Rosemount Flame Photometric Detector For GC Hardware Reference Manual (contains information for the newer 700XA and 1500XA Gas Chromatographs) Manuals & Guides

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FPD for Gas Chromatographs

Hardware Reference Manual

7R00370-H01

Revision B

January 2018

Introduction

NOTICE

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WARRANTY

LIMITED WARRANTY: Subject to the limitations contained in Section 2 herein and except as otherwise expressly provided herein, Rosemount (“Seller”) warrants that the firmware will execute the programming instructions provided by Seller, and that the Goods manufactured or Services provided by Seller will be free from defects in materials or workmanship under normal use and care until the expiration of the applicable warranty period. Goods are warranted for twelve (12) months from the date of initial installation or eighteen (18) months from the date of shipment by Seller, whichever period expires first. Consumables and Services are warranted for a period of 90 days from the date of shipment or completion of the Services. Products purchased by Seller from a third party for resale to Buyer (“Resale Products”) shall carry only the warranty extended by the original manufacturer. Buyer agrees that Seller has no liability for Resale Products beyond making a reasonable commercial effort to arrange for procurement and shipping of the Resale Products. If Buyer discovers any warranty defects and notifies Seller thereof in writing during the applicable warranty period, Seller shall, at its option, promptly correct any errors that are found by Seller in the firmware or Services, or repair or replace F.O.B. point of manufacture that portion of the Goods or firmware found by Seller to be defective, or refund the purchase price of the defective portion of the Goods/Services. All replacements or repairs necessitated by inadequate maintenance, normal wear and usage, unsuitable power sources, unsuitable environmental conditions, accident, misuse, improper installation, modification, repair, storage or handling, or any other cause not the fault of Seller are not covered by this limited warranty, and shall be at Buyer's expense. Seller shall not be obligated to pay any costs or charges incurred by Buyer or any other party except as may be agreed upon in writing in advance by an authorized Seller representative. All costs of dismantling, re-installation and freight and the time and expenses of Seller's personnel for site travel and diagnosis under this warranty clause shall be borne by Buyer unless accepted in writing by Seller. Goods repaired and parts replaced during the warranty period shall be in warranty for the remainder of the original warranty period or ninety (90) days, whichever is longer. This limited warranty is the only warranty made by Seller and can be amended only in a writing signed by an authorized representative of Seller. Except as otherwise expressly provided in the Agreement, THERE ARE NO REPRESENTATIONS OR WARRANTIES OF ANY KIND, EXPRESSED OR IMPLIED, AS TO MERCHANTABILITY, FITNESS FOR PARTICULAR PURPOSE, OR ANY OTHER MATTER WITH RESPECT TO ANY OF THE GOODS OR SERVICES. not covered by our guarantee.

It is understood that corrosion or erosion of materials is

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Introduction

Table of Contents

1 Introduction .......................................................................... 1

1.1 Theory of operation ........................................................................................................2

1.2 Equipment description ...................................................................................................4

1.2.1

Model 700XA FPD ...............................................................................................6

1.2.2

Model 700XA FPD front entry .............................................................................7

1.2.3

Model 1500XA FPD .............................................................................................8

1.3 Glossary .........................................................................................................................9

2 Setup ................................................................................... 11

2.1 Gas connections .......................................................................................................... 11

2.2 Environmental Considerations ..................................................................................... 11

2.3 Utility gases ................................................................................................................. 11

2.4 Venting ....................................................................................................................... 12

3 Operation and maintenance.................................................. 15

3.1 Operation .................................................................................................................... 15

3.1.1

Igniting the flame manually ............................................................................. 16

3.2 Maintenance ............................................................................................................... 17

3.3 Troubleshooting.......................................................................................................... 18

A Appendix A: Drawings .......................................................... 21

A.1 Enclosure threaded entry details ................................................................................. 21

B Appendix B: Manufacturer’s manuals ..................................... 27

B.1 Flame Photometric Detector Operation Manual ........................................................... 28

B.2 GUB FPD 118500-3411 GUB ........................................................................................ 37

C Appendix C: Spare Parts List .................................................. 79

Figure

1 Introduction

The flame photometric detector (FPD) that you have received is factory-engineered to be used in conjunction with all Rosemount gas chromatographs. The FPD can be used as a solitary detector to measure low levels of sulfur compounds in natural gas or as a secondary detector in conjunction with a thermal conductivity detector (TCD) that allows the GC to analyze the full range of components present in a natural gas sample, including sulfur compounds.

1-1: Flame Photometric Detector (FPD)

Introduction

A. Flame photometric detector (FPD) B. Photomultiplier tube C. Flame cell D. Electrometer board

An FPD (A) typically consists of the following major components:

The flame cell (C) - Located in the lower enclosure, the flame cell has connections for fuel gas, hydrocarbon-free air, sample injection (process gas plus nitrogen carrier), and an exhaust pipe. It is fitted with an RTD to monitor the temperature when running, and an ignitor to light the fuel gas.

The photomultiplier tube (B) - Located in the lower enclosure, the photomultiplier tube contains the sensors that measure the light that is emitted from the flame cell during operation. It has one signal lead and one high voltage wire that take the signal from the detector to the electrometer board and provide the power for ignition. The leads are co-axial type cables.

