm configuration information.
See section E. Alarm Configuration.
Cal:
Pressing the “Cal” button brings up the calibration configuration
information. See section F. Calibration Configuration.
Set-Up:
Pressing the “Set-Up” button brings up the system configuration information. See
section G. System Configuration.
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Time:
Pressing the Time or Date at the top of the screen will bring up the clock
information. See section I. Clock Configuration.
Reset:
Pressing the “Reset” button performs a system reset and executes a tape
advance. Reset processing includes:







Initializing data queues
Tape advance
Initialize the tape timers
Check for broken tape condition
Check for out of tape condition
Update 4-20 mA output
Reset alarms as needed
Configuration and Parameter Data Entry:
To change the operation and settings of the analyzer, press the appropriate button on the touch
screen. These parameters generally include alarms, settings, configurations, etc.
S
Parameter Selection
To change user selectable parameters, the operator must first initiate the mode selection
function.
NOTE:
When performing mode operations, the alarms are disabled, and the
4-20 mA loop current is held at its last level in all modes except during
an Auto Cal sequence or 4-20 mA calibration.
To enter the mode selection functions press the appropriate button. For example, to edit
the alarm settings press the Alarm button.
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T
Alarm Configuration
From the main screen press the Alarm button. This will bring up the Alarm
Configuration screen.
The screen shows the Low Concentration, High Concentration and Diagnostic Alarm. To
edit one of the concentration alarms press the Low or High button on the left. The text on
the selected button will turn Red to indicate the selected alarm.
The current concentration will be displayed in the top left corner.
To return to the previous screen press the Back button.
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Low Concentration Alarm:
Description:
This parameter is used to set the H2S concentration level at which the “Low
Concentration Alarm” is to be activated.
The “Low Concentration Alarm” will return to normal when the concentration
reaches 98% of the entered alarm value unless the “Low Alarm Latching” feature
is enabled.
Fail-Safe:
The “Low Alarm Fail-Safe” determines the logic of the digital output when the
alarm is active, either low active or high active. When the analyzer is equipped
with mechanical relays, and when “Low Alarm Fail-Safe” is set, the alarm will
behave in a “fail-safe” manner. This means that a power failure will cause an
alarm-active state.
Latching:
The “Low Alarm Latching” is used to cause the “Low Concentration Alarm” to
latch when activated. This is a software latch only. A “System Reset” or a power
cycle sequence causes the alarm to unlatch and reset provided that the current
analyzer concentration is lower than the “Low Concentration Alarm” value.
Default:
3.00 PPM is the factory default value.
Range:
Minimum value: 0.0 PPM
Maximum value: Analyzer Range
To enter a new concentration value:
1. Press the Low button on the left side of the screen.
2. Enter in the new concentration value for the alarm (ex. 3.50). The new value will be
displayed above the keypad 3.50 . To clear an incorrect value, press the CLR button
then re-enter the value.
3. Press the Ent button to accept the value.
4. The entered value will be displayed at Low Alarm = 3.50
To change the Fail-Safe or the Latching status, press the corresponding button. The text on the
button will toggle between Black and Red as well as the button indicator will fill. The Red text
indicates that function is active.
To return to the previous screen press the BCK button.
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High Concentration Alarm:
Description:
This parameter is used to set the H2S concentration level at which the “High
Concentration Alarm” is to be activated.
The “High Concentration Alarm” will return to normal when the concentration
reaches 98% of the entered alarm value unless the “High Alarm Latching” feature
is enabled.
Fail-Safe:
The “High Alarm Fail-Safe” determines the logic of the digital output when the
alarm is active, either low active or high active. When the analyzer is equipped
with mechanical relays, and when the “High Alarm Fail-Safe” is set, the alarm
will behave in a “fail-safe” manner. This means that a power failure will cause an
alarm-active state.
Latching:
The “High Alarm Latching” is used to cause the “High Concentration Alarm” to
latch when activated. This is a software latch only. A “System Reset” or a power
cycle sequence causes the alarm to unlatch and reset provided that the current
analyzer concentration is lower than the “High Concentration Alarm” value.
Default:
4.00 PPM is the factory default value.
Range:
Minimum value: 0.0 PPM
Maximum value: Analyzer Range
To enter a new concentration value:
1. Press the High button on the left side of the screen.
2. Enter in the new concentration value for the alarm (ex. 4.50). The new value will be
displayed above the keypad 4.50 . To clear an incorrect value, press the CLR button
then re-enter the value.
3. Press the Ent button to accept the value.
4. The entered value will be displayed at High Alarm = 4.50
To change the Fail-Safe or the Latching status, press the corresponding button. The text on the
button will toggle between Black and Red as well as the button indicator will fill. The Red text
indicates that function is active.
To return to the previous screen press the BCK button.
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Diagnostic Alarm:
Fail-Safe:
The “High Alarm Fail-Safe” determines the logic of the digital output when the
alarm is active, either low active or high active. When the analyzer is equipped
with mechanical relays, and when the “High Alarm Fail-Safe” is set, the alarm
will behave in a “fail-safe” manner. This means that a power failure will cause an
alarm-active state.
Latching:
The “Diagnostic Alarm Latching” is used to cause the “Diagnostic Alarm” to
latch when activated. This is a software latch only. A “System Reset” or a power
cycle sequence causes the alarm to unlatch and reset provided that the diagnostic
fault has been cleared.
When this parameter is set, a diagnostic condition will trigger a digital output
state change and will remain in an alarm state until the operator intervenes. This is
a software latch only. A “System Reset” or power cycle sequence causes the
alarm to unlatch and reset provided that the diagnostic condition has been cleared.
If the unit is in a Diagnostic alarm the condition will be listed on the main screen:
“Broken Tape” or “Out of Tape” or “Auto Cal Failed”
To change the Fail-Safe or the Latching status, press the corresponding button. The text on the
button will toggle between Black and Red as well as the button indicator will fill. The Red text
indicates that function is active.
To return to the previous screen press the BCK button.
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U
Calibration Configurations
From the main screen press the Cal button. This will bring up the Calibration
Configuration screen.
Gas Calibration (Manual):
The current concentration will be displayed in the top left corner.
Description:
Cal Gas Value allows the operator to input the concentration of the calibration gas
used during “Manual Calibration”. Any variation of the analyzer measured value
and the calibration gas standard is reconciled by adjusting the “Calibration
Factor”.
Start:
The Start button will start a timer (20 minutes) to allow the analyzer
sufficient time to stabilize on the calibration gas being applied to the analyzer.
Reset:
The Reset button returns the H2S Factor back to the factory default of
3.50.
To enter a new concentration value:
1. Enter in the new value for the calibration gas standard (ex. 5.50). The new value will be
displayed above the keypad 5.50 . To clear an incorrect value, press the CLR button
then re-enter the value.
