Thermo Scientific SOLA II Flare User manual

SOLA II Flare
Sulfur Online Analyzer
User Manual
PN 90-1312-0

SOLA II Flare
Sulfur Online Analyzer
User Manual
PN 90-1312-0
Revision A

© 2015 Thermo Fisher Scientific Inc. All rights reserved.
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Thermo Scientific SOLA II Flare User Manual v
Revision History
Revision Level Date Comments
A 03-2015 Initial Release per ERO 8626

Thermo Scientific SOLA II Flare User Manual vii
Contents
Safety Information & Guidelines ................................................................ xiii
Safety Considerations ........................................................................................ xii
Safety Summary ................................................................................................. xii
Safety Operating Information.............................................................................xiv
Electrical Power...................................................................................................xv
Chapter 1: Product Overview...................................................................... 1-1
Function..............................................................................................................1-1
Oxidative Pyrolysis System.........................................................................1-3
Diagnostics and Communication Options ..................................................1-3
Dynamic Range Switching..........................................................................1-4
Validation....................................................................................................1-5
Calibration...................................................................................................1-5
Principle of Operation........................................................................................1-5
PUVF Detector.............................................................................................1-6
Pyrolyzer......................................................................................................1-6
Injection Valve ............................................................................................1-6
Mixing Chamber..........................................................................................1-7
Dual Measuring Range...............................................................................1-7
Dual PMT Power Supplies..........................................................................1-8
Specifications ....................................................................................................1-9
Analytical Specifications............................................................................1-9
Analog/Discrete Data Communications...................................................1-10
System Requirements/Dimensions/Area Classifications........................1-10
System Requirements......................................................................................1-11
Site Requirements ...........................................................................................1-11
Spare Parts ......................................................................................................1-12
Storage.............................................................................................................1-12
Chapter 2: Installation ............................................................................... 2-1
Requirements.....................................................................................................2-1
Sample Line Installation....................................................................................2-1
Electrical Connections .......................................................................................2-2

Thermo Scientific SOLA II Flare User Manual viii
DCS & External Connections.............................................................................2-2
Analog Outputs ...........................................................................................2-3
Other Outputs..............................................................................................2-3
I/O Control .........................................................................................................2-3
Installation Checklist .........................................................................................2-6
Chapter 3: Start-Up & Shutdown................................................................ 3-1
Initial Start-Up ...................................................................................................3-1
Startup After Short-Term Shutdown.................................................................3-3
Short-Term Shutdown .......................................................................................3-3
Maintenance Shutdown ....................................................................................3-4
Emergency Shutdown........................................................................................3-4
SOLA II Flare Menus..........................................................................................3-5
Chapter 4: Operation.................................................................................. 4-1
The Interface......................................................................................................4-1
Begin Analyzing .................................................................................................4-1
Suspending an Analysis ....................................................................................4-2
Injection Valve Failure Alarm ............................................................................4-2
Chapter 5: Configuration ............................................................................ 5-1
Analyzer Setup...................................................................................................5-1
Clock Setup........................................................................................................5-3
Modbus Setup ...................................................................................................5-4
Inject Setup........................................................................................................5-5
Alarms Setup .....................................................................................................5-6
Calibration..........................................................................................................5-8
Overview .....................................................................................................5-8
Calibration Setup ......................................................................................5-11
Manually Calibrating a Low Value ...........................................................5-11
Manually Calibrating a High Value ..........................................................5-11
The Recalibrate High Function...........................................................5-12
Adjusting the Reading ..............................................................................5-12
Calibration Setup Menu Items .................................................................5-13
Validation Setup ..............................................................................................5-17
4–20 mA Range Setup.....................................................................................5-20

Thermo Scientific SOLA II Flare User Manual ix
Chapter 6: Viewing Alarms......................................................................... 6-1
Chapter 7: Diagnostics............................................................................... 7-1
Input & Output Test ...........................................................................................7-1
Set Outputs .................................................................................................7-1
View MUX Analogs.....................................................................................7-3
View 4–20 mA Inputs .................................................................................7-3
View Digital Inputs .....................................................................................7-4
View Parameters ...............................................................................................7-4
Com Ports RX TX................................................................................................7-6
Pulse UV Control................................................................................................7-7
Chapter 8: Maintenance & Troubleshooting ............................................... 8-1
Safety Precautions.............................................................................................8-1
Maintenance Schedule......................................................................................8-1
Visual Inspection & Cleaning ............................................................................8-1
Leak Tests..........................................................................................................8-2
Clean Air Leak Test.....................................................................................8-2
Sample Flow Leak Test...............................................................................8-4
Clean Nitrogen Leak Test ...........................................................................8-5
Flow Rate Checks ..............................................................................................8-6
The Rotary Valve................................................................................................8-7
The Mixing Chamber .........................................................................................8-7
Replacing the Pyrolyzer Heater .........................................................................8-8
The Pyrolyzer Reaction Tube ...........................................................................8-16
Replacement .............................................................................................8-16
Decoking ...................................................................................................8-18
General Troubleshooting .................................................................................8-18
Chapter 9: Support..................................................................................... 9-1
Contact Information...........................................................................................9-1
Warranty............................................................................................................9-2
Items Not Covered Under Warranty...........................................................9-3
Appendix A: Watlow EZ Zone®PM6 Series ................................................A-1
Controller Description....................................................................................... A-1
Hardware Setup................................................................................................ A-1

