Bartec ORB P-800LT User manual

Process Analyzer
User Manual
P-800LT FREEZE POINT ANALYZER, LOW TEMP
CSA/CUS Class 1 Div 1 Group C + DATEX Zone 1 II B + T6

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P-800LT Freeze Point Analyzer i Foreword
FOREWORD
FOREWORD
Table of Contents........................................................................................................................................... i
Warranty........................................................................................................................................................ v
INTRODUCTION -SECTION 1
Analyzer Overview.....................................................................................................................................1-1
Principle of Operation.................................................................................................................................1-1
Component Identification ...........................................................................................................................1-4
Front View............................................................................................................................................1-4
Control Enclosure................................................................................................................................1-6
Measurement Enclosure......................................................................................................................1-7
Menu Structure....................................................................................................................................1-8
SPECIFICATIONS -SECTION 2
Models........................................................................................................................................................2-1
Performance...............................................................................................................................................2-1
Sample Requirements................................................................................................................................2-1
Signal Inputs/Outputs.................................................................................................................................2-2
Utility Requirements...................................................................................................................................2-2
Analyzer Enclosure....................................................................................................................................2-2
INSTALLATION AND STARTUP -SECTION 3
Site Requirements......................................................................................................................................3-1
Location...............................................................................................................................................3-1
Mounting..............................................................................................................................................3-1
Piping .........................................................................................................................................................3-4
Process Sample Lines.........................................................................................................................3-8
Instrument Air ......................................................................................................................................3-8
Cryocooler Coolant Supply..................................................................................................................3-8
Optional Detection Cell Purge Gas Supply .........................................................................................3-8
Validation Sample Line........................................................................................................................3-8
Wiring.........................................................................................................................................................3-9
Electrical Power...................................................................................................................................3-9
Control Room Signals........................................................................................................................3-10
Analog Output.............................................................................................................................3-10
Relay Output...............................................................................................................................3-10
Serial Output...............................................................................................................................3-10
Modbus .......................................................................................................................................3-11
Digital Inputs ...............................................................................................................................3-11
Customer Alarm....................................................................................................................3-11
Remote Standby...................................................................................................................3-11
Validation Request ...............................................................................................................3-11
Stream Select.......................................................................................................................3-11
Startup......................................................................................................................................................3-12

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P-800LT Freeze Point Analyzer ii Foreword
PROGRAMMING –SECTION 4
Main Run Screen .......................................................................................................................................4-1
Menu Navigation........................................................................................................................................4-1
Advance Screen Key...........................................................................................................................4-2
Index Key.............................................................................................................................................4-2
Enter Key.............................................................................................................................................4-2
Up/Down Arrow Keys ..........................................................................................................................4-2
Main Menu..................................................................................................................................................4-2
Analyzer Status....................................................................................................................................4-2
Alarm History.......................................................................................................................................4-2
Validation.............................................................................................................................................4-3
Service.................................................................................................................................................4-3
Setup ...................................................................................................................................................4-3
Security................................................................................................................................................4-3
Setup Sub-Menu........................................................................................................................................4-4
Output Settings....................................................................................................................................4-4
4-20 Out 1 / 4-20 Out 2.................................................................................................................4-5
Digital Output ................................................................................................................................4-5
Trend Display................................................................................................................................4-5
Cycle.......................................................................................................................................4-5
FP History...............................................................................................................................4-7
Alarm Settings .....................................................................................................................................4-8
Alarm Range.................................................................................................................................4-8
No Detect Time.............................................................................................................................4-8
No Detect Cycle............................................................................................................................4-8
Other Settings......................................................................................................................................4-9
Reload Defaults.............................................................................................................................4-9
Stream Select................................................................................................................................4-9
Come Read Time..........................................................................................................................4-9
Temperature Scale........................................................................................................................4-9
Valid EV ........................................................................................................................................4-9
Valid BW .......................................................................................................................................4-9
Digital Inputs .................................................................................................................................4-9
Customer Alarm....................................................................................................................4-10
Remote Standby...................................................................................................................4-10
Stream Select.......................................................................................................................4-10
Validation..............................................................................................................................4-10
Screen Settings...........................................................................................................................4-10
Flush Heat...................................................................................................................................4-10
Cell Heat .....................................................................................................................................4-10
CP Cool.......................................................................................................................................4-10
FP Heat.......................................................................................................................................4-10
Sig90 IR ......................................................................................................................................4-10
Mode Settings.............................................................................................................................4-10
Standby Mode ......................................................................................................................4-10
Mode.....................................................................................................................................4-10
CP Threshold........................................................................................................................4-10