2. Press the Ent button to accept the value.
3. The entered value will be displayed at Standard = 5.50
Before starting Manual calibration connect the calibration standard to the Cal Port. Start gas
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flow then press the Start button to start the calibration process.
NOTE:
If the calibration standard is higher than either the Low Concentration or the
High Concentration Alarms, the system will not exit Calibration until the
reading is below both the alarm set points.
NOTE:
The 4-20mA output will NOT track the calibration
To return to the previous screen press the BCK button.
Gas Calibration (Manual) Running:
Description:
Displays the current concentration reading, the number of seconds remaining and
if the reading is above the concentration alarm set points.
To cancel the calibration process, press the Cancel button. This will return to the previous screen
as long as the reading is below the Concentration Alarms.
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Gas Calibration (Manual) Complete:
Description:
Calibration Factor is a parameter that is used as a multiplying factor that scales
and/or calibrates the displayed concentration value. Increasing the “Calibration
Factor” value will cause the displayed concentration to increase and decreasing
the “Calibration Factor” value will decrease the displayed concentration. Most
analyzer systems use “Calibration Factor” values between 3.0 and 4.0.
Press the Accept button to complete the calibration or the Cancel button to discard the
calibration. The display will return to the Gas Calibration (Manual) screen after pressing either
button.
Gas Calibration (Auto):
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Description:
This screen shows when the next Auto Calibration will start, Auto
Calibration cycle, gas dwell times, calibration standard used in the Auto
Calibration process, if Auto Calibration is enabled or not, and the current
Auto Calibration factor.
Next:
The start time and date for when the next auto calibration is to
start.
Interval:
The interval time is the frequency at which the auto calibration
function will execute.
Dwell Times:
Dwell times are the duration in minutes that the calibration gas and
purge gas will remain on.
Cal Standard:
AutoCal standard is the concentration of the calibration gas used
during “Auto Calibration”.
AutoCal Enabled:
Shows if the Auto Calibration option is enabled.
Cal Factor:
The Cal Factor is a number ranging from 0.8 to 1.2 (determined by
“Auto Cal Limit” under Config) that is the current “Cal Factor”. The “Cal
Factor” is updated at the end of each Auto Calibration cycle.
Start Button:
Initiates the Auto Calibration sequence. Note that valid Auto
Calibration information must be stored using “Config” and the “System
Clock” must be set correctly.
Purge Button:
Initiates the Purge Gas Cycle. Note that valid Auto Calibration
information must be stored using “Config” and the “System Clock” must
be set correctly.
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The Purge Gas Cycle is ordinarily activated to purge the sample system
for a period of minutes specified by “Auto Cal Purge Gas Dwell Time”.
Reset Button:
During startup and operation of an Auto Calibration analyzer it is
sometimes useful to restart the Auto Calibration calculations with a known
“Calibration Factor”. “Reset Calibration Factor” allows quick reset of the
“Calibration Factor” to l.0.
Config Button:
To edit the parameters of the Auto Calibration cycle.
Back Button:
Return to the previous screen.
Gas Calibration (Auto) Configuration:
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Select the parameter that needs to be updated.
AutoCal Start Time and Date:
This sets the Time and date of the next Auto Calibration cycle.
Press the Back button to return to the previous screen.
AutoCal Dwell Times:
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Span:
The number of minutes that the Calibration Standard will run in the
calibration process.
Purge:
Auto Cal Purge Gas Dwell Time is the number of minutes that the “purge
gas” is applied to the sample system inlet to purge the analyzer before switching
back to the sample gas stream.
To enter a new time:
1. Select the parameter that is to be edited by pressing the data field. The indicator next to
the selected data field will turn blue to indicate that it is selected.
2. Enter in the new value for the time (ex. 15). The new value will be displayed above the
keypad 15 . To clear an incorrect value, press the CLR then re-enter the value.
3. Press the Ent button to accept the value.
4. The entered value will be displayed at Span = 15.
To return to the previous screen press the BCK button.
AutoCal Intervals:
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Minutes:
The number of minutes between cycles.
Hours:
The number of hours between cycles.
Days:
The number of days between cycles.
To enter a new value:
1. Select the parameter that is to be edited by pressing the data field. The indicator next to
the selected data field will turn blue to indicate that it is selected.
2. Enter in the new value for the time (ex. 15). The new value will be displayed above the
keypad 15 . To clear an incorrect value, press the CLR then re-enter the value.
3. Press the Ent button to accept the value.
4. The entered value will be displayed at Minutes=15.
Note: The three values are accumulative. Example if Days = 1 and Hours = 2 and the last
AutoCal was at 13:00 on 5/15/12 the next AutoCal cycle will be at 15:00 on 5/16/12.
To return to the previous screen press the BCK button.
AutoCal Set-up:
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Cal Gas:
Cal Gas allows the operator to input the concentration of the calibration gas used
during “Auto Calibration”.
Limit:
Limit is a parameter, in percent, which determines how much an Auto Cal
cycle can vary the computed concentration value. For instance, when the “Auto
Cal Limit” is set to 20, the “Auto Cal Factor” may range 20% above and below a
unity calibration factor (1.0). A 20% “Auto Cal Limit” would correspond to an
“Auto Cal Factor” that ranged from 0.8 to 1.2. If, during an Auto Cal cycle, the
newly calculated “Auto Cal Factor” is outside this range, the analyzer will fail the
Auto Cal Cycle and keep the old “Auto Cal Factor”.
Enabled:
Enables or disables the auto calibration feature.
To enter a new value:
1. Select the parameter that is to be edited by pressing the data field. The indicator next to
the selected data field will turn blue to indicate that it is selected.
2. Enter in the new value for the gas standard (ex. 25). The new value will be displayed
above the keypad 25 . To clear an incorrect value, press the CLR then re-enter the
value.
3. Press the Ent button to accept the value.
4. The entered value will be displayed at Cal Gas = 25.
5. To enable or disable the auto calibration, press the Enabled button.
To return to the previous screen press the BCK button.
Gas Calibration (Auto) Running:
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Description:
This feature provides software-controlled solenoid valves used to automatically
calibrate the analyzer at user-selected time intervals. This is a 5-step process. The
start time, time interval, and gas dwell times are set using “Auto Cal
Configurations” and “AutoCal Dwell Times” “Purge”. The Auto Cal process is
outlined below.
Cancel:
The "Cancel" button will stop the Auto Calibration process and return to the main
AutoCal screen. By cancelling the Auto Calibration process no changes are made
to the calibration factors.