Introduction

The electrometer board (D) - Located in the upper enclosure, the electrometer board amplifies and processes the signal data from the detector, and sends it to the CPU board on the GC. It also provides the ignition circuit, controls the re-light function, and generates the flame out alarm.

1.1 Theory of operation

NOTICE

See also Section 1.3 of this manual, for definitions of some of the terminology used in the following explanations.

The detection system in the FPD uses the reactions of sulfur components in a hydrogen or air flame as a source for analytical detection. The source of the FPD's signal is derived from the light produced by an excited molecule created in the flame's combustion, which is a photochemical process called chemiluminescence.

A thermocouple is fitted to the flame cell to ensure that the flame is present. If the flame is not detected, the electrometer shuts off the hydrogen to the flame cell. It then supplies a voltage to the igniter, waits five seconds and opens the hydrogen shut off valve. The electrometer will make ten ignition attempts if necessary. If it is not successful, then the hydrogen is shut off, an alarm is triggered on the GC and the unit awaits attention from the operator.

NOTICE

To ignite the flame manually, see Section 3.1.1.

The signal is sent from the PMT to the electrometer to be amplified. The electrometer also provides the PMT with the high voltage it requires to operate the auto re-light circuits.1.3

Introduction

Figure

1-2: Elution of Components

Carrier gas only at the detector

First component begins to elute from the columns and is sensed by the detector.

Peak concentration of first component.

The second component begins to elute from the columns and is sensed by the detector.

Peak concentration of the second component.

Introduction

The signal is then sent to the preamplifier board for further amplification. In addition, the preamplifier converts each voltage signal to a value that is proportional to the concentration of the component detected in the gas sample. The preamplifier provides four different gain channels as well as compensation for baseline drift. The signals are sent to the GC for computation or for viewing on a PC monitor or local operator interface (LOI).

While the GC is in Idle mode, prior to injecting a sample, the detector is exposed to pure carrier gas. In this condition, the output from the detector is electrically nulled. The detector output is set to 1 mV DC. This is measured on the red and black terminals on the preamplifier board, and adjusted using the potentiometer (R38) on the electrometer PCB.

1.2 Equipment description

FPDs are available in the following configurations:

• 700XA FPD

• 700XA FPD Front Entry

• 1500XA FPD

NOTICE

The Front Entry configurations include an additional frame to allow all the FPD enclosures to be mounted on the front of the unit. This allows the unit to be located close to a wall because no rear access is required for installation or maintenance.

All configurations are ATEX-certified. The differences between the configurations are detailed in later sections of this chapter.

Introduction

The FPD used with the Model 500, 700, and 700XA gas chromatographs has the following hazardous area certification markings:

Introduction

Figure

1.2.1

Model 700XA FPD

1-3: Model 700XA FPD

The Model 700XA FPD consists of four explosion-proof enclosures mounted on a frame plus an explosion-proof solenoid valve that acts as a hydrogen shut-off valve.

Introduction

Figure

The enclosures contain the following components:

• Electrometer assembly

• Flame cell and photometric detector tube

• Transformer, either a 230/110 Vac or a 110/110 Vac

• PID temperature controller and relay

• Hydrogen shut-off valve

Place the FPD as close as possible to its partner GC to minimize the length of sample tubing between them, and keep the cycle time as short as possible.

The tubing size required to operate the FPD flame cell is 1/16 in. OD 0.010 in. ID. All tubing enters the flame cell’s enclosure through a specially designed tubing gland. All internal fittings are Swagelok double ferrule compression fittings.

1-4: Specialized Tubing Gland

1.2.2

Model 700XA FPD front entry

The Model 700XA FPD front entry is comprised of the same components as the standard Model 700XA FPD with an additional frame added to allow all the enclosures to be mounted on the front of the unit. This allows the unit to be located close to a wall, because no rear access is required for installation or maintenance.

Introduction

Figure

1.2.3

Model 1500XA FPD

1-5: Model 1500XA FPD

The Model 1500XA FPD consists of four explosion-proof enclosures mounted on a frame plus an explosion-proof solenoid valve that acts as a hydrogen shut-off valve. The enclosures contain the following components:

• Electrometer assembly

• Flame cell and photometric detector tube

• Transformer, either a 230/110 Vac or a 110/110 Vac

• PID temperature controller and relay

• Hydrogen shut-off valve

Introduction

Figure

Place the FPD as close as possible to its partner GC in order to minimize the length of sample tubing between them, and therefore to keep the cycle time as short as possible.

1-6: Specialized Tubing Gland

1.3 Glossary

Auto Zero

Automatic zeroing of the preamplifier. May be entered into the controller to take place at any time during the analysis when either the component is not eluting or the baseline is steady (not normally used).

Chromatogram

A permanent record of the detector output. A chromatograph is obtained from a PC interfaced with the detector output through the GC controller. A typical chromatogram displays all component peaks and gain changes. It may be viewed in color as it is processed on a PC VGA display. Tick marks recorded on the chromatogram by the GC Controller indicate where timed events take place.

Component

Any one of several different gases that may appear in a sample mixture. For example, sample gas usually contains the following components: ethyl mercaptan, t-butyl mercaptan, methyl ethyl sulphide, diethyl sulphide, hydrogen sulphide, and carbonyl sulphide.

