802 Manual - Rev 1.2 21 August 2007 (Single Stream)

8/19/2019 802 Manual - Rev 1.2 21 August 2007 (Single Stream)

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802Hydrogen Sulphide / Total Sulphur Lead Acetate

Tape Analyzer

OPERATION MANUALP/N: MA2533

Revision 1.2

May 7, 2007


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- ii -

Galvanic Applied Sciences, Inc.

7000 Fisher Road S.E.

Calgary, Alberta, Canada

T2H 0W3

Phone: (403) 252-8470

Fax: (403) 255-6287E-mail: [email protected]

World Wide Web: http://www.galvanic.com


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Table of Contents:

MANUFACTURER’S WARRANTY STATEMENT........................................................................................viii

SECTION 1 802 OVERVIEW.................................................................................................................... 1-1

1.1 PRINCIPLE OF OPERATION .................................................................................................................... 1-1 1.2 802 COMPONENTS IN BRIEF .................................................................................................................. 1-1

1.2.1 Electronics Enclosure .................................................................................................................. 1-2 1.2.2 Chassis......................................................................................................................................... 1-2 1.2.3 Keypad ......................................................................................................................................... 1-2 1.2.4 Total Sulphur furnace .................................................................................................................. 1-2 1.2.5 Sample Conditioning System........................................................................................................ 1-2

1.3 GRAPHICAL USER I NTERFACE .............................................................................................................. 1-2

SECTION 2 INSTALLATION AND PROCEDURES............................................................................. 2-3

2.1 I NSTALLATION CONSIDERATIONS......................................................................................................... 2-3 2.2 BASIC START-UP PROCEDURE............................................................................................................... 2-4 2.3 I NSTALLATION OF TAPE........................................................................................................................ 2-5 2.4 LEAK TESTING OF COMPRESSION HEAD ............................................................................................... 2-7

2.5 I NITIATING CALIBRATION, R EFERENCE, AND ZERO ............................................................................ 2-10 2.5.1 Manual Initiation of Reference .................................................................................................. 2-10 2.5.2 Manual Initiation of Calibration................................................................................................ 2-10 2.5.3 Manual Initiation of Zero........................................................................................................... 2-11 2.5.4 Manual Quick Calibration / Zero .............................................................................................. 2-11

2.5.4.1 Quick Calibration....................................................................................................................................2-12 2.5.4.2 Quick Zero..............................................................................................................................................2-12

2.6 TOTAL SULPHUR PROCEDURES........................................................................................................... 2-13 2.6.1 Replacing Quartz Reaction Tube............................................................................................... 2-13 2.6.2 Leak Checking Total Sulphur Furnace ...................................................................................... 2-14

SECTION 3 MECHANICAL AND HARDWARE................................................................................. 3-16

3.1 ELECTRONICS E NCLOSURE ................................................................................................................. 3-16 3.1.1 Front Panel................................................................................................................................ 3-16

3.1.1.1 LCD Display...........................................................................................................................................3-17 3.1.1.2 Front Panel LEDs....................................................................................................................................3-19

3.1.2 Electronics Assembly ................................................................................................................. 3-20 3.1.3 AC to DC Power Supply ............................................................................................................ 3-20 3.1.4 Intrinsically Safe Barrier ........................................................................................................... 3-20

3.2 CHASSIS.............................................................................................................................................. 3-21 3.2.1 Sample Chamber Assembly........................................................................................................ 3-21

3.2.1.1 Read/Rate Aperture Strip........................................................................................................................3-23 3.2.1.2 Sensor Block...........................................................................................................................................3-24

3.2.1.2.1 Sensor Block Calibration ..................................................................................................................3-24 3.2.1.2.2 Other Sensor Block Functions ..........................................................................................................3-25

3.2.2 Tape Transport System .............................................................................................................. 3-25 3.2.2.1 Supply and Take-Up Reels .....................................................................................................................3-26 3.2.2.2 Motor ......................................................................................................................................................3-26 3.2.2.3 Pulse Counter..........................................................................................................................................3-27 3.2.2.4 Optical Low Tape Sensor (Optional) ......................................................................................................3-27 3.2.2.5 Compression Head..................................................................................................................................3-28

3.2.3 Sample Flow Related Components............................................................................................. 3-28 3.2.3.1 Critical Orifice ........................................................................................................................................3-28 3.2.3.2 Sample Humidifier..................................................................................................................................3-29 3.2.3.3 Rotameter................................................................................................................................................3-29 3.2.3.4 Power Vent (Eductor) .............................................................................................................................3-30

3.3 K EYPAD.............................................................................................................................................. 3-31 3.3.1 Operator Menu .......................................................................................................................... 3-32


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3.3.2 Maintenance Menu..................................................................................................................... 3-34 3.3.3 Analyzer Alarm List ................................................................................................................... 3-36 3.3.4 Display....................................................................................................................................... 3-36

3.4 TOTAL SULPHUR OPTION.................................................................................................................... 3-37 3.5 SAMPLE CONDITIONING SYSTEM ........................................................................................................ 3-38

SECTION 4 OPERATION ....................................................................................................................... 4-40

4.1 EVENT SEQUENCE .............................................................................................................................. 4-40 4.2 STANDARD A NALYSIS ........................................................................................................................ 4-40

4.2.1 Sample Delay – Standard Analysis ............................................................................................ 4-40 4.2.2 Sample Interval – Standard Analysis ......................................................................................... 4-41 4.2.3 Tape Saturation Cut-off (TSC)................................................................................................... 4-41 4.2.4 Calculation of Concentration Value .......................................................................................... 4-41

4.3 TIMED A NALYSIS................................................................................................................................ 4-41 4.3.1 Sample Delay – Timed Analysis................................................................................................. 4-41 4.3.2 Sample Interval – Timed Analysis.............................................................................................. 4-42

4.4 A NALYSIS MODES .............................................................................................................................. 4-42 4.4.1 Normal Run................................................................................................................................ 4-42

4.4.1.1 Alarm 1 ...................................................................................................................................................4-42 4.4.1.2 Predictive Alarm Analysis (PAA)...........................................................................................................4-42

4.4.2 Calibration Run ......................................................................................................................... 4-43 4.4.2.1 Calibration % Deviation Alarm ..............................................................................................................4-43

4.4.3 Zero Run .................................................................................................................................... 4-44 4.4.3.1 Zero % Deviation Alarm.........................................................................................................................4-44

4.4.4 Reference Run............................................................................................................................ 4-44 4.4.4.1 Reference % Deviation Alarm ................................................................................................................4-45

4.5 BYPASS MODE.................................................................................................................................... 4-45

SECTION 5 GRAPHICAL USER INTERFACE................................................................................... 5-46

5.1 I NSTALLATION AND CONNECTION ...................................................................................................... 5-46 5.1.1 System Requirements ................................................................................................................. 5-46 5.1.2 Software Installation.................................................................................................................. 5-46 5.1.3 Connecting the 802 to the PC .................................................................................................... 5-46

5.1.3.1 Installation of USB Drivers – Windows XP ...........................................................................................5-47 5.1.3.2 Installation of USB Drivers – Windows 2000.........................................................................................5-49 5.1.3.3 Determining the correct COM Port.........................................................................................................5-51

5.2 I NTERFACE AND ICONS ....................................................................................................................... 5-52 5.2.1 Toolbar Buttons ......................................................................................................................... 5-53

5.2.1.1 Communicate Toolbar ............................................................................................................................5-54 5.2.1.2 Operation Toolbar...................................................................................................................................5-54 5.2.1.3 General Toolbar ......................................................................................................................................5-54

5.2.2 Menu System .............................................................................................................................. 5-55 5.2.2.1 File Menu................................................................................................................................................5-55 5.2.2.2 View Menu .............................................................................................................................................5-55 5.2.2.3 Tools Menu.............................................................................................................................................5-55 5.2.2.4 Help Menu ..............................................................................................................................................5-56