Step 1:




The sample gas is turned off
The calibration gas is turned on
Alarm output states are frozen
The analyzer waits for the dwell time specified in “AutoCal Dwell
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

Times”
The analyzer turns on the “Tape Advance on Demand”
The 4-20mA output tracks the calibration




The calibration gas is turned off
The purge gas is turned on
The display and 4-20 mA output is held at the current concentration
The analyzer waits for two minutes (As Found )

The analyzer calculates the new Auto Cal Factor based on the cal gas
value entered in “AutoCal Parameters” “Cal Gas”
The analyzer makes sure the new “Auto Cal Factor” is within the limits
specified by “Auto Cal Limit” (If an AutoCal failure occurs, the
diagnostic alarm is activated and no updates are made)
The display and 4-20 mA output is updated to show this new value, and
held constant
The analyzer waits for two minutes (As Left )
Step 2:
Step 3:



Step 4:


The analyzer releases the display and 4-20 mA output
If the value of the “Purge Gas Dwell Time” is greater than 4 minutes, the
analyzer waits for the “Purge Gas Dwell Time” to expire



The purge gas is turned off
The sample gas is turned on
The 4-20mA output and alarms are returned to normal operation
Step 5:
To cancel the calibration process, press the Cancel button. This will return to the previous screen.
AutoCal Purge Screen:
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Description:
This feature will flow the purge gas through the sample system for the amount of
time set for "Purge Dwell Time".
Cancel:
The "Cancel" button will stop the Purge gas process and return to the main
AutoCal screen.
LED/Detector Calibration:
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LED Voltage:
At analyzer startup the voltage to the LED is set to the parameter
value stored in “LED/Detector Calibration” “LED Voltage”. After setting
a new value in “LED Voltage” the screen will update the current LED
voltage and the Detector Voltage.
Detector Voltage:
The voltage read from the detector. The detector voltage should be
between 2.80 and 3.20.
By raising or lowering the LED voltage, the Detector voltage will be
changed in the same direction.
To enter a new value:
1. Enter in the new value for the LED Voltage (ex. 2.25). The new value will be displayed
above the keypad 2.25 . To clear an incorrect value, press the CLR button then re-enter
the value.
2. Press the Ent button to accept the value.
3. The entered value will be displayed at LED Voltage= 2.25.
4. Verify that the detector voltage is between 2.80 and 3.20.
To return to the previous screen press the BCK button.
4-20mA Calibration Screen:
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Description:
Reset:
This screen is used to calibrate the loop current output to an external current
meter. The current meter must be inserted in the loop between the analyzer and
the final measuring device. The operator enters the values measured on the
current meter for the 4mA and the 20mA.
The Reset button returns the calibration factors back to 4.00 and 20.00.
To enter a new value:
1. Press the 4mA button. The 4mA button text will turn Red to indicate it is selected.
2. Enter in the value measured with the external device (ex. 3.98). The new value will be
displayed above the keypad 3.98 . To clear an incorrect value, press the CLR then reenter the value.
3. Press the Ent button to accept the value. The 4mA output will be updated.
4. Press the 20mA button. The 20mA button text will turn Red to indicate it is selected.
5. Enter in the value measured with the external device (ex. 19.92). The new value will be
displayed above the keypad 19.92 . To clear an incorrect value, press the CLR then reenter the value.
6. Press the Ent button to accept the value. The 20mA output will be updated.
7. Repeat steps 1-6 as needed.
To return to the previous screen press the BCK button.
V
System Configurations
From the main screen press the Set-Up button. This will bring up the Tape Advance
screen.
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Tape Advance Set-Up:
Interval:
Tape Advance Interval Time parameter causes the analyzer to utilize a particular
spot on the CHEMFILMTM for the number of minutes specified. The analyzer will
wait for the specified time period even if the detector voltage drops below the
“Low Threshold Value” unless the “Advance on Demand” parameter is set to ON.
The default value of 5 minutes is long enough to effectively utilize the
CHEMFILMTM.
Duration:
The Tape Advance Duration Number determines “how long” the tape advance
motor is run. The tape advance motor run time determines the spacing between
reaction spots on the CHEMFILMTM. Ordinarily a default value of 25 spaces the
spots on the tape at about 3/8”- 1/2” intervals.
On Demand: When set to OFF, the tape advance cycle is triggered only by the “Tape Advance
Interval Time”.
When set to ON, the tape advance cycle may be triggered by the first occurrence
of either the “Tape Advance Interval Time”, or when the detector voltage reaches
the “Lower Threshold Value”.
To enter a new value:
1. Select the parameter that is to be edited by pressing the data field. The indicator next to
the selected data field will turn blue to indicate that it is selected.
2. Enter in the new value (ex. 15). The new value will be displayed above the keypad 15 .
To clear an incorrect value, press the CLR button then re-enter the value.
3. Press the Ent button to accept the value.
4. The entered value will be displayed at Interval = 15.
5. To enable or disable the On Demand, press the ON/OFF button.
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To return to the previous screen press the BCK button.
Data Logger Set-Up:
The Data Logger option allows for the easy collection and transfer of analyzer data. The Data
Logger uses an industry standard SD Card that can be inserted into a laptop or desktop computer
to retrieve the stored information.
Two events will cause data to be logged to the SD Card. First, a configurable timer controls the
period (in minutes) between data log entries under normal conditions. Additionally, the analyzer
will create a log entry when the H2S concentration varies by a set amount. That amount is also
configurable. See below for more information.
Interval:
Interval indicates the time period (in minutes) that the analyzer will record
concentration values to the Data Logger SD Card log file.
Change:
Change indicates a change in concentration that will cause a new entry to be
written to the Data Logger SD Card log file. If the current measured
concentration has changed by more than the “Change” value from the last value
logged to the SD Card, before the time in “Interval” has elapsed since the last log,
the data will be written to the SD Card.
To enter a new value:
1. Select the parameter that is to be edited by pressing the data field. The indicator next to
the selected data field will turn blue to indicate that it is selected.
2. Enter in the new value for the time (ex. 5). The new value will be displayed above the
keypad 5 . To clear an incorrect value, press the CLR then re-enter the value.
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3. Press the Ent button to accept the value.
4. The entered value will be displayed at Interval=5.
To return to the previous screen press the BCK button.
CAUTION: The SD Card should NOT be inserted or removed from the analyzer
when the analyzer is on. Damage to the data files, the SD Card, or the analyzer
may occur.
Installing and Removing the SD Card
To install the SD Card:
1. Turn the analyzer OFF.
2. Insert the SD Card, labeled side pointed up, into the Data Logger Port. (The SD
card will only fit one way.)
3. Turn the analyzer ON.
Data Logging will begin automatically.