Introduction

Response Factor

Correction factor for each component as determined by the calibration. It is defined by the equation:

where

= Area response factor for component n in area per mole percent (%)

ARF

= Height response factor for component n

HRF

= Area associated with component n in calibration gas

Area

= Height associated with component n in mole % in calibration gas

= Amount of component n in mole % in calibration gas

Cal

Retention time

The time in seconds that elapses between the start of analysis ( 0 seconds) and the sensing of the maximum concentration of each component by the analyser detector.

2 Setup

2.1 Gas connections

Use Silcosteel® or equivalent tubing for all calibration gas and process gas connections on all FPDs that are used to measure low range sulfur components. If you use Grade 316 or other stainless steel piping, the sulfur components will adhere to the internal surface of the pipe, and will continue to do so until the entire internal surface of the tubing is coated or conditioned, which will result in lower than expected levels of sulfur components reaching the detector for measurement. Conditioning may take one week or longer, depending on the levels of sulfur components and the length of the tubing.

2.2 Environmental Considerations

FPDs are sensitive to changes in temperature and pressure; therefore, place them in shelters that have stable temperature and pressure. Do not use positive pressurization for shelters.

2.3 Utility gases

FPDs require the following utility gases:

• Hydrogen - 99.995% purity

Setup

• Hydrocarbon-free air

• Nitrogen - 99.995% purity (carrier gas)

• Helium - 99.995% purity (optional second carrier gas)

Setup

Figure

Make all utility and process gas connections with Swagelok fittings. Metric conversion kits are available; contact your Rosemount sales representative for more information.

These are typical values supplied for information only. Actual values are application specific.

2-1: Typical Pressure and Flow Rate Information

2.4 Venting

All Rosemount FPD modules have a vent from the flame cell that exits the GUB enclosure via a proprietary Exd breather/drain/ flame arrestor assembly. The exhaust from the flame cell emits water vapor as a result of burning hydrogen as fuel. This vapor condenses in the exhaust tubing outside the GUB enclosure, and can be seen as drips of water.

1/8-inch double ferrule compression

Vent the FPD exhaust to atmosphere. Do not subject the vent to any back pressure because this will have a detrimental effect on the detector, and may cause the flame to extinguish.

Setup

WARNING

Hydrogen-air mixtures can ignite with very low energy input. For reference, an invisible spark or a static spark from a person can cause ignition. Although the auto- ignition temperature of hydrogen is higher than those for most hydrocarbons, hydrogen's lower ignition energy makes the ignition of hydrogen–air mixtures more likely.

Use a container with the FPD module to collect the condensed water from the FPD vent. Do not pipe the vent away unless you can guarantee a continuous downward slope on the pipe and no back pressure or obstruction by water.

Setup

3 Operation and maintenance

3.1 Operation

The FPD operates as a separate detector. It is controlled by and reports to the GC. The flow rates for the utility gases and the carrier gas are factory set, and are specific to each FPD. These should only be adjusted by fully trained and authorized personnel.

The FPD is identified as Detector #1 on the Detector screen, which is viewable with MON2000, MON2020, and the LOI. When used in conjunction with a TCD, the FPD is Detector #1, and the TCD is Detector #2.

NOTICE

The electrometer switch (A), which has three positions—up for Reset, centered for Normal, and down for Override—should not be left in Override.

Operation and maintenance

A. Electrometer switch

3 - 1

Operation and maintenance

3.1.1

Igniting the flame manually

Connect air to the inlet and slowly bring the inlet pressure to 60 psig.

Connect hydrogen to the inlet and slowly bring the inlet pressure to 60 psig.

Remove tubing from flame cell exhaust and use a digital flow meter to adjust the air control valve until a reading of 160 cc/ min is obtained.

Turn off the air supply.

Set the auto relight switch (S1) on the electrometer PCB to the OVERRIDE position.

Use the digital flow meter to adjust the hydrogen control valve until a reading of 100 cc/min is obtained.

Turn on the air supply.

Set the auto relight switch (S1) on the electrometer PCB to the RUN position. The auto relight sequence starts as follows:

a. The LED on the electrometer comes on after 10 seconds, and the glow plug fitted to the

side of the flame cell is now supplied a voltage.

b. After another 5 seconds, the hydrogen shut off valve operates. c. The gas mixture is ignited. d. If the flame does not light in 5 seconds, the electrometer de-energizes the hydrogen

shut off valve to stop the flow into the flame cell.

e. The flame cell is then purged with air and nitrogen carrier. f. The process starts again—up to 10 times—until the flame stays lit.

g. If the flame does not stay lit, the LED flashes. If the alarm output is linked to the 2350A

controller discreet input, there will be an alarm present on the controller.

h. Set the auto relight switch (S1) on the electrometer PCB to the RESET position and then back

to the RUN position. The re-light sequence is restarted.

If the unit still fails to light after resetting the electrometer, recheck the air and hydrogen flows.

3.2 Maintenance

The FPD is a complex piece of equipment and needs to be regularly maintained, preferably as part of an annual planned maintenance process.

The following important maintenance procedures should be conducted on an annual basis:

• Replace the flame cell and photometric tube O-rings, except for the Kalrez O-ring, which

should be replaced every 24 months.