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P-800LT Freeze Point Analyzer iii Foreword
FP Threshold........................................................................................................................4-11
Detect ...................................................................................................................................4-11
Relay Setup.................................................................................................................................4-11
State Table Setup..............................................................................................................................4-12
Time/Date Setup................................................................................................................................4-14
Factory Setup ....................................................................................................................................4-14
NORMAL OPERATION –SECTION 5
Main Run Screen .......................................................................................................................................5-1
Freeze Point Analysis Results.............................................................................................................5-1
Date & Time.........................................................................................................................................5-1
Graphical Data Display........................................................................................................................5-1
Operational Status...............................................................................................................................5-2
Message Line ......................................................................................................................................5-2
Signal Outputs............................................................................................................................................5-2
4-20 mA Analog Output.......................................................................................................................5-2
Serial Output........................................................................................................................................5-3
Modbus Output....................................................................................................................................5-3
Alarms........................................................................................................................................................5-3
Types of Alarm Conditions ..................................................................................................................5-3
Alarm Warning ..............................................................................................................................5-3
Alarm Critical.................................................................................................................................5-3
Come Read...................................................................................................................................5-3
In Validation ..................................................................................................................................5-3
Validation ......................................................................................................................................5-3
Alarms History............................................................................................................................................5-5
Taking the Analyzer Off-Line......................................................................................................................5-5
Locally..................................................................................................................................................5-5
Remotely..............................................................................................................................................5-5
Performing a Validation Measurement.......................................................................................................5-5
Switching Sample Streams........................................................................................................................5-6
Loss of Power Restart................................................................................................................................5-6
Internal Sample Leak.................................................................................................................................5-6
ROUTINE MAINTENANCE &SERVICE –SECTION 6
Recommended Routine Maintenance Schedule .......................................................................................6-1
Service and Operational Checks ...............................................................................................................6-1
System Temperatures .........................................................................................................................6-2
Output Control .....................................................................................................................................6-2
Sample Solenoid...........................................................................................................................6-2
Validation Solenoid .......................................................................................................................6-2
Stream Solenoid............................................................................................................................6-2
4-20 Control.........................................................................................................................................6-2
Alarms..................................................................................................................................................6-2
Cell Temperature Control....................................................................................................................6-2
Optical System.....................................................................................................................................6-3
Run Autozero.......................................................................................................................................6-3
Az0 Volts..............................................................................................................................................6-3

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P-800LT Freeze Point Analyzer iv Foreword
Az90 Volts............................................................................................................................................6-3
Troubleshooting .........................................................................................................................................6-4
Assembly Drawings....................................................................................................................................6-5
Measurement Enclosure......................................................................................................................6-5
Control Enclosure................................................................................................................................6-6
Control Enclosure Door.......................................................................................................................6-7
SPARE AND REPLACEMENT PARTS –SECTION 7
Spare Parts Kits.........................................................................................................................................7-1
Replacement Parts.....................................................................................................................................7-2