5.2.3 Logging on to the 802 ................................................................................................................ 5-56 5.2.3.1 Read Only Mode.....................................................................................................................................5-58 5.2.3.2 Update Mode ..........................................................................................................................................5-58

5.3 APPLICATION SCREENS....................................................................................................................... 5-58 5.3.1 Watch Window........................................................................................................................... 5-59

5.3.1.1 Analysis Alarms......................................................................................................................................5-60 5.3.1.2 Analog Outputs .......................................................................................................................................5-60 5.3.1.3 Relays .....................................................................................................................................................5-60 5.3.1.4 Solenoids ................................................................................................................................................5-60 5.3.1.5 Discrete Inputs ........................................................................................................................................5-61 5.3.1.6 General Indicators...................................................................................................................................5-61

5.3.2 Archive....................................................................................................................................... 5-61


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5.3.2.1 Graphing Data.........................................................................................................................................5-62 5.3.2.2 Filtering Data..........................................................................................................................................5-64

5.3.2.2.1 Filtering Data by Date......................................................................................................................5-64 5.3.2.2.2 Filtering Data Numerically...............................................................................................................5-65

5.3.2.3 Exporting Data........................................................................................................................................5-66 5.3.2.4 Log Setup................................................................................................................................................5-66

5.3.3 Event Log................................................................................................................................... 5-67

5.3.4 Global ........................................................................................................................................ 5-68 5.3.4.1 General....................................................................................................................................................5-69 5.3.4.1.1 Tape Box ...........................................................................................................................................5-70

5.3.4.2 Global Alarms.........................................................................................................................................5-71 5.3.5 Stream........................................................................................................................................ 5-72

5.3.5.1 All Stream Parameters ............................................................................................................................5-73 5.3.5.1.1 Sample Timing Method .....................................................................................................................5-73

5.3.5.2 Normal Run ............................................................................................................................................5-74 5.3.5.2.1 Switching ...........................................................................................................................................5-74 5.3.5.2.2 Analog Output Managers..................................................................................................................5-75 5.3.5.2.3 Alarms...............................................................................................................................................5-76

5.3.5.3 Calibration ..............................................................................................................................................5-76 5.3.5.4 Reference ................................................................................................................................................5-78 5.3.5.5 Zero.........................................................................................................................................................5-78

5.3.6 Input........................................................................................................................................... 5-79 5.3.7 Output ........................................................................................................................................ 5-80 5.3.8 Ports........................................................................................................................................... 5-81 5.3.9 Modbus ...................................................................................................................................... 5-82

5.3.9.1 Enron ......................................................................................................................................................5-83 5.3.9.2 Modicon 16.............................................................................................................................................5-83 5.3.9.3 Modicon with Floating Point ..................................................................................................................5-83 5.3.9.4 Typical Modbus Setup ............................................................................................................................5-84

5.3.10 Maintenance............................................................................................................................... 5-85 5.3.10.1 Calibrating Analog Outputs................................................................................................................5-86 5.3.10.2 Relays and Solenoids..........................................................................................................................5-87 5.3.10.3 Tape Encoder Test..............................................................................................................................5-87 5.3.10.4 ArcNet Threshold (mV)......................................................................................................................5-87 5.3.10.5 Firmware Upgrade..............................................................................................................................5-87

SECTION 6 TROUBLESHOOTING...................................................................................................... 6-89 SECTION 7 DRAWINGS......................................................................................................................... 7-90

SECTION 8 CONFIGURATION............................................................................................................. 8-96

SECTION 9 CONFIGURATION FILE .................................................................................................. 9-98

SECTION 10 TECHNICAL SPECIFICATIONS................................................................................. 10-103

SECTION 11 MSDS INFORMATION.................................................................................................. 11-104

11.1 ACETIC ACID .................................................................................................................................. 11-104 11.2 LEAD ACETATE IMPREGNATED PAPER TAPE .................................................................................... 11-108

SECTION 12 REVISION HISTORY .................................................................................................... 12-112


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Figures

FIGURE 1-1: SCHEMATIC OF 802 FLOW PATH ....................................................................................................... 1-1 FIGURE 2-1: 802 POWER SUPPLY CONNECTIONS (FROM LEFT, 24VDC DIV. 2, AC DIV. 2, AC DIV. 1)................ 2-3 FIGURE 2-2: K EYPAD CONNECTOR LOCATION...................................................................................................... 2-4

FIGURE 2-3: STAIN APPEARANCE ......................................................................................................................... 2-5 FIGURE 2-4: TAPE E NCLOSURE PARTS R EFERENCE .............................................................................................. 2-6 FIGURE 2-5: I NSERTION OF TAPE END INTO TAKE-UP REEL.................................................................................... 2-6 FIGURE 2-6: CORRECT I NSTALLATION OF TAPE.................................................................................................... 2-7 FIGURE 2-7: MINIHELIC INDICATING A GOOD SEAL (L); CONNECTED TO VENT ELBOW (R) ................................... 2-8 FIGURE 2-8: SAMPLE CHAMBER ASSEMBLY EXPLODED VIEW ............................................................................. 2-8 FIGURE 2-9: LEAK TESTING THE HUMIDIFIER ....................................................................................................... 2-9 FIGURE 2-10: TOTAL SULPHUR FURNACE E NCLOSURE - EXTERIOR (L) AND I NTERIOR (R) ................................ 2-13 FIGURE 2-11: TOTAL SULPHUR QUARTZ R EACTION TUBE ................................................................................. 2-13 FIGURE 2-12: EXPLODED VIEW OF ULTRA-TORR FITTING.................................................................................... 2-14 FIGURE 2-13: LOCATION OF CAP FOR FURNACE LEAK CHECK ............................................................................. 2-15 FIGURE 3-1: 802 DIVISION 2 ELECTRONICS E NCLOSURE .................................................................................... 3-16 FIGURE 3-2: 802 FRONT PANEL .......................................................................................................................... 3-17 FIGURE 3-3: I NTRINSICALLY SAFE BARRIER CONNECTIONS............................................................................... 3-20 FIGURE 3-4: 802 DIVISION 2 CHASSIS (ALL COVERS R EMOVED)........................................................................ 3-21 FIGURE 3-5: SAMPLE CHAMBER ASSEMBLY EXPLODED VIEW ........................................................................... 3-22 FIGURE 3-6: SAMPLE FLOW ................................................................................................................................ 3-23 FIGURE 3-7: 802 SENSOR BLOCK (FROM LEFT: TOP VIEW, SIDE VIEW, I NSTALLED VIEW) ................................ 3-24 FIGURE 3-8: 802 TAPE TRANSPORT SYSTEM ...................................................................................................... 3-26 FIGURE 3-9: PULSE COUNTER ............................................................................................................................. 3-27 FIGURE 3-10: 802 COMPRESSION HEAD.............................................................................................................. 3-28 FIGURE 3-11: NAFION HUMIDIFIER ..................................................................................................................... 3-29 FIGURE 3-12: 802 CHASSIS R OTAMETER ............................................................................................................ 3-30 FIGURE 3-13: EDUCTOR ...................................................................................................................................... 3-30 FIGURE 3-14: 802 K EYPAD ................................................................................................................................. 3-31 FIGURE 3-15: OPERATOR MENU SCREEN............................................................................................................ 3-32 FIGURE 3-16: EDIT PARAMETER SCREEN............................................................................................................ 3-33

