ORB P-840LT User manual

Process Analyzer
User Manual
P-840LT NO FLOW ANALYZER, LOW TEMP
CSA/CUS Class 1 Div 1 Group C + DATEX Zone 1 II B + T4

02-01-2013
P-840LT Pour Point Analyzer i Foreword
FOREWORD
FOREWORD
Table of Contents........................................................................................................................................... i
Warranty........................................................................................................................................................ v
INTRODUCTION -SECTION 1
Analyzer Overview .....................................................................................................................................1-1
Principle of Operation.................................................................................................................................1-2
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...................................................................................................................................3-8
Instrument Air ......................................................................................................................................3-8
Cryocooler Coolant Supply..................................................................................................................3-8
Optional Detection Cell Purge Gas Supply .........................................................................................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
Startup......................................................................................................................................................3-12

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P-840LT Pour 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 ...................................................................................................................................................4-4
Setup Sub-Menu ........................................................................................................................................4-5
Output Settings....................................................................................................................................4-5
4-20 Out 1 / 4-20 Out 2 / 4-20 Out 3.............................................................................................4-5
Digital Output ................................................................................................................................4-5
Trend Display................................................................................................................................4-5
Alarm Settings .....................................................................................................................................4-5
PP Alarm 1 / PP Alarm 2...............................................................................................................4-6
No Detect ......................................................................................................................................4-6
Other Settings......................................................................................................................................4-7
Reload Defaults.............................................................................................................................4-7
Stream Select................................................................................................................................4-7
Come Read Time..........................................................................................................................4-7
Temperature Scale........................................................................................................................4-7
Valid EV ........................................................................................................................................4-7
Valid BW .......................................................................................................................................4-8
Digital Inputs .................................................................................................................................4-8
Customer Alarm......................................................................................................................4-8
Remote Standby.....................................................................................................................4-8
Stream Select.........................................................................................................................4-8
Validation................................................................................................................................4-8
Screen Settings.............................................................................................................................4-8
Flush Heat.....................................................................................................................................4-8
Cell Heat .......................................................................................................................................4-8
Mode Settings ...............................................................................................................................4-8
PP 1 Mode..............................................................................................................................4-8
PP 2 Mode..............................................................................................................................4-8
PP 1 Threshold.......................................................................................................................4-8
PP 2 Threshold.......................................................................................................................4-8
Cool Drag......................................................................................................................................4-8
Relay Setup...................................................................................................................................4-9
Relay.......................................................................................................................................4-9
Choice.....................................................................................................................................4-9
Conditions...............................................................................................................................4-9
State Table Setup..............................................................................................................................4-10

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P-840LT Pour Point Analyzer iii Foreword
Time/Date Setup................................................................................................................................4-10
Factory Setup ....................................................................................................................................4-10
NORMAL OPERATION –SECTION 5
Main Run Screen .......................................................................................................................................5-1
Pour Point Analysis Results ................................................................................................................5-1
Date & Time.........................................................................................................................................5-1
Graphical Data Display........................................................................................................................5-1
Operational Status...............................................................................................................................5-2
Message Line ......................................................................................................................................5-2
Signal Outputs............................................................................................................................................5-3
4-20 mA Analog Output.......................................................................................................................5-3
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............................................................................................................................................5-4
Taking the Analyzer Off-Line......................................................................................................................5-5
Locally..................................................................................................................................................5-5
Remotely..............................................................................................................................................5-5
Performing a Validation Measurement.......................................................................................................5-5
Switching Sample Streams........................................................................................................................5-5
Loss of Power Restart................................................................................................................................5-5
Internal Sample Leak.................................................................................................................................5-6
ROUTINE MAINTENANCE &SERVICE –SECTION 6
Recommended Routine Maintenance Schedule........................................................................................6-1
Service & Operational Checks...................................................................................................................6-1
System Temperatures .........................................................................................................................6-2
T1..................................................................................................................................................6-2
Sample..........................................................................................................................................6-2
Sensor...........................................................................................................................................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
PWM Load ....................................................................................................................................6-2
Heater............................................................................................................................................6-2
Cooler............................................................................................................................................6-3
Pressure System .................................................................................................................................6-3

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P-840LT Pour Point Analyzer iv Foreword
Pressure........................................................................................................................................6.3
DI .........................................................................................................................................................6-3
SPARE AND REPLACEMENT PARTS –SECTION 7
Spare Parts Kits .........................................................................................................................................7-1
1-Year Parts Kit ...................................................................................................................................7-1
2-Year Parts Kit ...................................................................................................................................7-1
Replacement Parts.....................................................................................................................................7-2
DRAWINGS AND SCHEMATICS –SECTION 8

02-01-2013
P-840LT Pour 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.