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P-800LT Freeze Point Analyzer v Foreword
WARRANTY
POLICY
Orb Instruments warrants its products to the original purchaser against any defects that are due to faulty
material or workmanship for a period of one year from date of shipment unless otherwise noted in the
product manual.
In the event that a defect is discovered during the warranty period, Orb Instruments agrees that, at its
option, it will repair or replace the defective product or refund the purchase price, excluding original
shipping and handling charges. Any product repaired or replaced under this warranty will be warranted
only for the remainder of the original product warranty period.
This warranty does not apply to consumable products such as chemical reagents, or consumable
components of a product, such as, but not limited to, lamps and tubing.
Contact ORB Instruments or your distributor to initiate warranty support. Products may not be returned
without authorization from ORB Instruments.
LIMITATIONS
This warranty does not cover:
•Damage caused by acts of God, natural disaster, labor unrest, acts of war (declared or
undeclared), terrorism, civil strife or acts of any governmental jurisdiction.
•Damage caused by misuse, neglect, accident or improper application or installation.
•Any product not used in accordance with the instructions furnished by ORB Instruments.
•Freight charges to return merchandise to ORB Instruments.
•Freight charges on expedited or express shipment of warranted parts or product.
•Travel fees associated with on-site warranty repair.
This warranty contains the sole express warranty made by ORB Instruments in connection with its
products. All implied warranties, including without limitation, the warranties of merchantability and fitness
for a particular purpose, are expressly disclaimed.
Some states within the United States do not allow the disclaimer of implied warranties and if this is true in
your state, the above limitations may not apply to you. This warranty gives you specific rights, and you
may also have other rights that vary from state to state.
This warranty constitutes the final, complete, and exclusive statement of warranty/terms and no person is
authorized to make any other warranties or representations on behalf of ORB Instruments.
LIMITATION OF REMEDIES
The remedies of repair, replacement or refund of purchase price as stated above are the exclusive
remedies for the breach of this warranty. On the basis of strict liability or under any other legal theory, in
no event shall ORB Instruments be liable for any incidental or consequential damages of any kind for
breach of warranty or negligence.

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P-800LT Freeze Point Analyzer 1-1 Introduction
INTRODUCTION SECTION 1
ANALYZER OVERVIEW
The ORB Instruments’ Model P-800LT Freeze Point Analyzer is an on-line instrument designed for the
continuous measurement of freeze point in hydrocarbon refining processes. Extremely rugged and simple
to operate, the compact P-800LT Freeze Point Analyzer combines rapid analysis, exceptional
measurement accuracy, and unmatched operational dependability to deliver highly reliable and
repeatable freeze point determinations day in, day out, month after month.
•Rapid analysis — 10 minutes or less typical cycle time.
•Superior repeatability — ±0.5°C (1.0°F) or better.
•Exceptional uptime — 99% or better.
•High pressure sample detection cell eliminates the need for atmospheric recovery.
For optimum installation and applications versatility, the P-800LT Freeze Point Analyzer incorporates a
wide variety of standard features, including:
•Isolated 4-20 mA analog output; optional second output available.
•Bidirectional serial output.
•Three SPDT dry contact alarm relays.
•Optional ModBus output.
•Separate electronics and measurement enclosures.
•NEC Class 1, Division 1, Group C, D or
European ATEX Zone 1, Group II B and H2 T4 hazardous area classification.
PRINCIPLE OF OPERATION
The P-800LT Freeze Point Analyzer is designed to provide freeze point determinations in correlation with
ASTM Method D-2386 and IP-16. A near infrared sensing system has been employed to monitor the
formation and removal of wax crystals through high-pressure optical windows that allow measurement
cycles to occur at process pressures, eliminating the need for atmospheric sample recovery A state-of-
the-art air- or water-cooled cryocooler provides cooling power to the detection cell down to -125°C
(-193°F). The use of the cryocooler eliminates the requirement of an external, explosion-proof re-
circulating chiller system.
See Figures 1-1a and 1-1b.