FIGURE 3-17: A NALYZER ALARM LIST............................................................................................................... 3-36 FIGURE 3-18: DISPLAY MENU ............................................................................................................................ 3-37 FIGURE 3-19: TOTAL SULPHUR FURNACE........................................................................................................... 3-38 FIGURE 3-20: TYPICAL SAMPLE CONDITIONING SYSTEM ................................................................................... 3-39 FIGURE 5-1: 802 DISPLAY BOARD WITH COMMUNICATIONS SELECT DIPSWITCH............................................... 5-47 FIGURE 5-2: WINDOWS XP USB I NSTALLATION SCREEN 1 ................................................................................ 5-48 FIGURE 5-3: WINDOWS XP I NSTALLATION SCREEN 2......................................................................................... 5-48 FIGURE 5-4: WINDOWS LOGO TESTING WARNING ............................................................................................. 5-49 FIGURE 5-5: WINDOWS 2000 USB I NSTALLATION SCREEN 1 ............................................................................. 5-49 FIGURE 5-6: WINDOWS 2000 I NSTALLATION SCREEN 2...................................................................................... 5-50 FIGURE 5-7: WINDOWS 2000 I NSTALLATION SCREEN 3...................................................................................... 5-50 FIGURE 5-8: WINDOWS 2000 I NSTALLATION SCREEN 4...................................................................................... 5-51 FIGURE 5-9: PORTS IDENTIFIED IN DEVICE MANAGER ....................................................................................... 5-52

FIGURE 5-10: 802 GUI PRIOR TO LOGON ........................................................................................................... 5-53 FIGURE 5-11: CLOSE FIRMWARE UPDATE MESSAGE BOX .................................................................................. 5-53 FIGURE 5-12: CHANGE UPDATE PASSWORD DIALOGUE BOX ............................................................................. 5-55 FIGURE 5-13: R ESET UPDATE PASSWORD CONFIMATION DIALOGUE BOX ......................................................... 5-56 FIGURE 5-14: ABOUT WINDOW .......................................................................................................................... 5-56 FIGURE 5-15: COMMUNICATIONS SETUP WINDOW............................................................................................. 5-57 FIGURE 5-16: LOGON PROGRESS I NDICATOR ...................................................................................................... 5-57 FIGURE 5-17: SELECT MODE DIALOGUE BOX .................................................................................................... 5-57 FIGURE 5-18: UPDATE MODE LOGON DIALOGUE BOX ....................................................................................... 5-58 FIGURE 5-19: WATCH WINDOW ......................................................................................................................... 5-59


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FIGURE 5-20: ARCHIVE SCREEN PRIOR TO DOWNLOADING DATA...................................................................... 5-61 FIGURE 5-21: ARCHIVE SCREEN AFTER DOWNLOADING DATA .......................................................................... 5-62 FIGURE 5-22: CHARTED DATA............................................................................................................................ 5-63 FIGURE 5-23: DATE SORTING SELECTION DIALOGUE BOX ................................................................................. 5-64 FIGURE 5-24: CUSTOM NUMERICAL FILTERING DIALOGUE BOX........................................................................ 5-65 FIGURE 5-25: ARCHIVE SETUP WINDOW ............................................................................................................ 5-66 FIGURE 5-26: EVENT LOG................................................................................................................................... 5-68 FIGURE 5-27: GLOBAL SCREEN .......................................................................................................................... 5-69 FIGURE 5-28: STREAM SCREEN ........................................................................................................................... 5-73 FIGURE 5-29: NORMAL R UN SCREEN ................................................................................................................. 5-74 FIGURE 5-30: CALIBRATION SCREEN.................................................................................................................. 5-76 FIGURE 5-31: CALIBRATION CONFIRMATION DIALOGUE BOX............................................................................ 5-78 FIGURE 5-32: I NPUT SCREEN .............................................................................................................................. 5-80 FIGURE 5-33: OUTPUT SCREEN........................................................................................................................... 5-81 FIGURE 5-34: PORTS SCREEN ............................................................................................................................. 5-82 FIGURE 5-35: CREATE MODBUS LIST DIALOGUE BOX ....................................................................................... 5-82 FIGURE 5-36: EMPTY MODBUS TREES. ............................................................................................................... 5-83 FIGURE 5-37: TYPICAL MODICON WITH FLOATING POINT LIST .......................................................................... 5-84 FIGURE 5-38: MAINTENANCE SCREEN................................................................................................................ 5-86 FIGURE 5-39: FIRMWARE UPGRADE SCREEN ...................................................................................................... 5-88 FIGURE 5-40: OPEN NEW FIRMWARE FILE WINDOW .......................................................................................... 5-88 FIGURE 7-1: 802 CLASS 1 DIVISION 1 DIMENSIONS (FRONT VIEW) .................................................................... 7-90 FIGURE 7-2: 802 CLASS 1 DIVISION 1 DIMENSIONS (SIDE VIEW)........................................................................ 7-91 FIGURE 7-3: 802 CLASS 1 DIVISION 2 DIMENSIONS (FRONT VIEW) .................................................................... 7-92 FIGURE 7-4: 802 CLASS 1 DIVISION 2 DIMENSIONS (SIDE VIEW)........................................................................ 7-93 FIGURE 7-5: 802 CLASS 1 DIVISION 1 WIRING DIAGRAM ................................................................................... 7-94 FIGURE 7-6: 802 CLASS 1 DIVISION 2 WIRING DIAGRAM ................................................................................... 7-95

Tables

TABLE 3-1: RUN CODES .................................................................................................................................... 3-17 TABLE 3-2: STATE CODES ................................................................................................................................ 3-18 TABLE 3-3: MENU EXPLANATIONS..................................................................................................................... 3-19 TABLE 3-4: FRONT PANEL LED FUNCTIONS....................................................................................................... 3-19 TABLE 3-5: SAMPLE CHAMBER ASSEMBLY PARTS LIST ..................................................................................... 3-22 TABLE 3-6: R EAD/R ATE APERTURE STRIP SIZES AND ASSOCIATED R ANGES ..................................................... 3-23 TABLE 3-7: K EYPAD K EY FUNCTIONS ................................................................................................................ 3-31 TABLE 3-8: OPERATOR MENU ............................................................................................................................ 3-33 TABLE 3-9: MAINTENANCE MENU...................................................................................................................... 3-34 TABLE 3-10: TOTAL SULPHUR R EACTIONS......................................................................................................... 3-37 TABLE 4-1: EVENT SEQUENCE............................................................................................................................ 4-40 TABLE 5-1: COMPUTER R EQUIREMENTS FOR 802 GUI ....................................................................................... 5-46 TABLE 5-2: COMMUNICATE TOOLBAR BUTTONS................................................................................................ 5-54

TABLE 5-3: OPERATION TOOLBAR BUTTONS...................................................................................................... 5-54 TABLE 5-4: GENERAL TOOLBAR BUTTONS......................................................................................................... 5-55 TABLE 5-5: APPLICATION SCREEN FUNCTIONS................................................................................................... 5-58 TABLE 5-6: WATCH WINDOW FIELDS................................................................................................................. 5-59 TABLE 5-7: CHART BUTTON FUNCTIONS............................................................................................................ 5-63 TABLE 5-8: CHART MANIPULATION OPTIONS..................................................................................................... 5-64 TABLE 5-9: DATA SORTING OPERATORS ............................................................................................................ 5-65 TABLE 6-1: TROUBLESHOOTING GUIDE.............................................................................................................. 6-89 TABLE 10-1: 802 TECHNICAL SPECIFICATIONS............................................................................................... 10-103


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MANUFACTURER’S WARRANTY STATEMENT

This product is warranted against defects in materials and workmanship for twelve months from the date of

shipment. During the warranty period the manufacturer will, as its option, either repair or replace products,

which prove to be defective.

The manufacturer or its representative can provide warranty service at the buyer’s facility only upon prioragreement. In all cases the buyer has the option of returning the product for Warranty service to a facility

designated by the manufacturer or its representatives. The buyer shall prepay shipping charges for productsreturned to a service facility, and the manufacturer or its representatives shall pay for return of the products to

the buyer. The buyer may also be required to pay round-trip travel expenses and labour charges at prevailing

labour rates if warranty is disqualified for reasons listed below.

