INSTRUCTION, OPERATING, AND MAINTENANCE …

1 Total Hydrocarbon Analyzer Teledyne Analytical Instruments i INSTRUCTION, operating , AND MAINTENANCE manual FOR MODEL 4020 Standard Software Version DANGER Toxic and/or flammable gases or liquids may be present in this monitoring system. Personal protective equipment may be required when servicing this instrument. Hazardous voltages exist on certain components internally which may persist for a time even after the power is turned off and disconnected. Only authorized personnel should conduct MAINTENANCE and/or servicing. Before conducting any MAINTENANCE or servicing, consult with authorized supervisor/manager. P/N M74661 4/24/15 Model 4020 Teledyne Analytical Instruments ii Copyright 2015 Teledyne Analytical Instruments All Rights Reserved. No part of this manual may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any other language or computer language in whole or in part, in any form or by any means, whether it be electronic, mechanical, magnetic, optical, manual , or otherwise, without the prior written consent of Teledyne Analytical Instruments, 16830 Chestnut Street, City of Industry, CA 91748.

2 Warranty This equipment is sold subject to the mutual agreement that it is warranted by us free from defects of material and of construction, and that our liability shall be limited to replacing or repairing at our factory (without charge, except for transportation), or at customer plant at our option, any material or construction in which defects become apparent within one year from the date of shipment, except in cases where quotations or acknowledgements provide for a shorter period. Components manufactured by others bear the warranty of their manufacturer. This warranty does not cover defects caused by wear, accident, misuse, neglect or repairs other than those performed by Teledyne or an authorized service center. We assume no liability for direct or indirect damages of any kind and the purchaser by the acceptance of the equipment will assume all liability for any damage which may result from its use or misuse. We reserve the right to employ any suitable material in the manufacture of our apparatus, and to make any alterations in the dimensions, shape or weight of any parts, in so far as such alterations do not adversely affect our warranty.

3 Important Notice This instrument provides measurement readings to its user, and serves as a tool by which valuable data can be gathered. The information provided by the instrument may assist the user in eliminating potential hazards caused by his process; however, it is essential that all personnel involved in the use of the instrument or its interface be properly trained in the process being measured, as well as all instrumentation related to it. The safety of personnel is ultimately the responsibility of those who control process conditions. While this instrument may be able to provide early warning of imminent danger, it has no control over process conditions, and it can be misused. In particular, any alarm or control systems installed must be tested and understood, both as to how they operate and as to how they can be defeated. Any safeguards required such as locks, labels, or redundancy, must be provided by the user or specifically requested of Teledyne at the time the order is placed.

4 Therefore, the purchaser must be aware of the hazardous process conditions. The purchaser is responsible for the training of personnel, for providing hazard warning methods and instrumentation per the appropriate standards, and for ensuring that hazard warning devices and instrumentation are maintained and operated properly. Teledyne Analytical Instruments, the manufacturer of this instrument, cannot accept responsibility for conditions beyond its knowledge and control. No statement expressed or implied by this document or any information disseminated by the manufacturer or its agents, is to be construed as a warranty of adequate safety control under the user s process conditions. Total Hydrocarbon Analyzer Teledyne Analytical Instruments iii Specific Model Information The instrument for which this manual was supplied may incorporate one or more options not supplied in the standard instrument. Commonly available options are listed below, with check boxes.

5 Any that are incorporated in the instrument for which this manual is supplied are indicated by a check mark in the box. Instrument Serial Number: _____ Options Included in the Instrument with the Above Serial Number: Power Requirements: This instrument may be designed for operation using a power source other than 115 VAC @ 60 Hz. If so, one of the boxes below will be checked indicating the power requirements for your instrument. 110 VAC @ 50 Hz 115 VAC @ 50 Hz 220 VAC @ 50/60 Hz Other: _____ Using Hydrogen as Sample: For applications where the sample gas is hydrogen, the sample gas doubles as the fuel for combustion. The gas connections made at the back panel are slightly different for this configuration. Connect the hydrogen sample gas to the sample input as usual. Connect a nitrogen source at 40 psig to the fuel input. This is discussed in the manual in the Installation section. Using Hydrogen as Fuel: For applications where the fuel is hydrogen, the gas connections made at the back panel are Model 4020 Teledyne Analytical Instruments iv slightly different.

6 At the FUEL inlet, replace the 40% H2/60% N2 with pure H2. This is discussed in the Installation section. Special Analysis Ranges: this model 4020 has special analysis ranges: Range 1: _____ Range 2: _____ Range 3: _____ Auto-Calibration Module Option: This module consists of solenoid for automatically selecting calibration or sample flow to the analyzer and provides the user with the ability to calibrate the analyzer on a user-programmed schedule. AP Options: Vented Sample System Covers; Perforated covers have been installed over the sample system compartment and analyzer top cover for venting purposes. Recommended warm-up period: hours Other: Total Hydrocarbon Analyzer Teledyne Analytical Instruments v Safety Messages Your safety and the safety of others is very important. We have provided many important safety messages in this manual . Please read these messages carefully. A safety message alerts you to potential hazards that could hurt you or others.