02-01-2013
P-840LT Pour Point Analyzer 1-1 Introduction
INTRODUCTION SECTION 1
ANALYZER OVERVIEW
The ORB Instruments’ Model P-840LT Pour Point Analyzer is an on-line instrument designed for the
continuous measurement of pour point in hydrocarbon refining processes. Extremely rugged and simple
to operate, the compact P-840LT Pour Point Analyzer combines exceptional measurement accuracy with
unmatched operational dependability to deliver highly reliable and repeatable pour point determinations
day in, day out, month after month.
•Superior repeatability — ±0.5°C (1.0°F) or better.
•Exceptional uptime — 99% or better.
•-125° to +25°C (-193° to +77°F) operating range.
•High pressure sample detection cell eliminates the need for atmospheric recovery.
For optimum installation and applications versatility, the P-840LT Pour Point Analyzer incorporates a wide
variety of standard features, including:
•One isolated 4-20 mA analog output standard; two additional analog outputs available.
•Serial output.
•Three SPDT dry contact alarm relays.
•Optional ModBus output
•Separate control and measurement enclosures.
•NEC Class 1, Division 1, Group C, D or
European ATEX Zone 1, Group IIB hazardous area classification.
PRINCIPLE OF OPERATION
The P-840LT Pour Point Analyzer is designed to provide pour point measurements in correlation with
ASTM Method D-97 and IP-15. A precision differential pressure sensing system has been employed to
monitor the loss of flow due to the formation of wax crystals during the measuring cycle cool down. The P-
840LT’s pressure sensor monitors the state of flow conditions through a high-pressure detection cell that
allows measurements to be performed 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-840LT Pour Point Analyzer 1-2 Introduction
Figure 1-1a: Flow Schematic
(Analyzers with a Water-Cooled Cryocooler)
3 ALARM RELAYS (PROGRAMMABLE) SPDT, 3A RESISTIVE CONTACTS
CUSTOMER
CONNECTION
BOX
4-20mA OUT, POUR POINT ISOLATED & SELF POWERED

02-01-2013
P-840LT Pour Point Analyzer 1-3 Introduction
Figure 1-1b: Flow Schematic
(Analyzers with an Air-Cooled Cryocooler)
A typical measurement cycle takes between 10 and 45 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 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 cryocooler is programmable, continuously
monitored, and automatically adjusted to maintain consistent cooling times to pour point detection.
4. While the sample cools, both the sample temperature and the signal from the pressure transducer are
monitored. The temperature at which the differential pressure in the detection cell changes is the pour
point.
5. When pour point is detected, the temperature is displayed locally and output as an analog and/or
serial signal.
6. The sample solenoid opens and a new measurement cycle is initiated.
BOX
CUSTOMER
CONNECTION
3 ALARM RELAYS (PROGRAMMABLE) SPDT, 3A RESISTIVE CONTACTS
4-20mA OUT, POUR POINT ISOLATED & SELF POWERED

02-01-2013
P-840LT Pour Point Analyzer 1-4 Introduction
COMPONENT IDENTIFICATION
FRONT VIEW
Figure 1-2a: Front View
(Analyzers with a Water-Cooled Cryocooler)
Control Enclosure
Measurement
Enclosure
Coolant
Reservoir
Coolant Circulating
Pump
Customer Connections
Enclosure
Measurement
Enclosure Drain
Air In Pressure
Regulator

02-01-2013
P-840LT Pour Point Analyzer 1-5 Introduction
Figure 1-2b: Front View
(Analyzers with an Air-Cooled Cryocooler)
Measurement
Enclosure
Control
Enclosure
Customer
Connections
Enclosure
Measurement
Enclosure Drain
Air In Pressure
Regulator

02-01-2013
P-840LT Pour Point Analyzer 1-6 Introduction
CONTROL ENCLOSURE
Figure 1-3: Control Enclosure
Fuses
Digital Inputs
Power Switch
RTD Conversion PCB
Serial Modbus
Serial RS232
Main Control
PCB
TCP/IP Ethernet
Connection for
Modbus

02-01-2013
P-840LT Pour Point Analyzer 1-7 Introduction
MEASUREMENT ENCLOSURE
Figure 1-4: Measurement Enclosure
Cryocooler Drive
Sample Hammer
Differential
Pressure Sensor
Leak Detector
Detection Cell
Water- or Air-Cooled
Cryocooler