Galvanic Applied Sciences Ltd. spare parts and products for the operation of their instruments, such as

chemically treated sensing tapes, are manufactured under a stringently controlled quality environment. If a

substitute is used, instrument performance may not be satisfactory. Accordingly, Galvanic Applied Sciences

Ltd. will not be responsible for the performance of instruments manufactured by it if product substitutes are

used. Without in any way limiting the foregoing, if at any time chemically treated sensing tapes other than thosesupplied by Galvanic Applied Sciences Ltd. are used in an instrument manufactured by it, this warranty shall be

void and of no further force of effect and no liability arising from the use of such other sensing tapes shall be

attached to Galvanic Applied Sciences Ltd. Further, Galvanic Applied Sciences Ltd. shall have no obligation toservice or repair any instrument in which such other sensing tapes are used that have not been approved for such

use by Galvanic Applied Sciences Ltd.

Limitation of Warranty

The foregoing warranty shall not apply to defects arising from:

• Improper or inadequate maintenance by the user.

• Improper or inadequate site preparation.

• Unauthorized modification or misuse.

• Operation of the product in unfavourable environments, especially high temperature, high humidity,

• Corrosive or other damaging atmospheres or otherwise outside published specs of analyzer.

Disclaimer

No other warranty is expressed or implied. The manufacturer specially disclaims the implied warranties of

merchantability and fitness for a particular purpose.

Caution

The manufacturer shall not be liable for personal injury or property damage suffered in servicing the product.

The product should not be modified or repaired in a manner at variance with procedures established by themanufacturer.


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Section 1 802 Overview

The Galvanic Applied Sciences Inc. 802 Lead Acetate Tape analyzer (henceforth referred to as the802) is an analyzer that has been designed to measure relatively low levels of hydrogen sulphide ortotal sulphur in natural gas streams. The 802 is capable of measuring up to 2000 parts per million(ppm) of hydrogen sulphide by volume without the requirement of sample dilution. With a new patent-

pending analysis algorithm, the 802 has a larger dynamic range and better linearity and repeatabilitythan previous models of lead acetate tape analyzers.

1.1 Principle of OperationWhen hydrogen sulphide, H2S, reacts with lead acetate, the previously white lead acetate beginsto turn brown due to a chemical reaction. The reaction is as follows:

Pb(CH 3COO)2 + H 2 S PbS + 2 CH 3COOH

The colour change is caused by the conversion of lead acetate into lead sulphide. When a papertape that has been impregnated with lead acetate is exposed to hydrogen sulphide, brown stainsare seen on the tape. The rate of colour change on the tape is directly proportional to the

concentration of hydrogen sulphide in the gas stream. Thus, if the rate of colour change ismeasured, the concentration of hydrogen sulphide in the gas stream can be determined. The

ASTM Method used by the 802 is D 4084-82 Analysis of Hydrogen Sulphide in Gaseous Fuels(Lead Acetate Reaction Rate Method). For more information on how the analysis is carried out,see sections 4.2 and 4.3.

1.2 802 Components in BriefThe 802 consists of 3 major components – the electronics enclosure, the chassis, and the keypad.The total sulphur version of the 802 has an additional component - the total sulphur furnace.Many 802s are also equipped with an external sample conditioning system. A schematic of the802 system is shown in Figure 1-1.

Figure 1-1: Schematic of 802 Flow Path


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All of the components in the 802 are described briefly here, and in depth in Section 3.

1.2.1 Electronics EnclosureThe electronics enclosure contains the 802’s LCD display screen that shows the user at aglance the current concentration reading in a large font, as well as other information pertinentto the analyzer’s operation. It also contains all of the analyzers inputs and outputs, as well as

the communication ports used to connect the 802 to a PC. The electronics enclosure isdescribed in detail in Section 3.1.

1.2.2 ChassisThe chassis is the black aluminium box that occupies the top half of the 802. It contains themotor used to advance the tape, the optics block (detector), the lead acetate tape, the pulsecounter used to accurately advance the tape, the flow meter, and the sample humidifier(bubbler). The chassis is described in detail in section 3.2.

1.2.3 KeypadThe keypad is attached to the chassis. This intrinsically safe keypad allows the user to reviewthe configuration of the 802 through the display screen, as well as to make any changes to theparameters that can be changed through the keypad. Because the keypad is intrinsically safe,it is able to be used even in classified areas. The keypad is described in detail in section 3.3.

1.2.4 Total Sulphur furnaceThe total sulphur furnace enclosure, located below the electronics enclosure, contains theheating element and reaction furnace used in total sulphur measuring 802s. The furnace isused to convert all sulphur compounds in the sample gas into hydrogen sulphide by reactionwith hydrogen at a high temperature. The total sulphur furnace is described in detail in section3.4.

1.2.5 Sample Conditioning SystemThe sample conditioning system is used to clean the sample gas and to reduce it to thecorrect operating pressure for the 802. As such, it usually consists of one or more filters toremove particulates and liquids from the sample gas, a regulator to control the samplepressure at the correct value, and a sample sweep. It also may contain a manual 3-way valveto allow selection of calibration or sample gas, a solenoid for auto-calibration purposes, and ahydrogen regulator for total sulphur 802s.

1.3 Graphical User InterfaceThe Graphical User Interface (GUI) that is included on the 802 configuration disk that is shippedwith the analyzer allows the user to configure and monitor the 802 from a PC. The GUI allows theuser to change many more parameters than are accessible from the keypad. As well, it allows theuser to download, review, and export archived data. Further, it allows the user to configure andcalibrate both analog outputs, the four digital inputs, and all eight outputs, both relays andsolenoids. Finally, it allows the user to monitor the status of the entire analyzer from one screen,something that is not possible on the 802’s LCD screen. The GUI is described in detail in Section5.


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Section 2 Installation and Procedures

This section outlines some installation considerations for the 802 and basic procedures used forvarious tasks related to the operation of the 802.

2.1 Installation ConsiderationsThe 802 should be mounted in a location where it is not exposed to excessive vibration. Inaddition, it should be mounted in a location where the ambient pressure remains relativelyconsistent over the course of any given day, and where the ambient temperature does notfluctuate wildly from day to night and winter to summer.

The vent line cannot have any backpressure on it, as backpressure can seriously impact readings.The vent line should have no vertical bends, and should be as short as possible to allow theunrestricted flow of sample out to the vent.

Allow approximately 15” on the left hand side of panel-mounted 802s to allow the removal of thetape cover on the side of the chassis, and to allow easy access for tape installation and removal.

Allow 6” on the left side of cabinet-mounted 802s for the installation of a vent line.

The seals on Class 1 Division 1 802s are not poured at the factory. Before starting use of the 802in a classified area, the seals must be poured. All explosion proof covers (motor box, electronicsenclosure, 110VAC to 24VDC power supply, and total sulphur furnace enclosure) must be closedand sealed before powering up the analyzer in a classified area.

For total sulphur 802s, the furnace enclosure contains packing material inside that is used toprevent damage to the system during shipping. Remove this packing material before powering upthe furnace.

Connect the correct power source. If the 802 has no AC to DC power supply, connect a 24VDCpower supply as shown in the leftmost image in Figure 2-1. If the 802 is a Division 2 AC-poweredunit, connect the AC power source to the AC to DC power supply as shown in the centre image in

Figure 2-1. If the 802 is a Division 1 AC-powered unit, connect the AC power source to the AC toDC power supply unit as shown in the rightmost image in Figure 2-1. The power terminal block onthe division 1 terminal block is on the left when looking up from underneath the 802. The terminalblock with the red and black wires is the 24VDC output block. Do not turn the power on yet.

Figure 2-1: 802 Power Supply Connections (From left, 24VDC Div. 2, AC Div. 2, AC Div. 1)

Using the wiring diagrams in Section 7, connect the analog outputs as desired. Remember thatthe analog outputs on the 802 require loop power, as the 802 does not provide power to them.Connect any other digital inputs, solenoids, or relay connections as desired.