Thermo Scientific SOLA II Flare User Manual x
Display & Keys.................................................................................................. A-1
Software Configuration.................................................................................... A-3
Pyrolyzer Settings ...................................................................................... A-3
Oven Settings........................................................................................... A-10
The Lockout Menu .......................................................................................... A-17
Appendix B: Rotary Valve Service ..............................................................B-1
Initial Precautions..............................................................................................B-1
Valve Disassembly.............................................................................................B-2
Cleaning the Valve Body....................................................................................B-4
Cleaning the Rotor.............................................................................................B-5
Rotor Assembly..................................................................................................B-5
Conditioning Procedure for High Temperature Valves .....................................B-7
Two-Position Air Actuator O-Ring Replacement ..............................................B-7
Disassembly................................................................................................B-7
Replacement ...............................................................................................B-9
Assembly...................................................................................................B-10
Valve Alignment ..............................................................................................B-11
Rebuild the Assembly......................................................................................B-12
Appendix C: TCP/IP Bridge .........................................................................C-1
Hardware Configuration ....................................................................................C-1
Software Configuration.....................................................................................C-1
Appendix D: Sample SOLA II Flare Modbus Register ..................................D-1
Modbus Map .................................................................................................... D-1
Appendix E: The Workstation ..................................................................... E-1
Installing SOLA II Flare Software......................................................................E-1
Workstation Operation ......................................................................................E-3
Statistics .....................................................................................................E-5
Total Sulfur & Frequency Plot.....................................................................E-5
Analyzer Status...........................................................................................E-5
Diagnostic Trends .......................................................................................E-6
Diagnostic Signals ......................................................................................E-7
SCS Controls ...............................................................................................E-7

Thermo Scientific SOLA II Flare User Manual xi
Appendix F: The X-Purge System................................................................ F-1
Description......................................................................................................... F-1
X-Purge Specifications ...................................................................................... F-3
Installation......................................................................................................... F-3
AC Power .................................................................................................... F-4
Alarm Signal ............................................................................................... F-5
Startup ............................................................................................................... F-5
Shutdown........................................................................................................... F-7
Power or Purge Loss Shutdown.................................................................. F-7
Maintenance...................................................................................................... F-8
Timer Adjustment .............................................................................................. F-9
Appendix G: PUVF Optical Bench................................................................G-1
Appendix H: Toxic & Hazardous Substances Tables....................................H-1
Appendix I: Related Technical Bulletins ...................................................... I-1

Thermo Scientific SOLA II Flare User Manual xiii
Safety Information & Guidelines
This section contains information that must be read and understood by all
persons installing, using, or maintaining this equipment.
Safety
Considerations
Failure to follow appropriate safety procedures or inappropriate use of the
equipment described in this manual can lead to equipment damage or injury to
personnel.
Any person working with or on the equipment described in this manual is
required to evaluate all functions and operations for potential safety hazards
before commencing work. Appropriate precautions must be taken as necessary
to prevent potential damage to equipment or injury to personnel.
The information in this manual is designed to aid personnel to correctly and
safely install, operate, and maintain the system described; however, personnel
are still responsible for considering all actions and procedures for potential
hazards or conditions that may not have been anticipated in the written
procedures. If a procedure cannot be performed safely, it must not be
performed until appropriate actions can be taken to ensure the safety of the
equipment and personnel. The procedures in this manual are not designed to
replace or supersede required or common sense safety practices. All safety
warnings listed in any documentation applicable to equipment and parts used
in or with the system described in this manual must be read and understood
prior to working on or with any part of the system.
Failure to correctly perform the instructions and procedures in this manual or
other documents pertaining to this system can result in equipment
malfunction, equipment damage, and/or injury to personnel.
Safety Summary The following admonitions are used throughout this manual to alert users to
potential hazards or important information. Failure to heed the warnings and
cautions in this manual can lead to injury or equipment damage.
Warning Warnings notify users of procedures, practices, conditions, etc. which
may result in injury or death if not carefully observed or followed. The
triangular icons with warnings vary depending on the hazard. ▲
Caution Cautions notify users of operating procedures, practices, conditions,
etc. which may result in equipment damage if not carefully observed or
followed. ▲