7 Each safety message is associated with a safety alert symbol. These symbols are found in the manual and inside the instrument. The definition of these symbols is described below: GENERAL WARNING/CAUTION: Refer to the instructions for details on the specific danger. These cautions warn of specific procedures which if not followed could cause bodily Injury and/or damage the instrument. CAUTION: HOT SURFACE WARNING: This warning is specific to heated components within the instrument. Failure to heed the warning could result in serious burns to skin and underlying tissue. WARNING: ELECTRICAL SHOCK HAZARD: Dangerous voltages appear within this instrument. This warning is specific to an electrical hazard existing at or nearby the component or procedure under discussion. Failure to heed this warning could result in injury and/or death from electrocution. Technician Symbol: All operations marked with this symbol are to be performed by qualified MAINTENANCE personnel only.

8 NOTE: Additional information and comments regarding a specific component or procedure are highlighted in the form of a note. STAND-BY: This symbol indicates that the instrument is on Stand-by but circuits are active. No Symbol Model 4020 Teledyne Analytical Instruments vi CAUTION: THE ANALYZER SHOULD ONLY BE USED FOR THE PURPOSE AND IN THE MANNER DESCRIBED IN THIS manual . IF YOU USE THE ANALYZER IN A MANNER OTHER THAN THAT FOR WHICH IT WAS INTENDED, UNPREDICTABLE BEHAVIOR COULD RESULT POSSIBLY ACCOMPANIED WITH HAZARDOUS CONSEQUENCES. This manual provides information designed to guide you through the installation, calibration and operation of your new analyzer. Please read this manual and keep it available. Occasionally, some instruments are customized for a particular application or features and/or options added per customer requests. Please check the front of this manual for any additional information in the form of an Addendum which discusses specific information, procedures, cautions and warnings that may be specific to your instrument.

9 Manuals do get misplaced. Additional manuals can be obtained from Teledyne at the address given in the Appendix. Some of our manuals are available in electronic form via the internet. Please visit our website at: Total Hydrocarbon Analyzer Teledyne Analytical Instruments vii Table of Contents Safety Messages .. v List of Figures .. xi List of Tables .. xii Additional Safety Information .. xiii Procedure for Removal of Internal Inaccessible Shock Hazards xv Introduction .. 1 Main Features of the Analyzer 1 Principle of Operation 2 Analyzer Description 2 Applications 3 Operational Theory .. 7 Introduction 7 Sample System 7 Input Porting 8 Sample Flow Control System 8 Fuel and Blanket Air Systems 8 Flame Ionization Detection Cell 9 Detection Cell 9 Electrometer-Amplifier 10 Anode Power Supply 11 Flame Guard Circuit 11 Flame Ignition Circuit 11 Proportional Temperature Control Circuit 11 Installation .. 13 Unpacking the Analyzer 13 Model 4020 Teledyne Analytical Instruments viii Mounting the Analyzer 13 User Connections 14 Electrical Power Connections 14 Gas Connections 14 Vent Connections 16 Electrical Connections 16 Primary Input Power 17 Fuse Installation 17 50-Pin Equipment Interface Connector 17 Analog Output 18 Alarm Relays 20 Digital Remote Cal Inputs 21 Range ID Relays 23 Network I/O 23 Pin Out Table 23 RS-232 Port 25 Supporting Gases 26 Sample Gas 27 Effluent 27 Sample Bypass Vent 27 Fuel and Air Connections 27 Operation.

10 29 Equipment 29 Preliminary Power-Off Check List 30 Placing the System in Operation 30 Activating the Support Gases 31 Air 31 Sample Gas 31 Span Gas 31 Fuel 31 Total Hydrocarbon Analyzer Teledyne Analytical Instruments ix Flame Ignition 32 Verification of the Flame Guard Circuit 32 Ignition and/or Flame Guard Circuit Failure 33 Analyzer Operation 33 Default Parameters 34 Style Conventions 34 Using the Controls 35 Mode/Function Selection 35 Analysis Mode 36 Setup Mode 37 Data Entry 38 ENTER 38 ESCAPE 38 Setting up an AUTO-CAL 40 Password Protection 42 Entering the Password 43 Installing or Changing the Password 44 Logging Out 45 System Self-Diagnostic Test 45 The Model Screen 46 Calibration Options 47 Zero and Span Functions 48 The Alarms Function 52 The Range Function 55 manual (Select/Define Range) Screen 56 Auto Range 57 Digital Mode 58 Digital Filter Setup 59 Fuel Display 60 Valve Selections 60 Model 4020 Teledyne Analytical Instruments x Disabled 61 User Select 62 Default (By Function) 63 Observing the gas Stream Concentrations 64 Standby 65 Advanced User Functions 66 Zero Offset Adjustment 66 Background Gas Selection 67 MAINTENANCE & Troubleshooting.