The dimensions of the 802, as well as the full wiring diagrams for both Class 1 Division 1 andClass 1 Division 2 are shown in Section 7.


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2.2 Basic Start-up ProcedureThe following is a list of steps involved in starting up the 802.

1. Connect the keypad to the connector on the right side of the chassis (below the motor boxon division 1 units). See Figure 2-2 for the connector location on a division 2 802. TheKeypad connector is in the same place on a division 1 802.

Figure 2-2: Keypad Connector Location

2. Unpack the humidifier and remove the plug from the top of the humidifier. Fill thehumidifier to the line on the front of the humidifier with the 5% Acetic Acid solutionincluded in the 802 crate. Once filled, replace the plug and place the humidifier into the

802 chassis, behind the lower door. Connect the two Tygon sample lines to the twobarbed connectors on the top of the humidifier.

3. Remove the tape cover on the left side of the 802 chassis. Install the tape as outlined insection 2.3.

4. Connect sample gas to the 802. If the 802 is equipped with a sample system, set thepressure regulator to 15psig. If not, ensure that the sample gas is clean and is regulatedto a pressure of 15psig before connecting it to the 802. If the 802 is a total sulphur model,set the sample flow meter to a flow of 0.5 and the hydrogen flow meter to a flow of 1.5.Test the furnace for leaks by following the procedure in section 2.6.2.

5. Power up the 802. Wait for the 802’s LCD screen to display 0.00ppm. Using the keypad,

enter the correct length of the reel of tape installed (section 3.3.1) – 300 foot reels of tapeare included in the crate with the 802.

6. If the 802 is a total sulphur unit, connect to the unit with the GUI (section 5.1) and ensurethat the Furnace Pulse Width in the Global screen (section 5.3.4.1) is set to the correctvalue for the AC Voltage being used (50% for 110VAC, 12.5% for 220VAC). WARNING:Failure to ensure that the furnace pulse width is set to the correct value could result infailure of the furnace element or melting of the quartz reaction tube.


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7. Follow the leak test procedure in section 2.4 to ensure that the tape is well sealed againstthe sample chamber by the compression head.

8. Allow the 802 to run on sample gas for approximately 1 hour. After 1 hour, inspect thestains on the tape and compare them to those in Figure 2-3. If the stains are crisp andwell spaced, the compression head is sealing the tape well against the sample chamber. Ifthe stains have fuzzy edges, check the seal again as in step 7, and also check to ensurethat the tape is flat against the sample chamber (i.e. not creased) and is correctlyinstalled.

Figure 2-3: Stain Appearance

9. Once the correct seal has been established, connect a calibration gas of knownconcentration to the calibration port and perform a manual reference run (section 2.5.1). Ifthe reading on the 802’s LCD screen is within ±2% of the certificate value for thecalibration gas, the 802 is within calibration and can be immediately entered into service.

10. If the 802 is not calibrated correctly, enter the calibration cylinder certificate concentrationinto the MNT (Maintenance) menu using the keypad. Initiate a manual calibration run byfollowing the procedure in section 2.5.2.

11. Once the 802 is calibrated, it is ready to start analyzing sample gas.

2.3 Installation of TapeThe correct operation of the 802 is dependent on the correct installation of the lead acetate tape.Follow this procedure exactly to ensure correct installation. Figure 2-4 shows a photo of the tapeenclosure with all components numbered – these numbers will be referenced in the procedure.The system MUST be in BYPASS mode prior to starting this procedure for replacement of tapes.

1. Remove the screw-on disks (not shown) from the supply reel (1) and take-up reel (2).

2. Take a new reel of tape and remove the adhesive tape securing the end. Place the tape reelon the supply reel. Make sure the tape is installed so that the loose end hangs down on theleft side of the reel, not the right.

3. Thread the tape over the lower sample chamber guide pin (3). Push the compression head (4)

back and slide the tape behind the compression head. Ensure that the tape is flat against thegroove in the sample chamber (8) and has no creases.


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Figure 2-4: Tape Enclosure Parts Reference

4. Pull the tape up over the upper sample chamber guide pin (5).

5. Thread the tape over the black aluminium or grey plastic (shown) capstan of the pulse counter(6).

6. Fold over the first 2 inches of the tape, and then slide this folded end of the tape into the sloton the take-up reel (2), as shown in Figure 2-5.

Figure 2-5: Insertion of tape end into take-up reel


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7. Replace the screw-on disks onto the supply and take-up reel. The larger disk goes on thetake-up reel.

8. Take up any slack in the tape by rotating the tape reel on the supply reel clockwise until thetape is tight.

Other components of interest in Figure 2-4 are the sensor block cover (8), the vent bulkhead (9),and the low tape sensor window (10). Once these steps have been followed, the tape should becorrectly installed on the tape transport system. Figure 2-6 shows the correct installation of tapeon the 802. The image on the left shows the completed tape installation without the anti-coningdisks and the one on the right shows the tape installation with the disks.

Figure 2-6: Correct Installation of Tape

2.4 Leak Testing of Compression HeadTo ensure that repeatable data is obtained, it is essential to have a good seal between thecompression head, the tape, and the sample chamber. To test the seal, Galvanic recommends aDwyer Minhelic II gauge, available from Galvanic Applied Sciences. The gauge measures a rangeof pressure from 0 to 5 inches of water column.

The following procedure is used to leak-check the 802 compression head and to obtain a properseal. Make sure the flow indicated on the chassis rotameter is approximately 2.0 before followingthis procedure. The system MUST be in BYPASS mode prior to carrying out this procedure.

1. Remove the vent line from the elbow at the base of the chassis and attach the Minihelic to theelbow, as shown in Figure 2-7.

2. Check the pressure indicated on the gauge. If the pressure reads 5 or above, as shown inFigure 2-7, the tape is well sealed against the sample chamber by the compression head.Press TAPE ADVANCE on the keypad and ensure that the pressure does not drop below 4even when the tape is moving. It should return to 5 by the time the tape stops moving.

3. If the pressure is NOT 5 or greater, there is a problem with the seal somewhere in thechassis. The first step will be to check and see if the problem is in the sample chamber itself.


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Figure 2-7: Minihelic indicating a good seal (L); connected to vent elbow (R)

4. Press BYPASS on the keypad to put the 802 into Bypass mode. Remove the compressionhead. Pull the tape away from the sample chamber and put a thumb over the hole in thesample chamber. If the pressure indicated on the Minihelic goes to 5 or greater, this willindicate that the leak problem is caused by the compression head itself. If the pressureindicated on the Minihelic with a thumb over the hole is close to zero, this is indicative of an

improperly installed gasket and/or window in the sample chamber assembly. Go to step 6. Ifthe pressure indicated is greater than 1, this is indicative of a leak in the humidifier. Go to step7.

5. If the problem is with the compression head, there are a couple of possible resolutions. First,take the compression head and rub the surface that actually contacts the tape on the paperwrapper from the lead acetate tape to try and smooth it down. Reinstall the compression headand check the pressure again. If the pressure is still not 5, remove the compression headagain, remove the setscrew from one side of the compression head and move it to the otherside to allow the compression head to be installed the other way in. Reinstall the compressionhead, press TAPE ADVANCE on the keypad, and check the pressure again. If it is still not 5,please call the service department at Galvanic Applied Sciences.

6. To check the sample chamber assembly for an improperly installed rear window and/orgasket, remove the sensor block cover (number 9 in Figure 2-4) and unscrew the two screwsretaining the sample chamber in the chassis. Disconnect the sample inlet line (top) and thesample vent line (bottom). Figure 2-8 shows an exploded view of the sample chamberassembly for reference in taking the chamber assembly apart.