To remove the SD Card:
1. Turn the analyzer OFF.
2. Press SD Card in and release the latch. The SD Card will eject slightly.
3. The card may now be safely removed from the Data Logger Port.
4. Turn the analyzer ON.
Data Logger Data Format
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The analyzer names data files on the SD Card according to the following format:
YYMMDD.CSV, where
YY = year (as set in the analyzer’s
clock)
MM = month (as set in the
analyzer’s clock)
DD = day (as set in the analyzer’s
clock)
Example: today’s date is 01/30/2014…so today’s log file will be “140130.CSV”
The .CSV file is a comma separated file and may be opened by any text or
spreadsheet program. The format of the data is as follows:
HH:MM:SS,ppm[,D][,L][,H]
Where HH:MM:SS = time of log (as set in the analyzer’s clock)
PPM = Concentration of gas
D1 = H2S Out of Tape Diagnostic Alarm Active
D2 = H2S Broken Tape Diagnostic Alarm Active
L = Low Concentration Alarm Active
H = High Concentration Alarm Active
D, L and H only appear in the log if the alarm is active.
Modbus Address:
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Description:
This is only used when the analyzer is equipped with the Modbus option.
Address:
The device address that the analyzer will respond to when using the Modbus
protocol. Acceptable addresses are 1 through 250.
Baud:
The device Rate is the Baud rate for the communication protocol. To
change the baud rate, enter the number for the corresponding rate required (ex. 6
for 57600).
To enter a new value:
1. Select the parameter that is to be edited by pressing the data field. The indicator next to
the selected data field will turn blue to indicate that it is selected.
2. Enter in the new value for the Modbus Address (ex. 50). The new value will be
displayed above the keypad 50 . To clear an incorrect value, press the CLR button
then re-enter the value.
3. Press the Ent button to accept the value.
4. The entered value will be displayed at Address = 50.
To return to the previous screen press the BCK button.
Unit of Measure:
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Description:
Concentration Units allows the operator to select concentration processing and
display in “PPM” or in “grains”. Press the Unit of Measure button to be selected,
PPM or grains. The text on the button will turn red to indicate it is selected. The
dot on the button will also be filled on the selected Unit of Measure.
NOTE: If Unit of Measure is changed, Low Concentration Alarm, High
Concentration Alarm, 4-20mA Scale and Calibration Gas Standard need to
be updated to reflect the selected unit of measure. If optional Data Logger
is installed PPM change also needs to be updated.
To return to the previous screen press the Back button.
4-20mA Loop Scale:
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Description:
The 4–20 mA Loop Scale value is used to scale the current concentration value
into a range represented within the 4–20 mA signal range (i.e. 0 PPM is
represented by 4 mA and a concentration which equals the “4-20 mA Loop Scale”
value is represented by a 20.0 mA signal).
To enter a new value:
1. Enter in the new value for the 4-20mA Scale (ex. 25). The new value will be displayed
above the keypad 25 . To clear an incorrect value, press the CLR button then re-enter
the value.
2. Press the Ent button to accept the value.
3. The entered value will be displayed at Scale = 25
To return to the previous screen press the BCK button.
W
System Information
From the main screen press the System button. This will bring up the System
Information screen.
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Software:
The Software Version parameter is a “Read Only” value that displays the current
software version as “major version dot minor version” value (i.e. 1.001, 1.003,
etc.). Major and minor versions are expected to increase as analyzer software
development continues.
Analyzer:
The Analyzer Full Scale Range is used to display the upper reading limit of a
particular analyzer configuration. The analyzer comes from the factory
configured to the customer’s specifications. The analyzer 4-20 mA scale may be
set lower but not higher than the maximum full-scale range as configured from
the factory.
LED:
Displays the current voltage powering the LED.
Detector:
Displays the current voltage from the Detector.
4-20mA:
Displays the current amperage being applied to the 4-20mA output.
Display:
Button to display the screen to set the display brightness.
Factory:
Button to display the screen for setting all parameters to factory settings.
Config:
Button to display the system configuration screen.
Back:
Returns to previous screen.
Display Configuration:
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Description:
Slider:
Back:
Shows the current settings for the display backlight.
Slide left and right to adjust the brightness of the display.
To return to the previous screen.
Instantaneous Response:
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Description:
In order for the analyzer to detect and display short term changes to the
concentration, this parameter sets the ± range of concentration values which will
cause the analyzer to reset the concentration value average buffer. By clearing the
concentration value average buffer, the displayed concentration will tend to track
the most current collected concentration data rather than averaging the data.
This is a factory setting and should only be set at the factory. Changing this
value could affect the operation of your analyzer.
To enter a new value:
1. Enter in the new value for the Instantaneous Response (ex. 40). The new value will be
displayed above the keypad 40 . To clear an incorrect value, press the CLR button then
re-enter the value.
2. Press the Ent button to accept the value.
3. The entered value will be displayed at Resp % = 40.
To return to the previous screen press the BCK button.
Number of Averages:
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Description:
This parameter is used to set the number of concentration values stored and
averaged at each display cycle.
Each time the analyzer scans the detector input and creates a new concentration
value, the value is then stored into a circular queue. All of the values in the queue
are then summed and averaged in order to generate an “average” concentration.
The “Number of Averages” value determines “how many” entries are contained
in the queue.
Note that “System Resets” and abnormally high/low concentration values will
cause the queue to empty and restart with a single entry and fill to the number of
entries specified in the “Number of Averages” parameter.
This is a factory setting and should only be set at the factory.
To enter a new value:
1. Enter in the new value for the Number of Averages (ex. 50). The new value will be
displayed above the keypad 50 . To clear an incorrect value, press the CLR button then
re-enter the value.
2. Press the Ent button to accept the value.
3. The entered value will be displayed at Averages = 50.
To return to the previous screen press the BCK button.
Coefficient 1:
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Description:
Coefficient is a factory calibration factor and should only be set at the factory.
DO NOT CHANGE THIS VALUE. CHANGING THIS VALUE WILL
INVALIDATE YOUR ANALYZERS CALIBRATION.
This is a factory setting and should only be set at the factory.
To enter a new value:
1. Enter in the new value for the Coefficient 1 (ex. 2.5). The new value will be displayed
above the keypad 2.5 . To clear an incorrect value, press the CLR button then re-enter
the value.
2. Press the Ent button to accept the value.
3. The entered value will be displayed at Coef1 = 2.50.
To return to the previous screen press the BCK button.
Factory Reset:
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Reset:
To set the analyzer to the Factory Default settings and return to the
previous screen.
0-1:
Sets all parameters to set the analyzer full range to 1PPM.
0-50:
Sets all parameters to set the analyzer full range to 50PPM.
0-300:
Sets all parameters to set the analyzer full range to 300PPM.
0-%:
Sets all parameters to set the analyzer full range to % level.
Back:
To return to the previous screen without setting the analyzer to Factory
Default settings.