02-01-2013
P-840LT Pour 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 — Validate Digital / Auto
Service —
Sys Temperatures
T1
Sample
Sensor
Output Control
Sample Solenoid
Validation Solenoid
Stream Solenoid
4-20 Control
4-20 1
4-20 2
4-20 3
Alarms
R1
R2
R3
Cell Temp Control
PWM Load
Heater
Cooler
Pressure System
Pressure
DI
For future use
Display only – sample temperature
Display only – pressure
On / Off
On / Off
On / Off
Outputs analog signal for device calibration
Outputs analog signal for device calibration
Outputs analog signal for device calibration
On / Off
On / Off
On / Off
Display only
On / Off
On / Off
Display only
Display only – status of digital inputs

02-01-2013
P-840LT Pour Point Analyzer 1-9 Introduction
Main Menu Sub-Menu Items Choices / Settings / Comments
Setup
Output
Settings
4-20 Out 1
4-20 Out 2
4-20 Out 3
Digital Output
Trend Display
Mode
Type
Enabled/Disabled
Low
High
Clear Graph
4 mA value / 20 mA value / offset
4 mA value / 20 mA value / offset
4 mA value / 20 mA value / offset
RS232N / RS232D
Live / History
Display only
Enables or disables graphing
Sets bottom of trend graph scale
Sets top of trend graph scale
Clears graph
Alarm Settings
PP Alarm 1
Low
High
PP Alarm 2
Low
High
No Detect
Time
Cycle
Stream 1 pour point alarm
Lowest allowable pour point
Highest allowable pour point
Stream 2 pour point alarm
Lowest allowable pour point
Highest allowable pour point
Maximum allowable time to detect pour point
Maximum number of cycles to detect pour point
Other Settings
Reload Defaults
Standby Mode
Stream Select
Come Read Time
Temperature Scale
Valid EV
Valid BW
Digital Inputs
Screen Settings
Flush Heat
Cell Heat
Mode Settings
PP1 Mode
PP2 Mode
PP 1 Threshold
PP 2 Threshold
Cool Drag
Relay Setup
Relay
Choice
Conditions
Restores factory settings
On / Off
Steam 1 / Stream 2 / Alternate / Auto Select
User selected in seconds
°C / °F
Expected pour point
Allowable deviation from expected pour point
Customer Alarm / Remote Standby / Stream Select /
Validation
Intensity / Screen Saver
% power applied to heater during flush step
% power applied to heater during cell heating
Detection mode for Stream 1
Detection mode for Stream 2
Pour point sensitivity setting for Stream 1
Pour point sensitivity setting for Stream 2
% power to heater to retard cryocooler cooling
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-840LT Pour Point Analyzer 1-10 Introduction
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P-840LT Pour Point Analyzer 2-1 Specifications
SPECIFICATIONS SECTION 2
MODELS
P-840LT-1400 For NEC Class I Division 1 Group C, D Hazardous Areas
P-840LT-1500 For ATEX Ex d IIB Hazardous Areas
PERFORMANCE
Measurement Range Minimum: -125°C (-193°F)
Maximum: +25°C (+77°F)
Repeatability ±0.5°C (1.0°F)
Reproducibility Meets or exceeds ASTM Method D-97 or IP-15
Resolution ±0.25°C (0.5°F)
Measurement Accuracy Meets or exceeds ASTM Methods D-97 or IP-15
Temperature Accuracy ±0.5°C (±1.0°F)
Measurement Cycle Time 10 to 45 minutes
Operating Temperature Range Minimum: 5°C (40°F)
Maximum: 40°C (105°F)
SAMPLE REQUIREMENTS
Sample 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: 100°C (212°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-840LT Pour Point Analyzer 2-2 Specifications
SIGNAL INPUTS/OUTPUTS
Analog Output One isolated 4-20 mA outputs standard;
optional two additional isolated 4-20 mA outputs available.
Signal output information is programmable.
Serial Communication 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) Analyzers with Water-Cooled Cryocooler:
1187 x 1803 x 660 mm (46.75 x 71.0 x 26.0 inches)
Analyzers with Air-Cooled Cryocooler:
935 x 1803 x 559 mm (36.75 x 71.0 x 22.0 inches)
Weight Approximately 270 kg (600 pounds)
Enclosure Rating NEMA 4X / IP65 rated EExd enclosures
Certification CE certified
Hazardous Classification Model dependent; see above.

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P-840LT Pour 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 p
erformed 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-840LT Pour 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 standard.
The P-840LT Pour Point Analyzer is either frame or shelter mounted and should be installed on a flat,
level surface free from intense vibration. Frame legs or shelter feet are designed for use with ½ inch
expansion bolts. See the Drawings section of this manual for exact system dimensions. When placing the
system, care should be taken to ensure that all sides of the system are easily accessible and that ample
space is provided for regular system maintenance.
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.

02-01-2013
P-840LT Pour Point Analyzer 3-2 Installation and Startup
Figure 3-1a: Dimensional Drawing
(Analyzers with a Water-Cooled Cryocooler)