CAUTION

Be certain that the flame cell has cooled down before touching it, because it often reaches a temperature of 170 °C (338 °F).

Operation and maintenance

• Lubricate the stem of the hydrogen shut-off valve.

For both of these operations, the GC should be shut down, and the appropriate permits and permissions gained before commencing.

Only trained and authorized personnel should carry out maintenance..

NOTICE

The flame out logic should always be tested to ensure it works at the end of any maintenance.

Failure to maintain the FPD may cause a loss of functionality and can result in permanent damage to the equipment.

Operation and maintenance

Fault symptom(s)

Possible solution(s)

When monitoring the baseline

• Check high voltage is present on coax.

Upsets are being seen, but there

• Check the 12 V GND wiring to the electrometer board. The two GND terminals on

3.3 Troubleshooting

Only competent trained personnel should troubleshoot FPDs.

The following list of faults is not definitive. It only details the most common faults.

in MON2020, there are no upsets present when the auto re- light circuit fires.

If no voltage, remove coax connector.

If voltage is present, check signal coax.

are no peaks when gas is injected.

• Approx. -600 Vdc

• If voltage now present on board, check coax cable.

• Check BNC coax connectors are tight.

• If there is no voltage, or the signal cable is OK, replace electrometer.

connector #2 are not linked on board. If there are three black wires, ensure that pins 1 and 4 are connected to the power supply. The other wire is for the flame cell GND.

• Check the tubing going into the bottom of the flame cell. Loosen fitting and pull

tubing downwards while watching CGM.

• If peaks appear, then the tubing needs to be cut.

• Check to see if there is flow from the metering valve next to the heater block.

• Check the sample is getting to the flame cell.

• Try replacing the columns one at a time.

• Check you are getting carrier through port 1 with valve 2 on and through port 5 with

valve 2 off. If not check the vents on the Alcon valve for back pressure.

Operation and maintenance

Fault symptom(s)

Possible solution(s)

Air and H2 flows are set

• Using a digital thermometer connected to the thermocouple wires

Unit give good size sample

There might be soot on the sample tube going to the flame-cell. Pull tube down

Flame cell temperature cannot

Check the flame cell thermistor.

Flame cell temperature is

• Check that the thermistor has not been pushed right through the flame

Unable to balance the bridge.

• Check the BNC connectors for the signal in and the high voltage. Ensure

Restrictor metering valve seems

restricting the output flow

Peaks are very small or appear

• Check nitrogen flow into union at flame cell.

correctly, and the unit fails to stay lit.

peaks; then after a while, the peaks are not present, but the relight still gives good peaks.

be controlled.

erratic.

coming from the bottom of the flame-cell, check that the temperature is 160 °C (320 °F).

• Check flame out thermocouple wires.

• Ensure no insulation is trapped under screw on terminal strip.

• Try pulling the sample tube out when it is attempting to light in case the

tube is affecting the fuel mixture.

• Replace the flame cell and try again.

• Ensure that the signal wires are connected to the correct place;

remember that the white signal wire should be connected to the TC+ of the CON5.

slightly while watching the CGM to see if that cures the fault.

The resistance is approximately 100 KΩ at ambient. Resistance goes down as

temperature goes up.

cell.

• In later models, the flame cell will be blanked at end of holes to ensure

that this cannot happen.

• Check there is enough heat-sink compound fitted around sensors.

that they are tight.

• Cut off the flame and check the response from the detector on a live

CGM.

• Try changing the filter.

to be completely.

to be back to front.

• Apply Snoop

• Change the metering valve.

• This should be no less than 15cc/min.

to the two fittings at the bottom of the metering valve.

Operation and maintenance

Fault symptom(s)

Possible solution(s)

Noisy baseline and/or very big

Check the air supply, which should be no lower than 500psi in the cylinder.

dips on the baseline.

DUK 7233/060/3

FPD Module Bottom Housing Assembly

DUK 7233/061/3

FPD Module Top Housing Assembly

DUK 7204/101/3

Model 700 FPD Module Temperature/Controller Enclosure

DUK 7233/007/3

FPD Module Transformer Housing Assembly

A Appendix A: Drawings

A.1 Enclosure threaded entry details

Appendix A: Drawings

Appendix B: Manufacturer’s manuals

B Appendix B: Manufacturer’s manuals

• Flame Photometric Detector Operation Manual

• PID Controller Manual

Appendix B: Manufacturer’s manuals

B.1 Flame Photometric Detector Operation Manual

23332-K026

Revision B April 25th, 2008

Information disclosed herein may not be reproduced in any form without the express

permission of GC EXPRESS.

