Ametek 682T-HP User manual

Model 682T-HP
Sulfur Analyzer
ATEX Zone 2 (pzc)
User Manual
9000-223-VE REV C

682T-HP Sulfur Analyzer
For ATEX Zone 2 Locations
USER MANUAL
June 2019
© 2019, by AMETEK, Inc.
150 Freeport Road, Pittsburgh PA 15238
Ph. 412-828-9040, Fax [phone]
www.ametekpi.com
R
PROCESS INSTRUMENTS

TableofContents
1INTRODUCTION 1
1.1How To Use This Manual .......................................................................................1
1.1.1Organization ..............................................................................................1
1.1.2Text Conventions........................................................................................1
1.1.3Software Conventions.................................................................................1
1.2Safety ....................................................................................................................2
1.2.1Enclosure Protection System ......................................................................2
1.2.2Radiation Protection...................................................................................2
1.2.3Possible Hazards ........................................................................................3
1.2.4Specific Conditions for Safe Use .................................................................3
1.3Theory of Operation ............................................................................................... 3
1.4Overview................................................................................................................5
1.4.1XRT/XRA Analyzer .....................................................................................7
1.4.2Controller...................................................................................................8
1.4.3Densitometer (Optional) .............................................................................9
1.5Notice of Operation ................................................................................................9
2INSTALLATION 10
2.1Site Selection.......................................................................................................10
2.3Utility Requirements............................................................................................ 11
2.3.1Gas Supply Specifications ........................................................................11
2.3.2Electrical..................................................................................................11
2.3.3Signal Connections ..................................................................................13
2.3.4Process Connections ................................................................................ 14
2.4 Purge Startup Procedure......................................................................................... 15
3OPERATION 16
3.1Quick Start..........................................................................................................16
3.1.1Run Conditions ........................................................................................17
3.1.2Screen Navigation ....................................................................................17
3.2Normal Start........................................................................................................19
3.3Normal Shut Down ..............................................................................................19
3.4Emergency Shut Down ........................................................................................20
3.5Cold Start ............................................................................................................20
3.5.1Password Screen ......................................................................................21
3.5.2Calibration Selection ................................................................................23
3.5.3Calibration Method Verification ................................................................ 24
3.5.4Calibration Method Lock ..........................................................................24
3.6Modifications to Main Screen...............................................................................25
3.6.1Product ID................................................................................................25

3.6.2Density Units ........................................................................................... 26
3.6.3Zoom Screen ............................................................................................27
3.7Trend 27
3.8Verification Utility................................................................................................28
3.9X-ray Warning Light ............................................................................................31
4CALIBRATION 32
4.1Calibration Sets................................................................................................... 32
4.2Sample Presentation............................................................................................ 33
4.3CAPTURE Procedure – Using Pushbutton Control................................................34
4.3.1Modifying Sample Data ............................................................................36
4.3.2Changing the Calibration Method............................................................. 38
4.3.3Saving the Calibration ..............................................................................38
4.3.4Initializing CalSet Records........................................................................38
4.4CAPTURE Procedure – Using Sample Table Control .............................................38
4.5Calibration Fit .....................................................................................................40
4.5.1Exponent method..................................................................................... 41
4.5.2Alpha method...........................................................................................42
4.5.3Hyperbolic method ...................................................................................43

4.6Calibration Errors................................................................................................44
4.7Precision..............................................................................................................44
4.8Counting Statistics ..............................................................................................45
5HARDWARE DETAILS 47
5.1Power Supplies ....................................................................................................47
5.2Type Z Purge .......................................................................................................47
5.3Terminal Blocks...................................................................................................48
5.4Leak Sensor……………………………………………………………. ............................... 49
5.5Inputs & Outputs ................................................................................................50
5.6AC Line Filter ......................................................................................................51
5.7Head Mounting Plate ........................................................................................... 51
5.8XRT/XRA Head and Detector...............................................................................51
5.9Fan......................................................................................................................52
5.10Sample Aperture Window .................................................................................... 52
5.11Flow Cell ............................................................................................................. 52
5.12Flow Cell Window ................................................................................................ 53
5.13Densitometer (Optional).......................................................................................53
5.14Heater (Optional) .................................................................................................54
5.15Touch Panel.........................................................................................................54
5.16PLC .....................................................................................................................56
5.16.1PLC Specifications....................................................................................56
5.16.2Battery Replacement ................................................................................56