Figure 2-8: Sample Chamber Assembly Exploded View


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Check that the two screws holding the sensor block clips (6) in position are as tight aspossible and then put a thumb back over the hole to check the pressure again. If the pressureis still less than 5, remove the sensor block (4) entirely by disconnecting the two (or three)electronics connectors on the sensor block, loosening the two screws holding the sensor blockretaining clips, and turning the clips outwards so that the sensor block is no longer retained.Remove the sensor block. Ensure that the gasket (5) underneath the plastic window (3) iscorrectly in position and that the plastic window is flat against the surface of the gasket, andproperly located within the indentation in the sample chamber. Check that the aperture strip(2), if present, is stuck to the inside of the sample chamber with silicone grease. Clean out anylint or dust noted in the square hole in the bottom of the sample chamber, as this may causethe sensor block to have a high sensor current. Place the sensor block back on the samplechamber, making sure not to knock the window out of position. Tighten it back down as far aspossible using the retaining clips. Reconnect the sample lines and check the pressure againby placing a finger over the hole in the sample chamber – it should be 5. If it is close to zero,follow the procedure in this step again to check if the window was knocked out of positionwhen the sensor block was reinstalled. If it is greater than 1, go to step 7 to leak check thehumidifier. Reinstall the sample chamber back in the chassis and reinstall the compressionhead, making sure that the tape is flat against the sample chamber. Check the pressure again.If it is not 5, follow step 5 to check the problems with the compression head.

7. To test the humidifier for leaks, remove the Minihelic from the vent elbow and slide theMinihelic’s rubber tubing over the end of the outlet barb on the humidifier, as shown in Figure2-9.

Figure 2-9: Leak Testing the Humidifier

As shown in the figure, the outlet barb is the fitting close to the back of the humidifier. Thefitting at the front of the humidifier is the inlet barb that brings the sample gas into thehumidifier. While the gas is flowing through the humidifier, there should be a pressure greaterthan 5 indicated on the Minihelic. If there is not, there is a leak in one of the fittings inside thehumidifier. Unscrew the 10 screws that hold the top onto the humidifier. Remove the top andcheck the nuts on either end of the Nafion tubing. Be careful not to touch the tubing more thanabsolutely necessary, as this may reduce the ability of the tubing to allow water vapour topass through it. Before putting the top back on, check the pressure again. If it is still not


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greater than 5, there may be a problem with the tubing or one of the fittings. Please contactGalvanic Applied Sciences Inc.’s service department for assistance. If the pressure is greaterthan 5, reattach the top to the humidifier and reconnect the Tygon tubing inside the chassis tothe outlet barb on the humidifier.

2.5 Initiating Calibration, Reference, and ZeroThe procedures for running a calibration, reference, and zero run are slightly different, so they willbe covered separately for greater concision. A zero run should be performed before a calibrationrun if both are to be done at the same time. NOTE: These runs will NOT initiate if an analysisalarm (Alarm 1 or PAA) is currently triggered on the Normal run. If the 802 is in Alarm 1 orPAA, the calibration, reference, or zero run will be entered into the run queue and will onlyrun once the alarm condition has cleared.

2.5.1 Manual Initiation of ReferenceThe following procedure will allow the user to run a manual reference run.

1. Connect a calibration cylinder containing a known concentration of hydrogen sulphide (or

total sulphur, if the 802 is a total sulphur unit) to the calibration port on the 802 samplesystem.

2. Open the cylinder and set the low pressure gauge pressure on the regulator to 15psig.

3. If the sample system has a manual 3-way selection valve to choose between calibrationand sample streams, turn the valve to select the calibration stream. If not, go to step 4.Make sure the chassis rotameter still reads a flow of 2.0. For total sulphur 802s, makesure the sample flow meter still reads 0.5 and the hydrogen still reads 1.5.

4. If the 802 is equipped with an automatic calibration solenoid, the solenoid must be turnedon through the keypad. Press the F4 key to access the MNT (maintenance) menu. Usingthe F4 (PGDN) key, scroll down through the maintenance menu until the line that saysRef OFF is seen. Use the F2 and F3 keys if necessary to move the black highlight bar to

highlight this line. Press the EDIT key. Pressing the ENTER key will toggle the 802 to puta reference run into the run queue.

5. Observe the results of the 802 measuring reference gas. If the reading is within ± 2% ofthe certificate concentration value for the cylinder, the 802 is within calibration. Turn the 3-way valve back to the sample stream to return to normal operation. If not, go section 2.5.2to manually calibrate the 802.

2.5.2 Manual Initiation of CalibrationThe following procedure will allow the user to manually initiate a calibration run.

1. Connect a calibration cylinder containing a known concentration of hydrogen sulphide (or

total sulphur, if the 802 is a total sulphur unit) to the calibration port on the 802 samplesystem.


3. Enter the calibration gas concentration using the keypad. Press F4 to access the MNT(maintenance) menu. Using the F4 (PGDN) key, scroll through the maintenance menuuntil the line that has a value of GCalGa in the left column is seen. Use the F2 (UP) or F3(DOWN) keys as necessary to move the black highlight bar to this line. Press EDIT. Enter


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the certificate value of the calibration gas concentration, and then press ENTER. PressEXIT to return to the default screen.

4. If the sample system has a manual 3-way selection valve to choose between calibrationand sample streams, turn the valve to select the calibration stream. Make sure the chassisrotameter still reads a flow of 2.0. For total sulphur 802s, make sure the sample flowmeter still reads 0.5 and the hydrogen still reads 1.5.

5. To initiate the calibration run, press the F4 key to access the MNT (maintenance) menu.Using the F4 (PGDN) key, scroll down through the maintenance menu until the line thatsays Cal OFF is seen. Use the F2 and F3 keys if necessary to move the black highlightbar to highlight this line. Press the EDIT key. Pressing the ENTER key will toggle the 802to put a calibration run into the run queue.

6. Once the calibration run is complete, run a reference to ensure that the calibration is valid.

7. Once satisfied with the calibration, return the 3 way valve to the sample position.

2.5.3 Manual Initiation of ZeroThe following procedure will allow the user to manually initiate a zero run.

1. Connect a cylinder containing no hydrogen sulphide, such as ultra pure nitrogen, to thededicated zero port (or calibration port, if the sample system does not have a dedicatedzero port) on the 802 sample system.


3. If the zero gas concentration is zero, this step can be skipped . If not, enter the zero gasconcentration using the keypad. Press F4 to access the MNT (maintenance) menu. Usingthe F4 (PGDN) key, scroll through the maintenance menu until the line that has a value ofOCalGa in the left column is seen. Use the F2 (UP) or F3 (DOWN) keys as necessary tomove the black highlight bar to this line. Press EDIT. Enter the certificate value of the zero

gas concentration, and then press ENTER. Press EXIT to return to the default screen.

4. If the sample system has a manual 3-way selection valve to choose between calibration /zero and sample streams, turn the valve to select the calibration / zero stream. Make surethe chassis rotameter still reads a flow of 2.0. For total sulphur 802s, make sure thesample flow meter still reads 0.5 and the hydrogen still reads 1.5.

5. To initiate the zero run, press the F4 key to access the MNT (maintenance) menu. Usingthe F4 (PGDN) key, scroll down through the maintenance menu until the line that saysZero OFF is seen. Use the F2 and F3 keys if necessary to move the black highlight bar tohighlight this line. Press the EDIT key. Pressing the ENTER key will toggle the 802 to puta zero run into the run queue.

6. Once the zero run is complete, run a reference run using the zero gas as the referencegas to ensure that the 802 does read 0, or very close to 0, on the zero gas.

7. Once satisfied with the zero, return the three way valve to the sample position.

2.5.4 Manual Quick Calibration / ZeroThis procedure can only be used on 802s equipped with the manual 3-way valve for selectionbetween the calibration stream and the sample stream. Note that this procedure will likelyresult in less accurate gain and zero offset factors than those produced by following the


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procedures in sections 2.5.2 and 2.5.3. Ensure that the 802 is in BYPASS mode beforefollowing these procedures.