Appendix B: Manufacturer’s manuals

IMPORTANT

order to obtain optimum performance from this detector, it is necessary to meet and

maintain the following conditions:

A. The following minimum purity standard for gases and liquids shall be maintained:

Helium - 99.999% (ultra high purity) or Nitrogen - 99.999% (ultra high purity) Hydrogen - 99.999%

(ultra high purity)

Air - 0.1 PPM total Hydrocarbons (ultra zero grade)

B. Stainless steel diaphragm regulators must be used.

C. All gas lines from source to instrument must be clean.

B.1.1 General Description

Introduction

The Flame Photometric Detector, FPD, is a very sensitive and selective detector for the analysis

of sulfur or organophosphorus containing compounds. The detector is very stable and easy to use. As the analyte is burned in a hydrogen and air flame, a characteristic wavelength of light is emitted at 394 nm for sulfur and 526 nm for wavelength may be installed to enhance the selectivity to the sulfur or phosphorus emission. The emitted light is amplified by the photomultiplier tube (PTM) and processed by the signal

processor. 'The response to phosphorus is linear and quadratic to sulfur.

phosphorus. A filter specific to the appropriate

The detector may be operated in either the sulfur mode or phosphorus mode by switching the filter and adjusting the air to hydrogen ratio to optimize response. A shielded flame design of the detector enhances sensitivity by lowering the noise created by the light emitted by the flame.

The detector uses a stainless steel jet, quartz windows, and silicone 0-rings in an all aluminum body.

Appendix B: Manufacturer’s manuals

Specifications

• Maximum operating temperature: 250 °C

•

Shielded stainless steel jet

• Sensitivity: 2 x 10·

• Sensitivity: 1 x 10·

•

Linear range: l 04 for phosphorus

•

Linear range: 103 with optional square root function for sulfur

•

Leak tight design to allow measurement of all flows from detector exhaust

•

Igniter voltage: 1.5V AC at 4 amps

• PMT voltage variable from approximately 650V

g/sec for sulfur

g/sec for phosphorus

Installation of the FPD Optical filter

In order to have the spec

must be in place. The phosphorus filter is a filter of 526 nanometers and the sulfur is a filter of 396 nanometers.

Before changing the filter, the power cable to the photomultiplier tube, PMT, must be

removed. This will prevent irreparable damage which can be caused by the introduction of

room light to the PMT. The two thumb screws securing the PMT to the detector body are

removed and then the PMT is slid off gently. Some resistance is felt due to the O-ring on the detector body which provides a light tight seal.

The filter may be removed and replaced with the appropriate filter. The sulfur filter is a very

dark blue color and the phosphorus filter a fluorescent yellow green. One side of the filter has

a mirror finish. There is not a front or back face to the filter.

The PMT is slid back in place and the two thumb screws secured to the detector body. Reattach the power mid signal cables to the back of the PMT.

ificity for su

lfur or phosphorus

detection

the appropriate optical filter

Figure B-1: Insertion of Capillary Column into the FPD

Appendix B: Manufacturer’s manuals

Operation

CAUTION

When working with the detector, never remove the photomultiplier from the detector with the dynode voltage applied. Exposure to high light levels will cause photocathode fatigue (sensitivity loss for an extended period of time) and may cause permanent damage.

Optimal detector temperature

The FPD may operate up to a temperature of 250 °C. Take care to operate the detector above the final temperature of the column to prevent the condensation of column bleed on the

surface of the optical windows which could result in loss of response.

CAUTION

Do not operate the detector above 250 °C or you may damage the plastic photomultiplier housing.

Optimizing flows and igniting the flame

The optimization of the detector is achieved by adjusting the ratio of hydrogen to air. The

oxygen content of air should be 0.2 - 0.4 of the hydrogen flow, with the optimum ratio being

Appendix B: Manufacturer’s manuals

0.3. The air flow should be 1.5 times the hydrogen flow. When optimizing conditions, the

higher the total gas flows; the higher the background noise.

Example:

Hydrogen flow 100 mL/min

100 mL/min x 1.5 = 150 mL/min air required

Nitrogen is the most common carrier gas used for packed columns. Helium is used for the

carrier gas for capillary column s with nitrogen for the make-up gas.

Once the flows are set and the detector is at a temperature of at least 125 °C, the flame may

be lit.

Selecting the Linear or Square Root Mode of Operation

The FPD electrometer has two modes of operation designated as" linear" and "square root". To

select the mode of operation, use the sq rt / linear switch.

the linear mode, the circuit performs as a basic electrometer giving a 10 volt output for an

input current of one microampere. This 10 volt full scale output is available at the 10 volt

output. A 1 volt output is also available. The linear mode is used when the detector is operated

in the phosphorus mode of operation with the phosphorus filter installed.

Phosphorus is detected as POH.

Appendix B: Manufacturer’s manuals

Sulfur is detected as S2 and the response is proportional to the square of the concentration of the sulfur containing compound. The square root mode is selected from the switch marked sq

rt / linear. In this mode the electrometer output is modified by a special resistor-diode matrix to correct for the non-linear (approximately square law) relationship between the detector output current and sulfur concentration when the detector is operated

When operating in the mode, the electrometer zero control should be set to provide a slightly

positive output from the module with the detector output at baseline.

Figure B-2: Replacement of O-rings and Windows

in the sulfur mode.

Appendix B: Manufacturer’s manuals

Maintenance

CAUTION

Cleaning the Detector

Column bleed may build up in the FPD housing. This stationary phase coating may be rinsed out

of the detector without disassembly. Follow the procedure listed below:

Disconnect the electrical connections from the detector.

Tum off the hydrogen and air supply lines to the

Cool the detector to ambient.

Disconnect the column, hydrogen and air lines from the detector body.