5.17Manual Valves ..................................................................................................... 57
5.18Intrinsically Safe Switching Amplifiers ................................................................. 58
6UTILITY SCREEN 70
6.1Valve Setup .........................................................................................................70
6.2Remote Count Time and Acquisition Delay .......................................................... 71
6.3X-Ray Enable.......................................................................................................72
6.4Password Maintenance ........................................................................................73
6.5LogOut ................................................................................................................74
6.6Configure Warning...............................................................................................74
6.7Set PLC Clock......................................................................................................75
6.8Setup 4-20mA Outputs .......................................................................................76
6.9Setup Bounds......................................................................................................77
6.10Density Update....................................................................................................78
6.11Pause ..................................................................................................................78
6.12Count Time..........................................................................................................78
6.13User Corrections..................................................................................................79
6.14Density Corrections ............................................................................................. 80
6.15Port Setup ...........................................................................................................80
6.16Transfer Data ...................................................................................................... 81
6.17Temperatures ...................................................................................................... 83
7ALARMS & I/O CONFIGURATION 85
7.1General Alarm, Error Messages ...........................................................................85
7.1.1Leak in Cabinet ........................................................................................ 86
7.1.2Exceeding Maximum Temperature ...........................................................86
7.1.3No X-rays/No Counts ...............................................................................86
7.1.4Purge Alarm ............................................................................................. 87
7.1.5Low Density (Warning) .............................................................................87
7.1.6I/O Error.................................................................................................. 87
7.2Inputs and Outputs.............................................................................................87
7.2.1Analog Outputs ........................................................................................ 87
7.2.2Digital Outputs ........................................................................................88
7.2.3Digital Inputs ...........................................................................................88
8SPECIFICATIONS & CERTIFICATION 90
8.1Specifications ......................................................................................................90
9 ADDITIONAL FEATURES………………………………………………………………………….92
9.1MODBUS Output and Control Option.................................................................. 91
9.1.1MODBUS Protocol ....................................................................................91

9.1.2Modbus Initialization................................................................................93
9.1.3Modbus Error Codes ................................................................................94
9.2Serial Output Option ...........................................................................................94
9.3Remote Method ...................................................................................................95
10MAINTENANCE & TROUBLESHOOTING 96
10.1Routine Service.................................................................................................... 96
10.1.1Removing the XRT Head ........................................................................... 96
10.1.2Sample Aperture Window Replacement ....................................................96
10.1.3Flow Cell Window Assembly .....................................................................98
10.1.4Replacing Parts ........................................................................................99
10.2Controller Update ................................................................................................99
10.2.1Updating the PLC Software....................................................................... 99
10.2.2Updating the TP-177B Software .............................................................100
WARRANTY A
APPENDIX B: RADIATION SAFETY B
B.1Your Obligations....................................................................................................b
B.2 Emergency Procedures ..........................................................................................b
B.3Safe Operation.......................................................................................................b
B.4Radiation Levels .................................................................................................... c
B.5Regulatory Obligations .......................................................................................... e
B.6Disposal ................................................................................................................ e
B.7Regulations In Other Countries ............................................................................. e


Chapter 1: Introduction, Page 1
Model 682T-HP USER MANUAL ATEX Zone 2
1 INTRODUCTION
This manual provides information on the installation, operation, calibration, and maintenance of the
AMETEK ASOMA 682T-HP Series On-Line Analyzer.
Please read the entire manual before operating. AMETEK recommends that each on-line analyzer have a record book. If
company policy allows, please start a loose leaf or other notebook where records of the instrument operation can be
recorded. This will become valuable as a reference for future changes and/or repairs.
1.1 How To Use This Manual
1.1.1 Organization
All sections and sub-sections are numbered in sequence. For example 2.3.4 is Section 2, sub-section
3.4. These numbers will be referred to when another section has more information.
Section 1 — Introduction — Describes the format of this manual, some safety precautions, theory of
operation, and some of its general features.
Section 2 — Installation — Describes requirements for receiving and installing the analyzer.
Section 3 — Operation — Describes how to use the analyzer including a quick start and condensed
operating procedures.
Section 4 — Calibration and Performance Testing — Describes how to calibrate and verify
performance of the analyzer.
Section 5 — Hardware Description — Describes the major hardware components of the analyzer.
Section 6 — Utilities — Describes how to use standard software features of the analyzer.
Section 7 — Alarms & I/O Configuration — Describes the available alarms and explains how to
configure the I/O.
Section 8 — Specifications & Certification — Includes schematics and certificates pertaining to the
analyzer.
Section 9 — Additional Features — Includes options that may be provided with the analyzer.
Section 10 — Maintenance & Troubleshooting — Describes how to maintain or make simple repairs
to the analyzer.
Appendix A— Warranty.
Appendix B— Radiation Safety
1.1.2 Text Conventions
Instructions for using the touch screen (to enter commands or start routines) will give the names of the
touch buttons to press in uppercase HELVETICA (a.k.a. BOOKMAN) typeface. The information in the
analyzer’s display will be in uppercase COURIER typeface. If an instruction uses the word, “press” —
touch the button(s) listed or the check box from which you choose. If an instruction uses the word,
“enter” — press the required button(s) and then press the ENTER button to activate the choice.
Acronyms will be written in UPPERCASE and described when they are first used in the text. For
example: RAM is Random Access Memory.
1.1.3 Software Conventions
The analyzer has several functions or routines that you can select with multiple display screens. These
routines control output, configure the instrument for analysis, collect and process data, develop
calibrations, and more. Some screens can only be accessed after the correct password is entered.