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P-800LT Freeze Point Analyzer 1-2 Introduction
Figure 1-1a: Flow Schematic
(Analyzers with a Water-Cooled Cryocooler)

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P-800LT Freeze Point Analyzer 1-3 Introduction
Figure 1-1b: Flow Schematic
(Analyzers with an Air-Cooled Cryocooler)
A typical measurement cycle takes less than ten minutes and is performed as follows:
1. The sample solenoid opens and fresh sample is flushed through the detection cell to warm
and dislodge any wax crystals which may have remained on the detection cell windows from
the previous measurement. The duration of the flush cycle is user-programmable.
2. The sample solenoid closes, locking fresh sample in the detection cell.
3. The cryocooler is activated. The power applied to the cyrocooler is programmable and
continuously monitored and automatically adjusted to maintain consistent cooling times to
cloud point temperature.
4. Simultaneously, the optical system takes a baseline reading and then continuously monitors
the sample as it cools for wax crystal formation. The temperature at which the crystals form is
the cloud point.
5. When cloud point is detected, power to the cryocooler is turned off and low power heat
applied to the detection cell. As this warming occurs, the wax crystals begin to disappear.
The temperature at which the last of the wax crystals melt is the freeze point temperature.
This value is displayed locally and output as an analog and/or serial signal.
6. The sample solenoid opens and a new measurement cycle is initiated.

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P-800LT Freeze Point Analyzer 1-4 Introduction
COMPONENT IDENTIFICATION
FRONT VIEW
Figure 1-2a: Front View
(Analyzers with a Water-Cooled Cryocooler)
Control Enclosure
Measurement
Enclosure
Customer Connections
Enclosure
Measurement
Enclosure Drain
Air In Pressure
Regulato
r

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P-800LT Freeze Point Analyzer 1-5 Introduction
Figure 1-2b: Front View
(Analyzers with an Air-Cooled Cryocooler)
Measurement Enclosure
Control
Enclosure
Custome
r
Connections
Enclosure
Measurement Enclosure
Drain
Air In Pressure
Regulato
r

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P-800LT Freeze Point Analyzer 1-6 Introduction
CONTROL ENCLOSURE
Figure 1-3: Control Enclosure
Fuses
Digital Inputs
Power Switch
Main Control
PCB

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P-800LT Freeze Point Analyzer 1-7 Introduction
MEASUREMENT ENCLOSURE
Figure 1-4: Measurement Enclosure
Cryocooler Drive
Leak Detecto
r
Detection Cell
A
i
r
- or Water-Cooled
Cryocooler

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P-800LT Freeze Point Analyzer 1-8 Introduction
MENU STRUCTURE
Main Menu Sub-
Menu Items Choices / Settings / Comments
Analyzer
Status — — On Line / Off Line
Alarm
History ——Display only
Validation — Validation Digital / Auto / Manual / Off
Service —
Sys Temperatures
T1
Sample
Sensor
Output Control
Sample Solenoid
Validation Solenoid
Stream Solenoid
4-20 Control
4-20 1
4-20 2
Alarms
R1
R2
R3
Cell Temp Control
PWM Load
Heater
Cooler
Optical System
NIR Power
NIR Source
0 Signal
90 Signal
Run Autozero
Az0 Volt
Az90 Volt
For future use
Display only – sample temperature
For future use
On / Off
On / Off
On / Off
Outputs analog signal for device calibration
Outputs analog signal for device calibration
On / Off
On / Off
On / Off
Display only
On / Off
On / Off
Percent power
On / Off
Display only
Display only
Initiates Autozero
Autozero volts for sig 0
Autozero volts for sig 90