Remove the detector from the GC.

Cap the hydrogen and air inlets with an 1/8" cap nut.

Flush the detector thoroughly with acetone through the column inlet port and exiting

through the exhaust tube.

GC.

Dry the detector with nitrogen thoroughly.

Uncap the gas inlets and reinstall the detector onto the GC.

Replacing the O-rings and Quartz Windows

After using the detector for about twelve months at 250° or more, the O -rings may become

brittle and begin to allow light to leak into the detector resulting in high background noise and

loss of response. The quartz window may need to be replaced as

O-rings in

PIN 116910-KAL REZ. Four are Kalrez and one is Teflon. The locations of these O- rings are shown in separated. ' The cross section view of the detector is shown in

There are two concentric O-rings between the window housing and flame base. A 1-1/4" Kalrez ring fits into a groove in the window housing itself and a 15/16" Teflon ring fits around a bushing between the window and the flame base. A 15/16" Kalrez ring is used between the window at the inner end of the filter housing and the heat radiator section. The following procedure should be used to replace the O -rings and quartz windows:

the O-ring rep

Figure B-2. These O -rings must be replaced any time a joint sea led by one of them is

Disconnect the power cable from the PMT.

Loosen the two thumb screws on the filter housing and remove the PMT.

Remove the filter.

With a Phillips screwdriver, disconnect the heater-igniter wiring bracket from the housing assembly.

lacement kit,

ll. There are a

Figure B-2.

total of

five

5. Pull the filter housing from the recess in the heat radiator, exposing first the window and

O-ring (15/16 in. Kalrez).

6. With a hex (Allen) wrench, remove the four screws holding the radiator and window housing to

the flame base.

Appendix B: Manufacturer’s manuals

Description

Part number

Igniter plug (includes O-ring seal) – 1.5 volt

116906-K001

Quartz window

23608-0019

O-ring kit

116910-KALREZ

7. Remove the heat radiator, window housing, and the window

8. Remove the old O-rings.

9. Place the 15/16 in. Teflon ring around the metal bushing.

10. Insert the 1-1/4-in. ring into the groove in the window housing.

11. With the bushing and its ring between the window and the flame base and grooved side of the

window housing toward the flame base, align the window housing with the threaded holes in the flame base.

12. Replace the heat radiator over the window housing with countersunk holes toward the outside

and aligned with the holes in the window housing and flame base.

13. Replace the Allen head screws and tighten.

14. Place the outer window in the recess in the inner end of the filter housing with the 15/16-in.

Kalrez O-ring between the window and the heat radiator.

15. Replace the filter housing and the wiring bracket.

16. Replace the filter and the PMT.

The 1 -1/4-in. Kalrez end cover O-ring is located between the end cover and the flame base.

Recommended spare parts

The figure below is a cross-section diagram of the FPD with associated part numbers. The parts listed below are used in the normal maintenance of the detector.

2 ea. # 2-27 Kalrez (1.437 O.D. x 0.70 dia cross section)

1 ea. #2-21 Kalrez (1.062 O.D. x 0.70 dia cross section)

1 ea. #c2118-021 PFTE (1.062 O.D. x 0.70 cross section)

1 ea. #568-010 Kalrez O-ring # S70010 ignitor

1 ea. #586-011 Kalrez O-ring #S70011 flame out TC

Appendix B: Manufacturer’s manuals

B.2 GUB FPD

118500-3411 GUB

Appendix B: Manufacturer’s manuals

B.2.1 Full function uP controlled FPD Rev G

FPD Processor Control Functions

Power on Initialization.

Reset State. The uP monitors the RESET/RUN/OVERRIDE Switch (R/R/0 Switch) (SW1), suspending any automatic operation until the R/R/ 0 Switch is set to the RUN position. If the R/R/0 Switch is set to the Override position, the uP continues to be Reset but the fuel valve will be manually activated . The fuel valve will remain activated until the R/R/0 Switch is manually switched to either the Reset or Run position.

Igniter and Flame on State. When the R/R/ 0 Switch is set to the R UN position, the uP attempts to ignite the flame. Tl1e ignition sequence consists of the following steps.

1. Tum the Igniter Drive and LED (D20) on and wait for 5 sec. This allows

the igniter

to reach a temperature that will cause ignition.

2. Open the fuel valve and wait for 15 sec.

3. Tum the Igniter Drive and LED off.

4. Check for Flame On by monitoring the thermocouple temperature sensor input at connector CON5.

no flame is detected, fuel valve will be closed and the uP will delay for

another 30 sec. before any attempt to retry the ignition sequence.

6. lf a flame is detected, the uP will continue monitoring the thermocouple

temperature sensor input for a flame on indication, maintaining the fuel valve on and the LED indicator off.

the uP does not detect a flame within 10 tries of the Ignition Sequence, it will set the

igniter and fuel

lenoid off and indicate a error condition by flashing the LED indicator

(D20) at a steady 2Hz. An external error control signal

(External Alarm

), which can be used to drive a remote indicator (LED, Buzzer, Etc.), will be activated at connector CON3.l. The uP will suspend any other operation until the R/ R/0 switch has been cycled off and back on or the power has been cycled off and back on.