Chapter 1: Introduction, Page 2
Model 682T-HP USER MANUAL ATEX Zone 2
MAIN SCREEN
The MAIN SCREEN is displayed whenever the analyzer is waiting for
instructions. The analyzer will not be ready to start analysis until the densitometer
indicates product is present in the sample cell and the X-ray tube is below the
maximum temperature. Some critical alarms (leak, system failure, etc…) will
prevent the analyzer from starting until the alarms are cleared.
1.2 Safety
The AMETEK ASOMA 682T-HP Series is constructed with the best safety considerations in mind. Although
this analyzer is designed to operate in hazardous environments, the integrity of the purge must not be
compromised.
1.2.1 Enclosure Protection System
An Enclosure Protection System (EPS), also known as the Cabinet Purge, is included with the analyzer
to allow the system to be operated in a hazardous environment. This system relies on an initial rapid
cabinet purge and then maintains a slight overpressure (compressed instrument quality air) to prevent
accumulation of flammable gases within the protected enclosure.
Details for starting the EPS are included in Section 2.4 Purge Setup Procedure.
1.2.2 Radiation Protection
This analyzer produces X-rays when the X-ray tube is energized. Under normal operating conditions,
the Model 682T-HP presents no significant radiation hazard since the operator is well shielded from
the X-ray tube at all times. Without shielding, however, a significant radiation hazard may be present.
Do not disable the X-ray safety interlocks.
Do not remove the X-ray head from the flow cell when the X-ray light is on.
Please refer to Appendix B: Radiation Safety at the end of this manual for more details.

Chapter 1: Introduction, Page 3
Model 682T-HP USER MANUAL ATEX Zone 2
1.2.3 Possible Hazards
The electronics enclosure contains high voltage. If the electronics enclosure is opened while the EPS is
bypassed, there may be up to 240VAC present at each power supply and some connecting terminal
blocks.
The flow cell may contain process fluid at high temperature and pressure. Care must be taken when
opening the manual vent and drain valves to avoid spilling process fluid where it is not intended.
If the analyzer is not used in the manner described in this manual, the protection provided by the
analyzer construction may be impaired.
1.2.4 Specific Conditions for Safe Use
1. The pressure of the sample system lines inside the Ex pz enclosure shall be externally limited to a
maximum pressure of 35 bar and the flow rate limited to 208 liters/minute.
2. Oxygen content of the process fluid shall not exceed 2% (V/V) and the Upper Explosive Limit
shall not exceed 80%.
3. The equipment shall be installed so the risk of mechanical impact on the display is low. To avoid
electrostatic charge, wipe the main and purge controller displays with a damp cloth only.
4. Before installing this unit in a Zone 2 area, the button cell in the battery board of the PLC must be
removed and taken from the hazardous area. This cell is only for memory retention during
extended storage and transport periods. Do not reinstall the cell unless the unit is in a non-
hazardous area.
1.3 Theory of Operation
The AMETEK ASOMA 682T-HP Series is designed for continuous monitoring of total sulfur in liquid process
streams.
X-ray Transmission (XRT) or Absorption (XRA) measures the change in X-ray intensity as the X-rays pass
through your product. The higher the concentration of sulfur, for example, the fewer X-rays pass through the
sample. The X-ray energy has been optimized so that the sulfur has an absorption coefficient much greater than
that of any other light element present in the product.