2.5.4.1 Quick Calibration

1. Connect a calibration cylinder containing a known concentration of hydrogen sulphide

(or total sulphur, if the 802 is a total sulphur unit) to the calibration port on the 802sample system.


3. Turn the 3-way valve to select the calibration stream. Make sure the chassisrotameter still reads a flow of 2.0. For total sulphur 802s, make sure the sample flowmeter still reads 0.5 and the hydrogen still reads 1.5.

4. Allow the 802 to run for two or three cycles until the readings look stable. Determinewhether the reading on the screen is too high or too low, and by approximately howmuch (percentage). Press the F4 key to access the MNT (Maintenance) menu. Usethe F4 key (PGDN) to scroll down through the menu until the line with the value Gain

in the left column is seen. Use the F2 (UP) and F3 (DOWN) keys as necessary tomove the black highlight bar to this line. Press EDIT. Enter a new gain factor. If thereading on the screen was too high relative to the certificate concentration value,lower the current gain factor by the same percentage that the reading was too high. Ifthe reading was too low, raise the current gain factor by the same percentage that thereading was too low. Press EXIT to return to the default screen to observe the newreading.

5. Use step 4 to fine-tune the gain as desired.

6. Once satisfied with the gain, return the 3-way valve to the sample position.

2.5.4.2 Quick Zero1. Connect a calibration cylinder containing no hydrogen sulphide to the calibration port

on the 802 sample system.


3. Turn the 3-way valve to select the calibration stream. Make sure the chassisrotameter still reads a flow of 2.0. For total sulphur 802s, make sure the sample flowmeter still reads 0.5 and the hydrogen still reads 1.5.

4. Allow the 802 to run for two or three cycles until the readings look stable. Determinewhether the readings look to be too high (positive) or too low (negative readings), andby numerically how much. Press the F4 key to access the MNT (Maintenance) menu.

Use the F4 key (PGDN) to scroll down through the menu until the line with the valueOffset in the left column is seen. Use the F2 (UP) and F3 (DOWN) keys as necessaryto move the black highlight bar to this line. Press EDIT. Enter a new zero offset. If thereading on the screen was positive, add this value to the current zero offset. If thereading was negative, add this negative value to the current zero offset (i.e. reducethe magnitude of the current zero offset). Press EXIT to return to the default screen toobserve the new reading.

5. Use step 4 to fine tune the zero offset as desired.


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6. Once satisfied with the zero offset, return the 3-way valve to the sample position.

2.6 Total Sulphur ProceduresThere are a couple of procedures that must be followed for maintenance and testing of total-sulphur furnace equipped 802s. These procedures are related to replacing the quartz reaction

tube and checking the furnace for hydrogen leaks after replacing the reaction tube.

IMPORTANT: It is essential that the power be turned off to the 802 beforecarrying out either of these procedures. The furnace enclosure must beallowed to cool for at least 45 minutes prior to initiating these procedures.Do NOT remove the end caps of the furnace enclosure until the furnace iscool – attempting to remove the end caps while the furnace is still hot couldresult in an explosion if even a small amount of hydrogen has leaked intothe furnace!

Figure 2-10 shows a numbered photo of the exterior and interior of the total sulphur furnace, forease of identifying all the parts discussed in these procedures.

Figure 2-10: Total Sulphur Furnace Enclosure - Exterior (L) and Interior (R)

The total sulphur furnace is housed inside an explosion proof enclosure (1). There are two screwon end caps (2,3) that screw onto large threads (10) at each end of the enclosure. A conduit (6)carries the power wiring (11,12) and the temperature sensor wiring (not visible) into the enclosure.The sample flows through flame arrestors (4,5) on the way into and out of the furnace. Thereaction takes place in a quartz reaction tube (8) inside the actual total sulphur furnace, which ishoused in a smaller aluminium enclosure (7). The sample lines are attached to the quartz tube bymeans of ultra-torr elbows (9) that have finger-tightened nuts to create an adequate seal.

2.6.1 Replacing Quartz Reaction TubeThe total sulphur reactions take place inside a quartz reaction tube inside the total sulphurenclosure. The quartz reaction tube is shown in Figure 2-10.

Figure 2-11: Total Sulphur Quartz Reaction Tube


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In some situations it may be necessary to replace the quartz reaction tube. Depending on thecomposition of the sample gas, the tube may coke up over time and cause flow impediment.

Alternatively, if the tube cokes up significantly, it may reduce the catalytic behaviour of thereaction tube that helps the total sulphur reactions occur. The following procedure is to befollowed to replace a quartz reaction tube. Refer back to Figure 2-10 for assistance inidentifying parts in the total sulphur enclosure assembly.

1. As mentioned previously, turn off the power to the 802. Allow the furnace to cool down forat least 45 minutes before removing the end caps.

2. Turn off the hydrogen and sample flow at the rotameters on the sample conditioningsystem.

3. Unscrew the nuts all the way on the reaction tube sides of the two ultra-torr elbows insidethe furnace assembly.

4. Pull the ultra-torr elbows away from the reaction tube. Slide the old tube out of the furnaceassembly. Slide the nuts, ferrules and O-rings off the old tube.

5. Carefully slide the new tube into the furnace. Slide the old nuts and ferrules onto the two

ends of the tube, as well as two new kal-rez high temperature rubber o-rings. The correctorder is shown in the exploded view in Figure 2-11.

Figure 2-12: Exploded view of ultra-torr fitting

Slide the nut (4) with the threads facing toward the end of the tube, the ferrule (3) with thenarrower end facing toward the end of the tube, and the kal-rez high temperature o-ring(3) over the end of the quartz reaction tube (5). Slide the end of the tube into the end ofthe elbow (1) until it cannot be pushed in any further. Carefully tighten the nut onto theelbow. DO NOT OVERTIGHTEN! This may cause the tube to break. Tug on the elbowslightly after tightening to ensure that the elbow is snugly attached to the end of the tube.

6. Repeat step 5 for the other end of the tube.

7. Replace the end caps on the furnace enclosure. Be sure to align the threads correctly.The end-caps will screw on very easily if the threads are aligned correctly. DO NOTFORCE! Cross threading will seriously impair the explosion proof nature of the enclosure.

2.6.2 Leak Checking Total Sulphur FurnaceOnce the quartz reaction tube has been replaced, it is necessary to leak check the furnaceprior to powering it back on. Follow this procedure for leak checking the total sulphur furnace.


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Turn the sample and hydrogen flow back on. Ensure hydrogen is flowing at 1.5 and sample isflowing at 0.5 on the rotameters.

Place a cap on the top side of the flame arrestor on the right hand side of the total sulphurfurnace, as shown in Figure 2-13. This will block flow through the total sulphur furnace.

Figure 2-13: Location of Cap for furnace leak check

Watch the flow on the hydrogen and sample rotameters on the sample conditioning system. Ifthere is a good seal in the furnace, the flow on both rotameters should drop to zero within 1minute.

If the flow does not drop to zero, use liquid leak detector (e.g. Snoop) to check all external fittingsfor leaks. If there are none, remove the end caps from the furnace enclosure and ensure that allthe fittings on the four ultra-torr elbows inside the enclosure, especially the two on the reactiontube itself, are as tight as possible. Again, be careful not to break the tube while tightening thefittings.

Once the leak has been fixed, replace the end caps, remove the cap, and reattach the sampleline to the top of the flame arrestor. Ensure that this fitting is tight.

Restore power to the 802 and begin normal operation.


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Section 3 Mechanical and Hardware

As was described previously in Section 1, the 802 is divided into five major components – theelectronics enclosure, the chassis, the keypad, and optionally the sample conditioning system and thetotal sulphur furnace. Each component will be described separately.