The uP will enter the Ignition Sequence and will attempt ignition:

a. On power up if the R/R/0 Switch is set to RUN.

b. Anytime the R/ R/0 Switch is cycled from RESET or OVER RIDE to RUN.

nominal operation , whenever the flame has been on and has gone out.

If the flame cannot be started within 10 tries of the Ignition Sequence , the uP will not try

to re-ignite until the R/R/0 Switch has been manually cycled off and back on or the power has been turned off and back on.

Any time the R/R/0 Switch is cycled from RUN to RESET, the uP will stop fuel flow by turning

the fuel solenoid off. No attempt will be made to restart the flame until the R/ R/0 Switch is returned to the RUN position.

Warning: The R/R/0 Switch is a three-position switch, and once switched to the OVERRIDE

position there is no automatic termination of the fuel valve activation. This feature

R/R0/ S

set.up of the fuel flow only. To deactivate the fuel valve, the s

witched back to

outline of uP functions.

the RUN or RESET positions.

Refer to FPO Firmware Flowchart for detailed

witch must be manually

used for

Current source setting (AMPS)

Recorder reading at direct output

-1 x 10

-10

1.0 MV +-2%

-1 x 10-9

10.0 MV +-2%

-1 x 10-8

0.100 V +-2%

-1 x 10-7

1.0 V +-2%

-1 x 10-6

V +-2%

Appendix B: Manufacturer’s manuals

FPD Electrometer Power Supply:

Use caution. AC Voltage (120 Volts AC) is present and DC Voltage in excess of 600 Volts is generated on the PCB when power is applied.

A. Extemal Power, AC Volts:

120 Volts AC routed thru CON4 is switched by the

Solid State Relay U7 (S101DH2). The Gas Valve/Solenoid is controlled by this

switched AC Voltage signal.

B. External Power, DC Volts:

12 Volt DC to low voltage power connector CON2.

CON2, Pins I & 2, power the low current section of the PCB. CON2, Pins 3 & 4, power

high current circuits (HV Regulator, Igniter, fuel solenoid, etc.).

C. On board low voltage:

1. An on board DC to DC Converter (U6) generates +/- 15 Volts

2. A LM4040 Voltage Regulator (U5) generates +5 Volts

D. On board high voltage:

On board high voltage converter generates approximately 650 Volt DC (J4)

FPD Linear Mode Test

Set the Linear / Sq. Root Switch (SW3) to Linear Mode

B. During the following test steps, monitor U3.6 output line with an oscilloscope to

check for oscillation or other signs of faulty operation.

With Signal In input connector (J3) open, recorder span set to 1 mV. full scale and the Zero Switch (SW4) set to OFF, adjust R57 for best output null.

D. With Signal In input connector (J3) open, set the Zero Switch (SW4) ON. Adjust

(

the manual zero pot

R38, can be located on the PCB or mounted on the front

panel) completely CW and check for an output of +0.055V to +0.075V. Adjust

the zero pot completely CCW and check for a smoothly changing voltage

output to - l. l 5V to -

1. 55V. Return the Zero voltage control to approx. 0 volts

output.

Connect a current source to the Signal In input connector (J3). With a Voltmeter

or recorder, monitor the output at the l OV output pin (CON I. 4). Change

recorder span as necessary to check output range and linearity per following

table.

Appendix B: Manufacturer’s manuals

Current source

Direct output (10

-0.00 x 10

-11

-0.5 ¸ “Zero” < +0.5

R62 = 191K

R62 = 90.9K

-2.00 x 10

“Zero reading”

+.167 + .1

+.335 +-.1

-6.00 x 10

-11

“Zero reading”

+.470 + -.15

_.945+-1.5

-1.60 x 10

“Zero reading”

+1.16 +-.2

+2.34+-.2

-6.40 x 10

-10

“Zero reading”

+3.34 + -.3

+6.71+-.3

-2.50 x 10-9

“Zero reading”

+7.62 +-.6

+15.3 +-.6

-1.00 x 10-8

“Zero reading”

+15.68 +-.9

+31.5+-.9

-4.00 x 10-8

“Zero reading”

+31.56 +-.1

+63.4 +-.1

-1.60 x 10-7

“Zero reading”

+64.7 +-3.0

+130 +-3.0

-6.40 x 10-7

“Zero reading”

+129 +-5.0

+260 +5.0

-2.56 x 10-6

“Zero reading”

+319 +-12

+641 +-12

4. FPD Square Root Mode Test

A. Set the Linear / Sq. Root Switch (SW3) to Square Root Mode

B. Set diode oven temperature adjustment pot (R59) near the center of its range of

adjustment. Monitor U3.6 with oscilloscope for oscillation or other signs of faulty

circuit operation.

C. Connect a variable span recorder or DVM (10 megoluns input impedance

minimum) to the lOV output (CONl. 4), and a current source to the input

connector (J3). Set the ZERO SW to ON.

D. Check electrometer and recorder zeros and carefully rese t if necessary. Refer to

Section 3, FPD Linear Mode Test,

E. Set the ZERO SW to ON, the input current to -4.0 X 10·8 amps and adjust the diode

oven temperature by means ofR59 so that when temperature stabilizes the

recorder or DVM reads 31.56 mV as closely as possible.