Safety Information & Guidelines
Thermo Scientific SOLA II Flare User Manual xiv
Caution Static sensitive component. Appropriate handling precautions required
to prevent damage. ▲
Note Notes emphasize important or essential information or a statement of
company policy regarding an operating procedure, practice, condition, etc. ▲
Safety Operating
Information
This section contains general safety and operating information applicable to
analytical systems, which must be understood by all persons installing, using, or
maintaining the analyzer system. This information is designed to aid personnel
in the safe installation, operation, and service of the analyzer and sample
systems. It is not designed to replace or limit appropriate safety measures
applicable to work performed by personnel. Any additional safety and operating
measures that are required must be determined by and followed by personnel
performing work on the system.
Caution Failure to heed the following information may lead to equipment
damage or injury to personnel. ▲
Protective eyewear (glasses with side shields or goggles as appropriate) must be
worn when servicing any part of the analyzer or sample system. When servicing
the sample system, chemical resistant gloves appropriate for the materials in the
system must be worn. When servicing the hot analyzer oven, internal
components (e.g., detectors), or hot sample system components, appropriate
gloves must be worn. Heated components should be allowed to cool before
servicing if possible. Other appropriate equipment or clothing must be used as
required by the type of work performed.
Caution Ovens, internal components, and sample systems may be hot even
when power is not applied to the unit. Take appropriate precautions to prevent
injury resulting from contact with hot items. ▲
All applicable regulations and procedures must be followed for the work
performed. Before beginning any work on the system, carefully consider all the
potential hazards and ensure that appropriate measures are taken to prevent
injury to personnel and damage to equipment.

Safety Information & Guidelines
Thermo Scientific SOLA II Flare User Manual xv
Electrical Power The system uses AC power at 110 Vac (an optional step-down transformer is
available for 220 Vac). The AC power is converted to DC at several voltage
levels. Appropriate precautions must be taken to prevent sparks present in the
analyzer environment that may ignite combustible materials. Precautions must
also be taken to prevent electrical shock if the analyzer or sample system
enclosures are opened.
The AC power to the system must be free from noise, surges, sags, and spikes
for proper system operation. AC power circuit breakers and wiring must be
sized properly for the required current. All wiring installations must meet
applicable electrical codes.
The fuse is located on the analyzer terminal block.
Caution If it becomes necessary to replace the fuse, it must be replaced with one
of the same rating: Fuse, 3 A S/B (p/n TE-4510). ▲
Warning Remove power prior to performing any work internal to the
instrument. An override is available for use in non-hazardous areas; however,
removal of components while the instrument is energized is not permitted. ▲

Thermo Scientific SOLA II Flare User Manual 1-1
Chapter 1: Product Overview
The Thermo Scientific SOLA II Flare sulfur online analyzer combines proven
detection technology, easy-to-use, menu-driven software, and advanced
diagnostics to offer unsurpassed flexibility and reliability. The instrument offers
field programmable ranges, high sensitivity, total sulfur measurement, fast
response time, linearity through all ranges, and low consumables.
Function Major components of the SOLA II Flare include a sample injection valve,
carrier gas flow control system, mixing chamber, pyrolyzer, and a pulsed
ultraviolet fluorescence (PUVF) detector.
The SOLA II flare is a single assembly with one software program and one user
interface. The SOLA II Flare is a specialized version of the widely used SOLA II
total sulfur analyzer. The SOLA II Flare is specially configured to accommodate
the wide variety of sample conditions that can be experienced when monitoring
flare systems, and is suitable for analyzing over a dynamic range of 10 ppm to
100% sulfur by volume using a single analyzer system.
To meet this dynamic measurement range, the SOLA II Flare uses dual PMT
(photomultiplier tube) power supplies and dual sample injection valves to
achieve two independent measurement ranges. The low measurement range is
configured as 1% of the high measurement range. For example, a high
measurement range of 50% (500,000 ppm/v) will set the low range at 5,000
ppm/v. The SOLA II Flare software will automatically select the appropriate
measurement range based upon the sulfur output level being measured and will
select the appropriate PMT power supply and sample injection valve for the
measurement range.
The PUVF (pulsed UV fluorescence) detector utilizes a PMT to measure the
SO2present in the measuring cell. The sensitivity of the PMT is adjusted by the
supplied voltage. Using dual power supplies allows the sensitivity of the two
measurement ranges to be set independently. By utilizing two sample injection
valves, the SOLA II Flare provides precise control of the amount of the sample
that is injected as well as control of the dilution ratio (typically 100:1) between
the two injection valves. For the low measurement range, a 100 μl sample loop
is used and for the high measurement range a 1 μl sample loop is used. This
allows approximately the same amount of total sulfur to be injected into the
detector no matter which measurement range is in use.

Chapter 1
Product Overview
Thermo Scientific SOLA II Flare User Manual 1-2
These two features provide complete flexibility within a single analyzer system.
The lower detectable limit for the low measuring range is based upon the high
range selected; for example, if the high range is set to 1,000,000 ppm (100%)
the low range is automatically fixed at 10,000 ppm (1% of full scale). This
would dictate a lower detectable limit on the low range of 100 – 200 ppm
depending upon the final set-up used.
Figure 1-1. Typical SOLA II Flare analytical oven flow diagram
Set-up and programming of the SOLA II Flare is easy using the front panel
display. When compared to a zinc-continuous lamp, the Xenon flash lamp in
the SOLA II Flare has a cooler operating temperature. This allows for a longer
lifespan of the lamp, as well as increased sensitivity to the high energy generated
when the lamp pulses. The PUVF detector uses a 120-second rolling average
that updates the output every second, providing an excellent response time to
process changes.