Additional hardware may need to be installed in order to change the
analyzer range. Consult the factory before changing the analyzer range.
X
Clock Configuration
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From the main screen press the Time or Date at the top of the screen. This will bring up
the Time and Date screen.
System Clock:
This sets the system Time and Date.
Press the arrow(s) for the value to be edited to increase or decrease the value.
Press the Back button will set the new time and date and return to the previous screen.
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Section VI
Troubleshooting
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TROUBLESHOOTING
The tips in this guide should be used as a preliminary guide to identify and remedy operational
troubles with Del Mar Scientific’s SULFURELITETM H2S analyzers. When problems arise, it is
important that the maintenance person understand the fundamentals of the equipment. Time
should be spent reading and studying the flow diagrams and wiring diagrams and operating
procedures to get an understanding of functionality and location of the various components in the
system.
When troubleshooting the equipment, please adhere to good troubleshooting techniques and
principles. Turn off power when removing and replacing components. Cover all live wires that
may be exposed during troubleshooting to prevent accidental grounding and potential injury. Turn
off gas when replacing any sample system parts.
If you have any questions about the system, or you are not sure how to proceed, please contact
your local Representative or Del Mar Scientific at 972-661-5160.
NOTE:
Y
Before troubleshooting the equipment, check the flow diagram or data sheet
and correct all pressures and flows.
Typical Problems Encountered
Diagnostic Alarm
The SULFURELITETM analyzer is equipped with a diagnostic alarm. The system
will show the fault on the main screen. This occurs when the CPU detects the
detector reading from the detector block is above or below a given set of
parameters (when the output of the detector block assembly is below 2.40 VDC or
above 4.025 VDC after tape advance).
There are many possible causes of a diagnostic alarm. Listed below are the
potential problems, in the order they should be checked.
a.
Broken CHEMFILMTM - (For the ensuing discussion, please refer to the
drawing in Section IX – Drawings.) Broken CHEMFILMTM will cause a
diagnostic alarm for two reasons.
1. If the tape breaks on the right side of the detector block assembly the
tape will be pulled through and there will not be any tape in the
detector block assembly. This causes a detector reading higher than
4.025 VDC. This will be noted as “Out of Tape” on the main screen.
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2. If the tape breaks on the left side of the detector block assembly
between the detector block and the pressure roller, it will stop the tape
from advancing. This leaves the same piece of tape under the optical
sensor. Eventually this will be exposed to enough H2S to cause a very
dark spot, which will drive the detector reading below 2.40 VDC
immediately after tape advance. This will be noted as “Broken Tape”
on the main screen.
b.
If the supply roll of CHEMFILMTM runs out, there will not be any tape in the
detector block assembly. This causes a detector reading higher than 4.025
VDC. This will be noted as “Out of Tape” on the main screen.
c.
Illumination Source & Detector Failure - The CPU monitors the output of
the detector to determine if either the detector or illumination source has
failed. To Troubleshoot the Illumination Source refer to Component
Checkout Procedures #4.
d.
Optical Sensor Window - If the lens is dirty or covered in oil, some of the
light will be unable to reach the detector. This may cause the detector’s
reading to be below 2.40 VDC immediately after tape advance. Remove
and clean the lens/window on the optical sensor.
e.
Optical Sensor Adjustment - When supplied with clean, white
CHEMFILMTM, the optimal operating range of the voltage reading from the
Optical Sensor is between 2.8 and 3.2 VDC immediately after tape
advance. If, at any point, this voltage is above 4.025 VDC or below 2.40
VDC immediately after tape advance, the CPU will initiate a diagnostic
alarm. To check and/or adjust the voltage reading, refer to Component
Checkout Procedures #2.
f.
Tape Drive Motor - Failure of the tape drive motor will cause the same
section of CHEMFILMTM to remain under the optical sensor. Eventually,
this section will be exposed to enough H2S to cause a very dark stain,
which will drive the detector reading below 2.40 VDC immediately after
tape advance. To check the Tape Drive Motor, refer to Component
Checkout Procedures #3.
g.
Auto Calibration Failure - Consult Factory at (972) 661-5160.
h.
CPU Failure - The CPU monitors other parameters on the electronics boards
that make up the CPU assembly. If steps (a.) through (e.) do not clear the
diagnostic alarm, replace the CPU.
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Erratic Readings on the Display
One cause may be low, high or unstable voltage supply to the system or the CPU.
To check the power supplied to the CPU, refer to Component Checkout Procedures
#1 and Component Checkout Procedures #5.
Other possible causes may be a faulty CPU, loose or corroded terminals on the front
panel. Check all connections for continuity.
Inoperable Alarm Relay(s)
Disconnect the analyzer from any external connections. Change the “Fail Safe”
setting in the “Alarm Configuration” of the respective alarm. The LED and the
contacts on the relay for the respective alarm should change state. If the LED does
change state, but the contacts do not the alarm relay needs to be replaced. If neither
the LED nor the contacts change state, the alarm relay and/or the main processor
needs to be replaced.
Inoperable 4-20 mA Analog Output
Disconnect the analyzer from any external connections. Measure the current on the
output of the 4-20mA isolator. Go to the “4-20mA Calibration” screen. There
should be 4mA on the output. Pressing the 20mA button should drive the output to
20mA. If the output is not present, the 4-20mA isolator and/or the main processor
needs to be replaced.
If you are not familiar with 4-20 mA loop powered analog signals, please contact
your local representative or Del Mar Scientific.
Unrolled ChemFilm™ in Bottom of Sensor Cabinet
A broken or loose take-up reel drive belt will cause unrolled CHEMFILMTM. Replace
the drive belt (refer to drawing number 020-0242-00 in Section IX – Drawings).
Larger Than Normal Tape Advance
This may be due to an improper number programmed in “Tape Advance Duration
Number”. For additional information regarding tape advance, refer to Section V,
Part G.
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Z
Component Checkout Procedures
1.
Power Supply
a. 110 VAC Power Input - The power supply is mounted on a DIN rail behind the
display. The power supply takes 110 VAC input and provides a regulated DC
output voltage of 24 VDC. To check the inputs and outputs of the power supply,
please refer to the Wire Diagram located in the Section IX - Drawings.
Check for AC input to the power supply.
Green wire
White wire
Black wire
=
=
=
Field Ground
AC Neutral
AC Line
When reading Volts AC, please ensure that the meter is set to read AC Volts
and the range is selected to read the proper voltage. You should read 110115 VAC between the black and white wires. To insure that the Field
Ground is hooked up, you should read 110-115 VAC between the black and
green wire.
b. DC Power Input – The power supply may be a DC-DC converter. In this case the
input power should be between 10VDC and 32VDC.
Check for DC input to the power supply.