F. Reset input current to zero and note recorder/DVM reading. Return input current

to-4.0 X 1·0

and trim diode oven temperature if necessary so that the difference

in recorder/DVMreadings for input currents of zero and -4.0 X 10·

31.56mV, plus or minus O. l mv.

G. Check response curve per following table. (lf zero reading falls outside permitted

limits, readjust the offset pot (R57) and repeat previous step.

for zero set procedure.

amps is

setting (AMPS)

-11

-10

Noise and Drift Test

A. Conduct test with all shields and covers in place and electrometer operating in the

VFS) reading (mV)

"square root" mode. (SW3 set to square root) Connect lOMV F.S. recorder to the

Direct Output (CONl.4) with the chart speed set to approx. 0.25 cm/min.

Disconnect input cable, tum the Zero Switch (SW4) ON and set the zero control pot

(R38) so that trace is near center of plot.

B. Record data for at least 30 minutes in a stable ambient temperature.

C. Acceptance specifications are as follows:

Max. Peak-to-peak noise - 2% of full scale.

Appendix B: Manufacturer’s manuals

Occasional unexplained spikes - no more than one per half hour and not to

exceed 5% full-scale peak height.

Max. Drift - 1.5% full scale during half hour nm.

FPD Thermocouple Temperature Setup.

The thermocouple input at CONS Pin1 and Pin2 will be factory adjusted to operate

Detector temperatures that range from approximately 150 Degrees C to 200 Degrees

with C.

Appendix B: Manufacturer’s manuals

02122 0020

Hydrogen shut-off valve (Alcon)

02122 0023

O-ring kit for Alcon valve

02122 0044

Hydrogen shut-off valve (Asco)

02122 0057

O-ring kit for Asco valve

4-5000-391

Utility gas regulator (H2 or air)

59551 2097

Heater (flame cell and exhaust breather)

116901-GUB

Photometric tube

115000-0008

Power supply for electrometer board

115003-0001

Electrometer board

116910-KALREZ

O-ring kit for flame cell and detector

116906-0001

Ignitor with Kalrez O-ring

23608-0019

Heat filter

23608-0027

Optical filter

C Appendix C: Spare Parts List

Appendix C: Spare Parts List

NOTICE

For price & delivery information please contact your local Emerson Sales office, or email

gc.csc@emerson.com.

NOTICE

For spare parts for Model 500 or Model 700 Gas Chromatographs, please refer to the appropriate GC manual.

FPD for Gas Chromatographs

7R00370-H01

North America Regional Office

Solutions 10241 West Little York,

Suite 2200

Houston, TX 77040 USA

Latin America Regional Office

Solutions 1300 Concord Terrace,

Suite 400 Sunrise, FL 33323, USA

Europe Regional Office

Emerson Automation Solutions Europe GmbH

Neuhofstrasse 19a P.O. Box 1046 CH 6340 Baar Switzerland

Asia Pacific Regional Office

Emerson Automation Solutions Asia Pacific Pte LTD

1 Pandan Crescent Singapore 128461

Middle East and Africa Regional Office

Emerson Automation Solutions Emerson FZE P.O. Box

17033 Jebel Ali Free Zone - South 2

Emerson Automation

+1 866 422 3683 or +1 713 396 8880 +1 713 468 8175

GC.CSC@Emerson.com

Emerson Automation

+1 954 846 5030 +1 952846 5121

GC.CSC@Emerson.com

+1 954 846 5030 +1 952846 5121

GC.CSC@Emerson.com

+65 6777 8211 +65 6777 0947

GC.CSC@Emerson.com

+971 4 8118100 +971 4 88665465

GC.CSC@Emerson.com

Manual

January 2018

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Rosemount Flame Photometric Detector For GC Hardware Reference Manual (contains information for the newer 700XA and 1500XA Gas Chromatographs) Manuals & Guides

Specifications and Main Features

Frequently Asked Questions

User Manual

NOTICE

WARRANTY

1 Introduction

1.1 Theory of operation

NOTICE

NOTICE

1.2 Equipment description

NOTICE

Model 700XA FPD

Model 700XA FPD front entry

Model 1500XA FPD

1.3 Glossary

2 Setup

2.1 Gas connections

2.2 Environmental Considerations

2.3 Utility gases

2.4 Venting

WARNING

3 Operation and maintenance

3.1 Operation

NOTICE

Igniting the flame manually

3.2 Maintenance

CAUTION

NOTICE

3.3 Troubleshooting

A Appendix A: Drawings

A.1 Enclosure threaded entry details

B Appendix B: Manufacturer’s manuals

B.1 Flame Photometric Detector Operation Manual

B.1.1 General Description

Introduction

Specifications

Installation of the FPD Optical filter

Operation

CAUTION

Optimal detector temperature

CAUTION

Optimizing flows and igniting the flame

Maintenance

CAUTION

Cleaning the Detector

Replacing the O-rings and Quartz Windows

Recommended spare parts

B.2.1 Full function uP controlled FPD Rev G

C Appendix C: Spare Parts List

NOTICE

NOTICE

Europe Regional Office

Emerson Automation Solutions Europe GmbH

Asia Pacific Regional Office

Emerson Automation Solutions Asia Pacific Pte LTD

Middle East and Africa Regional Office