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P-800LT Freeze Point Analyzer 1-9 Introduction
Main Menu Sub-
Menu Items Choices / Settings / Comments
Output
Settings
4-20 Out 1
Output
4 mA
20 mA
Offset
4-20 Out 2
Output
4 mA
20 mA
Offset
Digital Output
Mode
Trend Display
Mode
Rate
Range
Trend = CP History
Trend = Cycle
CP1 / CP2 / Cell Temp / Sig 0 / Sig 90 / Validation
Value = 4 mA signal
Value = 20 mA signal
Offset value
CP1 / CP2 / Cell Temp / Sig 0 / Sig 90 / Validation
Value = 4 mA signal
Value = 20 mA signal
Offset value
RS232 / Modbus
CP History / Cycle
Full / Half (Cycle mode only)
Horizontal range of trend graph (Cycle mode only)
CP 1
Enabled / Disabled
Low = Bottom of graph scale
High = Top of graph scale
Clear graph = Clears graph
CP 2
Enabled / Disabled
Low = Bottom of graph scale
High = Top of graph scale
Clear graph = Clears graph
Temp
Enabled / Disabled|
Low = Bottom of graph scale
High = Tope of graph scale
Sig 0
Enabled / Disabled|
Low = Bottom of graph scale
High = Tope of graph scale
Sig 90
Enabled / Disabled|
Low = Bottom of graph scale
High = Tope of graph scale
Alarm
Settings
Alarm Ranges
Low
High
No Detect Time
No Detect Cycle
Lowest allowable Freeze Point
Highest allowable Freeze Point
Maximum allowable time to detect freeze point
Maximum number of cycles to detect freeze point
Setup
System
Settings Reload Defaults
Stream Select
Come Read Time
Temperature Scale
Valid EV
Valid BW
Digital Inputs
Customer Alarm
Remote Standby
Stream Select
Validation
Restores factory settings
Stream 1 / Stream 2 / Alternate / Auto Select
User selected in seconds
°C / °F
Expected Freeze Point
Allowable deviation from expected freeze point
Enable / Disable
Enable / Disable
Enable / Disable
Enable / Disable

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P-800LT Freeze Point Analyzer 1-10 Introduction
Screen Settings
Flush Heat
Cell Heat
CP Cool
Sig 90 IR
Mode Settings
Standby Mode
Mode
CP Threshold
Detect
Relay Setup
Relay
Choice
Conditions
Intensity / Screen Saver
% power applied to heater during flush step
% power applied to heater during cell heating
% power applied to the cooling module
Sensor sensitivity (Detect = Sig90 only)
On / Off
Baseline / First Derivative / Delayed T
Cloud point sensitivity setting
Sig0 / Sig90
R1 / R2 / R3
Off / Alarm Warning / Alarm Critical / Come Read /
In Validation / Validation
Normal / Failsafe
State
Table
Setup —Steps in measurement cycle
Time/Date
Setup
Time Format
Date Format
Date
Time
12 hour / 24 hour)
US / EU
MM/DD/YY or DD/MM/YR
HH/MM/SS
Factory
Setup —For factory use only
Security — — Enable / Disable

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P-800LT Freeze Point Analyzer 2-1 Specifications
SPECIFICATIONS SECTION 2
MODELS
P-800LT-1400 For NEC Class I, Division 1, Group C and D areas.
P-800LT-1500 For ATEX Zone I, II B + H2 T4 areas.
PERFORMANCE
Measurement Range Minimum: -100°C (-148°F)
Maximum: +25°C (+77°F)
Repeatability ±0.5°C (1.0°F)
Reproducibility Meets or exceeds ASTM Method D-2386 or IP-16
Resolution ±0.25°C (0.5°F)
Measurement Accuracy Meets or exceeds ASTM Methods D-2386 or IP-16
Temperature Accuracy ±0.5°C (±1.0°F)
Measurement Cycle Time Less than 10 minutes
Operating Temperature Range Minimum: 5°C (40°F)
Maximum: 40°C (105°F)
SAMPLE REQUIREMENTS
Sample Bypass Flow Rate Minimum: 1 liter/minute
Maximum: 2 liters/minute
Sample Return Pressure Atmospheric to 10 bar (150 psi) maximum
Sample Pressure Minimum: 1.4 bar (20 psi)
Maximum: 14 bar (200 psi)
Sample Temperature Minimum: 2°C (35°F)
Maximum: 65°C (150°F)
Sample Particulates Less than 10 µm; optional sample conditioning system available
Sample Conditions Homogeneous, single-phase sample. Must be free of water
or water moisture