Green wire
Black wire
Red wire
=
=
=
Field Ground
DC Return
DC Positive
When reading Volts DC, please ensure that the meter is set to read DC Volts
and the range is selected to read the proper voltage. You should read
between 10 VDC and 32 VDC.
If you do not read the appropriate voltage, check the power from the source
and/or repair wires as necessary.
c. Check for DC output from the power supply
The AC power supply has one output at the bottom labeled –V and +V. The
–V is the DC ground and +V is +24Volts DC.
The DC to DC power supply has one output at the top labeled DC- and DC+.
The DC– is the DC ground and DC+ is +24Volts DC.
When reading Volts DC, please ensure that the meter is set to read DC Volts
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and the range is selected to read the proper voltage. Polarity is important
when reading DC Voltage. Red lead on the voltmeter is considered positive
(+) and should be installed in the positive (+) jack of the voltmeter. You
should read positive (+) 24 VDC between the two output pins of the power
supply output connections when the red lead is on the pin marked +V and
the black lead is on the -V pin as shown on the Wire Diagram in Section IX
- Drawings.
2.
Optical Sensor
To check for the proper detector setting, proceed as follows:
3.
a.
Turn off the sample gas stream and allow any gas in the analyzer to
dissipate.
b.
Rotate the tape, press the “Reset” button a couple times to ensure there is a
clean, white piece of tape is under the detector block assembly.
c.
Press the “System” button. The detector voltage will appear on the display.
The voltage should read above 2.40 VDC with clean white tape. (Ideal
voltage is between 2.8 and 3.2 VDC).
d.
If the detector voltage is not between 2.8 and 3.2, the LED must be
calibrated. See Section V Part F LED/Detector Calibration. for details.
e.
If the detector voltage is too low, increase the “LED Voltage”. If the “LED
Voltage” must be raised to 4.0 V to get a detector reading above 2.80 VDC,
then the LED must be replaced. See Section VII Part b #3.
f.
If the detector voltage is too high, decrease the “LED Voltage”. If “LED
Voltage” is less than 1.8 V and the detector voltage stays at 4.025 V, then
the optical sensor needs to be replaced. See Section VII Part b #2.
g.
If there is a diagnostic alarm on the display, execute a “Reset” and the alarm
should clear.
Motor Drive
The motor will advance when you execute a “Reset”. The tape should advance
approximately 1/4". The motor operates on 12 VDC. If the motor fails to operate:
a.
Check “Tape Advance Duration Number”. See Section V part G.
There should be a value around 25. Increase or decrease this number to
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adjust the amount the tape will advance.
b.
Check the zener diode network output.
This can be done at the 9 pin terminal strip on the back of the front panel
(refer to the “Assy, SulfurElite Front Panel” drawing 020-0242-00 in
Section IX – Drawings). The motor needs to be disconnected from the
terminal strip before testing the zener diode network. Measure the voltage
from terminal 5 (+) to terminal 7 (-). Execute a “Reset” and there should
be 12 VDC (for approximately 2 seconds) measured at this point. If there
is no voltage present, replace the zener diode network. If there is still no
voltage present, check the connections.
c.
Check the CPU output.
Measure the voltage on the red wire (+) from the CPU on the connector
labeled Power (refer to the Wire Diagram in Section IX – Drawings) to the
black wire (-) from the CPU on the connector labeled Tape Deck (refer the
wire diagram in Section IX – Drawings). Execute a “Reset” and there
should be 24 VDC (for approximately 2 seconds) measured at this point. If
there is no voltage present, replace the CPU.
If the motor still fails after steps (a.) through (c.), replace the motor.
4.
Illumination Source
To check the illumination source, pull down the pressure block assembly. A red
glow should be noted. An illumination source failure will activate a diagnostic
alarm. If LED is not glowing, check LED voltage. See Section V Part f LED/Det.
Calibration. If the LED is not glowing, lower the front panel. The LED is powered
from the CPU at approximately 1.7 volts. Set the voltmeter across the violet wire
from terminal 4 on the terminal strip and the orange wire on terminal 3 on the
terminal strip. There should be approximately 1.7 volts. If the reading is correct,
replace LED cable assembly. If there is not 1.7 volts, replace the CPU.
5.
CPU
The CPU is the "brains" of the system. The CPU has a programmable chip or
"Flash" on the board which contains the CPU’s program. Relay operation,
concentration limits, main operating program, solenoid timing, "fail-safe mode",
and other parameters are stored on the CPU. The CPU also does all the calculations
and runs the algorithms required by the system, as well as updates the display board.
The CPU controls all the optional outputs that are installed in the analyzer.
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To check the basic operation of the CPU:
a.
Check input power.
Power input to the CPU is 24 VDC on the terminal labeled POWER on the
CPU (refer to the wire diagram in Section IX – Drawings). The red wire is
positive, black wire is negative. If there is no 24 VDC, check the power
supply and wiring to the CPU.
b.
Check Low Concentration Alarm Output.
Connections to alarm outputs must be removed.
Record the current setting of “Low Concentration Alarm Failsafe”.
Place the positive lead of a voltmeter to the red wire on the terminal labeled
A1+ on the relay (refers to the wire diagram in Section IX – Drawings).
Place the negative lead of your meter to the red wire on the terminal labeled
A2- on the relay board (refer to the wire diagram in Section IX – Drawings).
The red wire from the CPU is the digital output for the Low Concentration
Alarm.
Press the “Low Concentration Alarm Failsafe Button”. This will
automatically activate the system and trip the Low Concentration Alarm.
When this happens, you will either see an increase of voltage from 0 VDC
to 18-24 VDC or a loss of voltage from 18-24 VDC down to 0 VDC.
If this does not occur, verify the connections to the CPU. If all of the
connections are good up to the CPU, replace the CPU.
After you have checked this alarm, reprogram the alarm back to the initial
setting.
c.
Check High Concentration Alarm Output.
Connections to alarm outputs must be removed.
Record the current setting of “High Concentration Alarm Failsafe”.
Place the positive lead of a voltmeter to the red wire on the terminal labeled
A1+ on the relay (refers to the wire diagram in Section IX – Drawings).
Place the negative lead of your meter to the brown wire on the terminal
labeled A2- on the relay (refer to the wire diagram in Section IX –
Drawings). The brown wire is the digital output for the High Concentration
Alarm.
Press the “High Concentration Alarm Failsafe Button”.
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This will
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automatically activate the system and trip the High Concentration Alarm.
When this happens, you will either see an increase of voltage from 0 VDC
to 18-24 VDC or a loss of voltage from 18-24 VDC down to 0 VDC.
If this does not occur, verify the connections to the CPU. If all of the
connections are good up to the CPU, replace the CPU.
After you have checked this alarm, reprogram the alarm back to the initial
setting.
d.