Chapter 1: Introduction, Page 4
Model 682T-HP USER MANUAL ATEX Zone 2
Measurement takes place through the flow cell. The flow cell section of the pipe is a two-inch diameter
stainless steel tube with proprietary “windows” specially coated to eliminate erosion. These windows,
positioned opposite each other and aligned with the source and detector, are highly transmissive to X-rays and
able to withstand high pressure and temperature.
A fully integrated densitometer automatically corrects the detected X-ray transmission for any changes in the
density of the product.

Chapter 1: Introduction, Page 5
Model 682T-HP USER MANUAL ATEX Zone 2
1.4 Overview
The AMETEK ASOMA 682T-HP is designed for analysis of sulfur in highly viscous hydrocarbons. This
system is ideal for processes where sample pressures are high and in situations where fouling of flowcell
windows with paraffin or similar substances can occur.
The 682T-HP provides continuous, reliable detection of sulfur at pressures up to 35 bar (508 psig). It can
operate either as a stand-alone analyzer or can be tied in to plant-wide automation systems to provide real-time
strategic measurements.
Among the key features of the analyzer are a fully integrated Densitometer (optional), automatic density
compensation, touch-screen controls, password-protected screens, and rapid update rates as frequent as once
per second.
Operation of the analyzer is regulated by an integral PLC. The PLC monitors instrument parameters such as
process temperature, density, and system diagnostics. It also provides a comprehensive suite of alarms and a
standard platform for communicating to a plant-wide DCS. Due to its unique design and robust construction,
the system has minimal, if any, sample conditioning and recovery requirements.
`

Chapter 1: Introduction, Page 6
Model 682T-HP USER MANUAL ATEX Zone 2
Features and Benefits
• Ideal for analysis of crude and other highly viscous hydrocarbons,
pipelines, terminals, blending
• Sample stream temperatures up to 464° F / 240° C (with high temperature option)
• Proprietary window in flowcell can withstand pressures
In excess of 500 psig / 35 bar
• Certified to industry standards
• Large flowcell diameter (2 inches / 5 cm) reduces interferences
• Detection limit for sulfur of 0.02% - 6.0%
The analyzer consists of the three major components described below:

Chapter 1: Introduction, Page 7
Model 682T-HP USER MANUAL ATEX Zone 2
1.4.1 XRT/XRA Analyzer
 
DETECTOR  X-RAY TUBE HEAD
FLOW CELL
The XRT/XRA Analyzer components consist of the Flow Cell, X-ray Tube Head, Detector Head, and
related electronics. The signal from the Detector Head is fed to the Controller where it is corrected for
density and applied in the calibration equation to yield the correct result.
The sample lines in this system are made of materials compatible with your samples. After analysis the
material is returned to the process providing a clean, non-destructive measurement.

Chapter 1: Introduction, Page 8
Model 682T-HP USER MANUAL ATEX Zone 2
1.4.2 Controller
The Controller components consist of the PLC and Touch Screen Display. The Controller performs
three major functions:
The first function is to monitor for error conditions. These conditions can include low purge pressure,
piping leaks inside the sampler enclosure, communication failures, density errors, and temperatures
outside the set limits. To do this monitoring, the system uses various sensors and user definable limits.
The second function is to schedule and control the analysis sequence.
The third function is to handle communication with operators and other computers. This
communication is done using the Touch Screen Display and any industry standard input/output meth-
ods, such as 4-20 mA or ProfiBus.
The Controller automatically logs the data from any standards and then fits the data with a density
corrected XRT/XRA model that uses an advanced calibration equation. A trend of the results
measured during automatic analysis can be displayed for the last 5 to 60 minutes of operation
(depending on the sample time).

Chapter 1: Introduction, Page 9
Model 682T-HP USER MANUAL ATEX Zone 2
1.4.3 Densitometer (Optional)
The Densitometer components consist of the in-line density meter and processor that calculates the
liquid density and feeds that signal to the Controller.
The liquid density meter uses the spring mass principle for measuring fluid density. A portion of the
measurement tube is energized to vibrate at its natural resonant frequency by using an electrical
feedback driving system. A change in the vibrating mass, (as a result of change in the fluid density)
shifts the resonant frequency. A signal processing unit for density uses temperature, pressure and the
shift in frequency to determine the density of the measured fluid.
NOTE: The factory-installed densitometer is an option. However, if the analyzer is ordered without
the densitometer, the customer must supply a 4-20 mA density signal to the unit.
1.5 Notice of Operation
This analyzer is equipped with an emergency stop button or switch located on the front of the door of the
enclosure. This switch is provided for service technicians who need ready access to power for maintenance or
troubleshooting purposes. The operator of this equipment must be aware that some terminals are still energized
inside the enclosure even when the switch is in the “OFF” position. These connections are between the switch
and Terminal Block 1. If the operator of this equipment requires all internal circuits to be de-energized for any
reason, he must provide an AC junction box before the analyzer.
Do not open the enclosure when explosive atmospheres may be present