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P-800LT Freeze Point Analyzer 2-2 Specifications
SIGNAL INPUTS/OUTPUTS
Analog Output One isolated 4-20 mA output standard;
Optional second isolated 4-20 mA output available.
Signal output information is programmable.
Serial Communication Bi-directional RS232 (RS485 optional)
Relay Output Three SPDT failsafe relay contacts rated at 3A resistive load at
250 VAC. May be programmed for normal or failsafe operation.
The conditions activating these relays are programmable.
ModBus Optional; consult ORB Instruments
UTILITY REQUIREMENTS
Power Auto-selecting 100 to 125 VAC (±10%) and 200 to 240 VAC
(±10%), 50/60 Hz, single phase, 10A.
Optional Detection Cell Purge
Gas Supply Clean, dry nitrogen (better than 98% pure) or other inert gas at 0.07 bar (1.0 psi).
Instrument Air Analyzers with Water-Cooled Cryocooler (for sample solenoid):
Clean, dry instrument air at a minimum of 4 bar (58 psi).
Analyzers with Air-Cooled Cryocooler (for sample solenoid and
cryocooler):
Clean, dry instrument air at 6-8 bar (87-116 psi); 50 cfm
consumption.
Cryocooler Coolant
Analyzers with Water-Cooled Cryocooler only: Clean, filtered plant cooling water or closed-loop chiller system.
Fluid Temperature: Up to 35°C (95°F);
Flow rate: 2-4 liters/minute (0.5-1.0 gpm);
Pressure: 2 bar (30 psi) minimum.
ANALYZER ENCLOSURE
Dimensions (W x H x D) 935 x 1803 x 762 mm (36.75 x 71.0 x 30 inches)
Weight Approximately 318 kg (700 pounds)
Enclosure Rating NEMA 4X / IP65 rated EExd enclosures
Certification CE certified
Hazardous Classification Model dependent; see above.
Due to ORB Instruments’ commitment to continual product improvement, specifications subject to change without notice.

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P-800LT Freeze Point Analyzer 3-1 Installation and Startup
INSTALLATION AND STARTUP SECTION 3
WARNING: Installation or operation of this Analyzer outside of the parameters indicated
in the Specifications could result in personal injury or damage to the Analyzer.
Installation, operation, and maintenance should performed only by fully qualified
personnel.
SITE REQUIREMENTS
Your particular site, application, and installed options will ultimately determine the need for any
accessories or auxiliary equipment. This section defines the various parameters to be considered.
Consult ORB Instruments for specific recommendations regarding your P-800LT Freeze Point Analyzer.
LOCATION
For ease of operation, your Analyzer should be installed as close as possible to the process stream to be
monitored. To optimize performance, it should be housed in an appropriate shelter and protected against
direct sunlight, moisture, and other adverse conditions. The shelter’s ambient temperature should remain
between 5° and 40°C (40° and 105°F) at all times.
MOUNTING
NOTE: An optional free-standing mounting rack is available.
The P-800LT Freeze Point Analyzer is housed in a dual-chamber enclosure designed for wall mounting. It
should be located on a flat, vertical surface and isolated from intense vibration. The cabinet incorporates
mounting ears to facilitate installation.
The bottom of the enclosure should be located approximately 12 inches (30.5 cm) above the floor of the
shelter. Adequate clearance (approximately 12 inches/30.5 cm) should also be allowed on either side of
the unit for sample, utility, and control room connections.
See Figures 3-1a and 3-1b.

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P-800LT Freeze Point Analyzer 3-2 Installation and Startup
Figure 3-1a: Dimensional Drawing
(Analyzers with a Water-Cooled Cryocooler)