Check Diagnostic Alarm Output
Connections to alarm outputs must be removed.
Place the positive lead of a voltmeter to the red wire on the terminal labeled
A1+ on the relay (refers to the wire diagram in Section IX – Drawings).
Place the negative lead of your meter to the yellow wire on the terminal
labeled A2- on the relay (refer to the Wire Diagram in Section IX –
Drawings). The yellow wire is the digital output for the Diagnostic Alarm.
Pull down the detector block and remove the CHEMFILMTM to expose the
illumination source. You should see a red light source. Press “Reset” and
you will get “Out of Tape” on the display screen. When this happens, you
will either see an increase of voltage from 0 VDC to 18-24 VDC or a loss
of voltage from 18-24 VDC down to 0 VDC.
If this does not occur, verify the connections to the CPU. If all of the
connections are good up to the CPU, replace the CPU.
After you have checked this alarm, you must execute a “Reset” to clear the
diagnostic alarm status.
e.
Check LED Drive Output
The violet wire on the terminal labeled TAPEDECK (refer to the Wire
Diagram on Section IX – Drawings) is the 1.7 volts power source for the
LED illumination source. See Section VI part 4 "Illumination Source" to
check this output.
f.
Check the 4-20 mA Output
A 4-20 mA signal output is from the brown (+) wire and the white/brown () wire on the terminal labeled POWER on the CPU (refer to the Wire
Diagram on Section IX – Drawings). The CPU can adjust or calibrate the
4-20 mA signal through “4-20mA Cal”. Check output if necessary.
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6.
Display Assembly
If the information on the display is incomplete or there is no response from the
touch screen, check wiring between display and CPU. Replace the touch screen
assembly if necessary.
7.
Relay(s)
The relay(s) provides operation to indicate a diagnostic alarm, low concentration
alarm, high concentration alarm, or auto calibration indicator. The alarm relays are
wired on the terminals on the bottom on the relay housing. This is where the
customer will use the relay configuration to route voltage to their various
equipment. The red wire located on the terminal labeled A1+, is the common +24
VDC power for all the relays. The other wires are as follows:
Yellow
Brown
Red
= Diagnostic Alarm
= High Concentration Alarm
= Low Concentration Alarm
With the power off to the system, all relays will be de-energized. Relay contacts
#11 and #14 will be open (no continuity) and Relay contact #11 and #12 will be
closed (continuity). With the power turned on, the relays should stay in the same
configuration unless the alarm output is set to be “Fail-Safe” (refer to Alarm
Configuration). To check relay operation repeat CPU Checks number 5b, c and d
above. Use a continuity meter to check for relay operation.
If the instrument continues to function improperly, contact the factory for further
troubleshooting advice. (972) 661-5160.
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Section VII
Maintenance
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Section VII
MAINTENANCE
A Scheduled Maintenance
Del Mar Scientific’s SULFURELITETM analyzers require minimal scheduled maintenance.
The following table is provided as a guideline. This schedule is suitable for most
applications. However, the table should be reviewed and revised, as necessary, to meet
specific application needs.
Monthly
Quarterly
CHEMFILMTM Replacement
Humidifier Solution Refill
Humidifier Solution Replacement*
Humidifier Filter Replacement
Sample Filter Replacement
Genie Filter Replacement
Calibration Check**
X
X
X
X
X
X
X
*The humidifier solutions will last four weeks under most conditions. However, actual
time can be affected by ambient temperature, gas dryness, etc.
**EPA Fuel gas analyzers are required to have a daily zero and span calibration.
B Non-Scheduled Maintenance
The following section describes the procedures for removal and replacement of defective
components.
Prior to performing any maintenance, ensure that the shutdown procedure has been
followed.
1.
Front Panel Opening
a.
2.
Remove the two screws securing the Front Panel. Swing the Front Panel
down.
Optical Sensor Replacement/Cleaning
a.
Open the Front Panel assembly as described in B.1.
b.
Remove the 1/4" and 1/8" tubing from the optical sensor assembly.
c.
Disconnect the blue and white wires going to the optical sensor assembly
from pins 1 and 2 on the terminal block.
d.
Remove the three screws securing the optical sensor assembly. While
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depressing the pressure block, remove the optical sensor assembly.
3.
4.
e.
Ensure that the lens is clear and free of any debris. Clean with alcohol or
soap and water as required. It might necessary to remove the bottom plate
to thoroughly clean the lens. Care should be taken not to remove the grease
on the bottom plate. DO NOT USE CONTACT CLEANER.
f.
If necessary, remove the two screws securing the top cover plate to the
block. Remove the two screws securing the detector. Replace the detector,
making sure to snug the set screw after mounting the detector mounting
plate.
g.
Reassemble the optical sensor assembly in the reverse order, and re-install.
h.
Ensure that gas fittings are tightened sufficiently to prevent leaks.
i.
Close the front panel assembly.
Pressure Block / LED Replacement
a.
Open the front panel assembly as described in B.1.
b.
Disconnect the violet and orange wires going to the pressure block from
pins 3 and 4 on the terminal block.
c.
Remove the two screws securing the pressure block mount and remove the
pressure block assembly.
d.
Remove the two guide bolts holding the pressure block to the pressure block
mount. Use care when removing to avoid loss of the pressure block
springs.
e.
If necessary, remove the two screws that hold the LED in place. Install a
new LED, ensuring that the lens is clear and free of any debris.
f.
Install the pressure block in the reverse order.
g.
Close the front panel assembly.
Humidifier Filter Replacement
a.
Open the front panel assembly as described in B.1.
b.
Disconnect all gas lines from the humidifier.
c.
Remove the humidifier mounting screw and remove the humidifier.
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5.
6.
d.
Unscrew the large stainless steel nut and remove the filter stem.
e.
Slide the old filter off the stem and install the new one. Take care to notice
the O-ring. It must be installed for proper humidifier operation. Clean
any plugged holes in the filter stem.
f.
Refill the humidifier with an approved solution. See Section III Part E.
g.
Reassemble in reverse fashion. Ensure that the gas lines are tightened
sufficiently to prevent leaks.
h.
Close the front panel assembly.
Humidifier Replacement
a.
Open the front panel assembly as described in B.1.
b.
Disconnect the sample gas input and output lines from the humidifier.
c.
Remove the humidifier-mounting screw.
d.
Remove the humidifier
e.
Fill the new humidifier with an approved solution. See Section III Part E.
f.
Install new humidifier.
g.
Reconnect the sample gas lines. Ensure that the gas fittings are tightened
sufficiently to prevent leaks.
h.
Close front panel assembly.
Motor Replacement
a.
Open the front panel assembly as described in B.1.
b.
Disconnect the red and black wires connected to pins 5 and 7 on the
terminal block.
c.