Chapter 2: Installation, Page 10
Model 682T-HP USER MANUAL ATEX Zone 2
2 INSTALLATION
This Section describes requirements for receiving and installing the analyzer. Site requirements consist of selecting the
proper location and preparing it for process access, plant services (power, air, etc.), and suitable environmental
conditions. Installer must confirm that the installation and process conditions, as well as the specifications in Section 8
are reviewed to determine that the installation is appropriate with the classified hazardous area.
2.1 Site Selection
The system is shipped secure in a wood container with screws and bands and then covered. The top is secured
with wood screws. The container can be handled using a forklift truck, hand truck, or trolleys.
Selecting the proper location for the analyzer is critical to realizing optimal process measurement. Some of the
important factors governing the selection process are: representative process sample, environmental immunity
(especially temperature and vibration), availability of plant services, and adequate space for maintenance
access, drainage (no standing water), etc. The system is designed for a NEMA 4X (IP-66) environment.
The analyzer is approximately 62 inches (158 cm) high and 47 inches (120cm) wide. Be aware that the analyzer
is designed to have the process stream connected to the top and bottom flanges (standard connection is 1” -
600# ANSI RF). Adequate space must be allowed above and below the analyzer. The analyzer may be
delivered with a mounting rack. See the Customer Drawings included with your analyzer documentation
package for weight and dimension details.
This equipment is designed to operate under the following conditions:
 Indoor use or outdoor with shelter from direct sunlight.
 Ambient temperature range 10˚C to +50˚C with installed environmental control.
 Altitude to 2000m
 Relative humidity not exceeding 90%, non-condensing.
 Mains supply fluctuations not exceeding 10%
 Over voltage category II IEC 60364-4-443 (able to withstand transient over-voltages typically present
on the mains supply).
 Pollution degree 2 (normally only non-conductive pollution – temporary conductivity caused by
condensation expected).
 Analyzer shall be installed in such a way that the risk of mechanical danger is low.
Depending upon the optional equipment ordered, the analyzer may weigh approximately 250 pounds (113 kg).
Appropriate mounting fixtures must be designed to support the analyzer weight. The mounting holes at the
corners of the enclosure have clearance for UNC 3/8” bolts (approximately 10 mm diameter). Take all
necessary precautions when securing the analyzer to the mounting fixture.

Chapter 2: Installation, Page 11
Model 682T-HP USER MANUAL ATEX Zone 2
2.3 Utility Requirements
2.3.1 Gas Supply Specifications
Purge air (or protective gas) is connected to a 3/8” NPT entry at the purge controller. Refer to the
Customer Drawings Except for cylinder-supplied gases, the point at which the protective gas enters
the supply duct(s) should be situated in a non-hazardous area.
Compressed Air Purge Instrument Grade 4 - 5 bar (60 - 72 psi) 226 NL/min (8 scfm)
initial purge; 28 NL/min
(1 scfm) continuous
p
ur
g
e

Chapter 2: Installation, Page 12
Model 682T-HP USER MANUAL ATEX Zone 2
2.3.2 Electrical
The incoming AC utilized for all analyzers should be “clean” AC, that is, AC with no transient
voltages on the line. No voltage dropout 10% below nominal and no voltage spikes 10% above
nominal VAC. AC voltages should be consistently maintained to 90% nominal VAC on the low end
and 110% nominal VAC on the high end. The AC voltage input can be 230 VAC single phase, 50 Hz,
1600 watts maximum power.
MAINS supply cords shall be rated for the maximum current for the equipment and the cable used
shall meet the requirements of IEC 60227 or IEC 60245. MAINS supply cords certified or approved
by a recognized testing authority are regarded as meeting this requirement.
The instrument must be connected to a protective earth ground.

Chapter 2: Installation, Page 13
Model 682T-HP USER MANUAL ATEX Zone 2
2.3.3 Signal Connections
Instrument signals can be connected through 3/4” conduit hubs. Refer to the Custoemr Drawings and Wiring
Diagrams supplied with your analyzer for connection details.
Signal cables need to be connected to the analyzer through cable glands or conduit hubs. The cables and fittings
must be rated for the environment for which the analyzer is intended. All cables and conduits must maintain the
integrity of the enclosure.