3.1 Electronics EnclosureThe Electronics enclosure is the brain of the 802. It contains the main processor, the systemmemory, the power supply, the LCD display, the analog outputs, the relays, the solenoids, and thecommunications ports – USB, RS-232, RS-485, and high speed LAN. In Class 1 Division 1 (XP)units, the electronics enclosure also contains the intrinsically safe barrier through which pass allelectrical connections between the electronics enclosure and the chassis. The interior of a Division2 electronics enclosure is seen in Figure 3-1.

Figure 3-1: 802 Division 2 Electronics Enclosure

The front of the electronics enclosure is dominated by the large LCD display. There are nine LEDssurrounding the display, and on the right hand side of the display is a USB Type A connector thatcan be used in either USB mode or RS-232 mode. See section 5.1.3 for more information.

3.1.1 Front PanelThe front panel serves as the user interface for the 802. It consists of the LCD display and thesurrounding LEDs. Simply by looking at the front panel, the user can immediately gain a gooddeal of insight as to the current state of the 802. The front panel, including the lamacoid, isshown in Figure 3-2.


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Figure 3-2: 802 Front Panel

3.1.1.1 LCD Display

The LCD display on the 802 is much larger than the displays found on previous Galvaniclead acetate tape analyzers. The default display can be seen clearly in Figure 3-2. In thedefault display mode, there are three separate ‘zones’ on the LCD display. At the top ofthe screen are 4 status indicators, marked mV, RUN, STATE, and TAPE. The middle ofthe screen shows the calculated concentration value. The bottom of the screen showsfour menus that can be accessed by using the keypad.

The mV indicator indicates the current output of the sensor block. This number is adjustedto zero at the beginning of an analysis, and becomes larger as the tape gets darker onexposure to H2S. The larger this number is, the darker the stain on the tape is.

The RUN indicator indicates which analysis mode the 802 is currently in. The fourpossible values of this indicator are shown in Table 3-1.

Table 3-1: RUN Codes

Code Meaning

NR0 to NR9 The 802 is currently analyzing the sample stream.

CR0 to CR9The 802 is currently running a calibration analysis tocalculate a new gain factor.

RR0 to RR9 The 802 is currently running a reference analysis tocheck the validity of the current calibration.

ZR0 to ZR9The 802 is currently running a zero analysis tocalculate a new zero offset.

The four run types are explained in detail in section 4.4. The numeral in the code indicateswhich analysis cycle in the sequence the 802 is currently carrying out.


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The STATE code indicates what state the 802 is currently in. There are seven possiblecodes that may be seen in this indicator. They are explained in Table 3-2.

Table 3-2: STATE Codes

Code Meaning

INITThe sensor block is initializing. This code is only seen

on power-up and during a user-forced tape advance.

IDLEThe electronics assembly is waiting for measurementfrom the sensor block. This code is only seen on powerup and during a user-forced tape advance.

TATape advance in progress. This code is seen at powerup, during a user-forced tape advance, and at the endof every analysis cycle.

CSENS

The sensor block is recalibrating and auto-zeroing theoutput so that the sensor output starts at 0mV for thenext analysis run. This code is seen at the beginning ofevery analysis cycle.

SDSample Delay. Results obtained during this section ofthe analysis cycle are considered invalid by the 802

and are not used in the concentration calculation.

SISample Interval. This is the standard analysis modewhere results are collected to calculate theconcentration.

PRG

The system is purging. This code is only seenimmediately after a stream change. The system purgesfor a given period of time before beginning an analysison the new stream.

The INIT, IDLE, and CSENS codes are explained in more detail in section 3.2.1.2, whichdescribes the operation of the sensor block. The SD and SI codes are explained in moredetail in sections 4.2 and 4.3, which explain the standard analysis cycle and the timedanalysis cycle.

The TAPE indicator displays the length of tape currently remaining on the reel. Thisallows the user to quickly determine the amount of tape left without having to open thetape enclosure. This number MUST be reset every time the tape is changed to ensurethat this value is correct. The tape length can be reset through the keypad (Section 3.3)or through the GUI (Section 5.3.4.1.1).

The centre of the LCD display is occupied by a large concentration display. This displaysthe last calculated concentration value for the current stream. That is to say, if theanalyzer switches streams, the screen will switch to show the last calculated value forthat stream. If that stream has not been run since the 802 was powered up, the displaywill read 0.00. The concentration value will update live if the 802 is in PAA Alarm (section4.4.1.2) or if the user has configured the LCD to display live concentration values, either

through the keypad or through the GUI. The units’ value, by default set to PPM, can beconfigured to display any units of the users choosing through the GUI (section 5.3.5.1). Ifthe 802 is configured to display the live concentration reading, the concentration units willhave an L in front of them. For example, PPM would become LPPM.

The bottom portion of the LCD is taken up by four menus. The codes F1, F2, F3, and F4 indicate the keys on the keypad used to access these menus. The purpose of each menuis outlined in Table 3-3, and described in detail in section 3.3.


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Table 3-3: Menu Explanations

Code Meaning

OPER

The Operator menu. This menu, accessed by pressing F1 on the keypad, allows the user to configure a small numberof parameters and view several other parameters. Seesection 3.3.1.

ALRM The Analyzer Alarms List, accessed by pressing F2 on thekeypad, allows the user to view a list of all of the currentlytriggered alarms on the 802. See section 3.3.3.

DISP

The Display configuration, accessed by pressing F3 on thekeypad, allows the user to toggle between liveconcentration and previously calculated concentrationvalues, as well as between raw and net sensor output. Seesection 3.3.4.

MNTThe Maintenance menu, accessed by pressing F4 on thekeypad, is a menu that allows the user to change manyparameters on the 802. See section 3.3.2.

3.1.1.2 Front Panel LEDsThere are a total of nine coloured LEDs on the front panel of the 802. These LEDsindicate specific status and communications related parameters. The functions of the 9LEDs are explained in Table 3-4.

Table 3-4: Front Panel LED Functions

LED Label Colour Function

LAN ACCESS

Green(blinks)

This LED blinks green if the unit is being communicated to via thehigh speed LAN port.

LAN DATA Green (solid)This LED indicates that there is communication between thevarious components of the LAN electronics.

Tx USBGreen(blinks)

This LED blinks green if the unit is transmitting data via the USBconnection.

Rx USB Red (blinks) This LED blinks red if the unit is receiving data via the USBconnection.

ALARM Red (solid)When lit, this LED indicates that at least one alarm has beentriggered.

BYPASSYellow(blinks)

This LED blinks yellow if the unit is in bypass mode (section 4.5)

FAILRed (solid)Red (blinks)

This LED is lit for three purposes. On start-up, if there is aproblem with the primary or backup firmware, this LED will light toindicate copying of a good copy of the firmware from one storagelocation to the other. It also lights during a memory-wipe process.If the LED is blinking red, it means that the 802 is currently inDirect Board Control Enable mode, which is triggered throughthe GUI (section 5.3.10)

KEYPD Green

This LED illuminates any time a key on the keypad is pressed. Itremains illuminated until the input from the keypad has been

processed by the electronics assembly, and no other presses onthe keypad will be recognized until this LED turns off.

SERIALCOM

GreenThis LED illuminates any time the 802 is communicating via aserial link. It will illuminate for communications on the RS-232,RS-485, or USB communications ports.


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Revision 1.2 3-20 21/08/2007

3.1.2 Electronics AssemblyWithin the electronics enclosure are three separate circuit boards that are stacked together.Together these 3 boards comprise the electronics assembly. The top of the assembly isoccupied by the display board, which controls the 802’s LCD display and is home to the

USB/RS-232 connector. Below that, invisible from directly in front of the analyzer, is theprocessor board. This board contains the unit’s flash memory, which stores the unit’sconfiguration file, ar

802 Manual - Rev 1.2 21 August 2007 (Single Stream)

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