Remove the two screws securing the motor plate to the front panel and
remove.
d.
Press down on the press roller and pull out the motor and shaft. Slowly
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release the pressure roller so that the spring doesn’t fly. Loosen the three
setscrews on the tape drive shaft and remove.
7.
8.
e.
Install the shaft on the new motor. Press down on the pressure roller and
insert the shaft and motor through the front panel.
f.
Install the new motor plate to the front panel.
g.
Reconnect the red motor wire to pin 5 and the black motor wire to pin 7 on
the terminal.
h.
Close the front panel assembly.
Pressure Block Spring Replacement
a.
Open the front panel assembly as described in B.1.
b.
Remove the pressure block as described in B.3.
c.
Remove the two guide bolts securing the pressure block to the pressure
block mount.
d.
Remove the old springs and replace with new ones.
e.
Reinstall the guide bolts hand tight. Do not tighten with wrench.
f.
Reinstall the pressure block.
g.
Close the front panel assembly.
Drive Belt Replacement
a.
Open the front panel assembly as described in B.1.
b.
Remove the two screws securing the motor plate to the front panel.
c.
Press the pressure roller down and pull the motor and shaft out. Slowly
release the pressure roller so the spring doesn’t fly. Remove the two screws
from the plate for the take up reel shaft and remove the plate.
d.
Remove the old belt by sliding it over the pulleys, and install the new belt.
Ensure that the drive belt is installed with a half twist.
e.
Reinstall the motor plate and take up reel plate.
f.
Close the front panel assembly.
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9.
Drive Shaft Replacement
a.
Open the front panel assembly as described in B.1.
b.
Remove the two screws securing the motor plate to the front panel
assembly.
c.
While depressing the pressure roller, slide the drive shaft out, slowly release
the press roller so the spring doesn’t fly.
d.
Remove the drive belt from the drive shaft pulley.
e.
Remove the three set screws in the tape drive shaft and remove the motor.
f.
Remove the two set screws securing the pulley to the drive shaft and remove
the pulley.
g.
Take the new shaft and install the drive shaft pulley and the motor.
h.
Slip on the belt over the pulley, press down on press roller, and reinsert the
drive shaft through the panel.
i.
Reinstall the motor plate.
j.
Close the front panel assembly.
.
10.
Pressure Roller/Spring Replacement
a.
Open the front panel as described in B.1.
b.
Remove the drive belt from the drive pulley.
c.
Remove the two screws securing the motor plate to the front panel.
d.
While holding the pressure roller down, slide the motor plate backwards
until the tape drive shaft no longer extends through the front panel.
e.
Gently release the pressure roller, remove the spring and replace with a new
one.
f.
Remove the pressure roller, if required, by removing the setscrew while
holding the nut on the back of the panel. Retain the spacer mounted between
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the pressure roller and tape deck. Install the new pressure roller.
11.
g.
Reinstall the drive belt with a half twist.
h.
While depressing the pressure roller, slide the motor plate back in position
and secure.
i.
Close the front panel assembly.
Sample Filter Replacement (Optional)
CAUTION: Turn sample gas flow off and bleed line pressure before attempting
filter replacement.
12.
a.
Unscrew the filter housing, unscrew the filter mounting stem and slide the
old filter off the filter-mounting stem.
b.
Install the new filter and reassemble the filter housing. Ensure that the
housing is tightened sufficiently to prevent leaks.
c.
Check for leaks.
Membrane Filter Replacement (Optional)
CAUTION: Turn sample gas flow off and bleed line pressure before attempting
filter replacement.
a.
Unscrew the filter housing, lift and remove the O-ring using a fingernail or
small screwdriver.
b.
Remove the used membrane from the housing and discard.
c.
Install new membrane filter.
d.
Reinstall the O-ring.
e.
Reinstall the filter housing.
f.
Check for leaks.
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Section VIII
Revision
1.0
REVISION TABLE
Description
Initial Release
Date
2-20-14
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Section IX
Drawings
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Section IX DRAWINGS
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Section X Warranty
INSTRUMENT WARRANTY
Del Mar Scientific, Ltd. warrants that each instrument shall be free from defects in workmanship and materials,
when used in accordance with applicable specifications and with appropriate maintenance, for a period of one
(1) year from the initial purchase from factory (recorded as the ship date), unless otherwise specified in writing.
Instruments or components that malfunction may be returned, shipment prepaid, to Del Mar Scientific for test
and evaluation. Instruments or components determined to be defective and in warranty will be repaired or
replaced at no charge to the customer. Instruments or components out of warranty will be evaluated and
notification of costs will be issued prior to proceeding with repair or replacement. Repaired products will be
warranted 90 days from date of shipment from factory or for the balance of the original warranty whichever is
longer. Test and evaluation for warranty claims are performed at the factory. Field Service Labor and travel
expenses are NOT covered under warranty.
Failures due to shipping damage, accident, misuse, improper mechanical installation, improper electrical
installation, improper operation, improper maintenance, acts of God (i.e. Lightening Strikes, flooding, etc.),
internal clogging and/or corrosion are excluded from warranty coverage.
Del Mar Scientific’s obligation for breach of this warranty, or for negligence or otherwise, shall be strictly and
exclusively limited to the repair or replacement of the product or part. This warranty shall be void on any
product that has been modified without prior written approval from Del Mar Scientific or on which the serial
number has been altered, defaced or removed.
No other statement or claim about the product by any employee, agent or representative of Del Mar Scientific
shall constitute a warranty by Del Mar Scientific or give rise to any liability or obligation of Del Mar Scientific.
Del Mar Scientific shall not be liable for any damage, injury or loss arising out of the use of the product,
whether as a result of a defect in the product, or otherwise, if, prior to such damage, injury or loss, the product
was: (1) damaged or misused; (2) repaired, altered or modified by persons other than Del Mar Scientific
employees; (3) not properly maintained; (4) operated with unauthorized parts and/or supplies; or (5) not
installed in accordance with applicable codes or standard practices (i.e. grounding in accordance with NEC
guidelines).
Components that are not manufactured by Del Mar Scientific shall carry the original manufacturer’s warranty.
Such parts returned to Del Mar Scientific will be sent to the original manufacturer for warranty service as
defined by the applicable warranty statement.
Please contact Del Mar Scientific prior to the return of any merchandise for shipping instructions.
SPARE PARTS WARRANTY
Spare parts have a warranty of 90 days from date of shipment. All other terms and conditions apply.
DISCLAIMER
Installation or replacement of any component which compromises an intrinsically safe barrier/seal
automatically declassifies the area classification of the analyzer to General Purpose. Pursuant to item
number two (2) listed above, Del Mar Scientific is not responsible for changes made unless the work is
performed by an authorized factory representative.
2005
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