Thermo Scientific SOLA II User manual

SOLA II
Su lfur Online Analyzer
User Guide
P/N 90-1307-0
Revision A B
P ar t of Thermo Fisher S cien tific

SOLA II
Su lfur Online Analyzer
User Guide
P/N 90-1307-0
Revision A B

© 2017Thermo Fisher Scientific Inc.All rights reserved.
“Teflon”is aregistered trademark of E.I. du Pont de Nemours and Company.
“Watlow” and “EZ-ZONE” are registered trademarks of Watlow Electric Manufacturing Company.
“VICI is a registered trademark of Valco Instruments Co. Inc. and VICI AG.
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All other trademarks are theproperty of Thermo Fisher Scientific Inc. and its subsidiaries.
Thermo Fisher Scientific (Thermo Fisher)makes every effort toensure the accuracy and completeness of this manual.
However, wecannot beresponsible for errors, omissions, or any loss of data as the result oferrors or omissions.
Thermo Fisher reserves theright tomake changes to the manual orimprovements to the product atany time without
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from Thermo Fisher.

Thermo Fisher Scientific SOLA II User Guide v
Revision History
Revision Level Date Comments
A 02-2004 Initial release.
B 04-2005 Applied standardized formatting, changes to analyzer menu,
stream setup, autocal setup menus; added “At Line Grab
Sample” menu and related items; edited Modbus register for
software v. 1.20.
C 04-2006 Address change.
D 01-2007 Company name change (ECO 5457).
E 04-2007 Revised per ECO 5625.
F 08-2007 Revised per ECO 5921.
G 10-2007 Revised per ECO 6018.
H 03-2008 Revised per ECO 6230.
J 04-2008 Revised per ECO 6320.
K 06-2008 Revised per ECO 6419.
M 04-2009 Revised per ECO 6903.
N 05-2009 Revised per ECO 6915.
P 06-2009 Revised per ECO 6968.
R 04-2010 Revised per ECO 7351.
S 11-2010 Revised per ECO 7578.
T 01-2011 Revised per ECO 7627.
U 04-2011 Revised per ECO 7694.
V 01-2012 Revised per ECO 7897.
W 02-2013 Revised per ECO 8126.
X 01-2014 Revised per ECO 8332.
Y 11-2014 Revised per ECO 8545.
Z 06-2016 Revised per ECO 8659.
AA 06-2016 Revised per ECO 8667.
AB01-2017Revised per ECO 8995.

Thermo Fisher Scientific SOLA II User Guide vii
Contents
Safety Information & Guidelines...................................................................1-1
Safety Considerations.......................................................................................................1-1
Safety Summary ................................................................................................................1-2
Safety Operating Information.......................................................................................1-2
Electrical Power.................................................................................................................1-3
Product Overview...........................................................................................2-1
Function...............................................................................................................................2-1
Total Sulfur Measurement............................................................................................2-2
Principle of Operation....................................................................................................2-4
PUVF Detector..............................................................................................................2-5
Pyrolyzer.........................................................................................................................2-5
Dryer................................................................................................................................2-6
Mixing Chamber...........................................................................................................2-6
Injection Valve ..............................................................................................................2-7
Specifications.....................................................................................................................2-8
Parts List............................................................................................................................2-10
Spare Parts........................................................................................................................2-15
Storage ...............................................................................................................................2-21
Installation......................................................................................................3-1
Requirements .....................................................................................................................3-1
Sample Line Installation ................................................................................................3-2
Sample Tubing Preparation..........................................................................................3-2
Electrical Connections....................................................................................................3-3
DCS & External Connections.......................................................................................3-3
Digital Inputs ................................................................................................................3-3
Optional Analog Inputs..........................................................................................3-4
Analog Outputs ........................................................................................................3-5
Other Outputs..........................................................................................................3-5
Installation Checklist.......................................................................................................3-5
Startup & Shutdown.......................................................................................4-1
Initial Startup.....................................................................................................................4-1
Startup after Short-Term Shutdown.........................................................................4-3
Short-Term Shutdown .................................................................................................. 4-4
Maintenance Shutdown ................................................................................................ 4-4
Emergency Shutdown.....................................................................................................4-5
Chapter 1
Chapter 2
Chapter 3
Chapter 4

Contents
viii SOLA II User Guide Thermo Fisher Scientific
Operation ........................................................................................................5-1
The Interface ......................................................................................................................5-1
Begin Analyzing................................................................................................................5-2
Suspending an Analysis .................................................................................................5-2
Injection Valve Failure Alarm ......................................................................................5-3
Configuration..................................................................................................6-1
Analyzer Setup ..................................................................................................................6-1
Stream Setup.................................................................................................................... 6-4
Clock Setup ...................................................................................................................... 6-6
Modbus Setup...................................................................................................................6-7
Dual Range Setup........................................................................................................... 6-8
Inject Setup....................................................................................................................... 6-9
Autocal Setup.................................................................................................................. 6-10
Alarms Setup................................................................................................................... 6-13
Calibration .......................................................................................................................6-16
Overview....................................................................................................................... 6-16
Performing a Low Calibration at Zero* ............................................................. 6-19
Performing a High Calibration............................................................................. 6-20
The Calibrate High Function ............................................................................ 6-20
The Recalibrate High Function......................................................................... 6-20
Adjusting the Reading.............................................................................................. 6-21
Calibration Setup Menu Items ............................................................................. 6-22
Density Compensation Setup ................................................................................... 6-25
Viewing Alarms...............................................................................................7-1
Diagnostics.....................................................................................................8-1
Input & Output Test Menu...........................................................................................8-1
Set Outputs ....................................................................................................................8-1
View MUX Analogs......................................................................................................8-2
View 4–20 mA Inputs................................................................................................8-3
View Digital Inputs .................................................................................................... 8-4
View Parameters ..............................................................................................................8-5
View Com Activity ......................................................................................................... 8-6
Pulse UV Control.............................................................................................................8-7
At Line-Grab Sample......................................................................................9-1
Safety Precautions ...........................................................................................................10-1
Maintenance & Troubleshooting.................................................................10-1
Maintenance Schedule....................................................................................................10-1
Visual Inspection & Cleaning......................................................................................10-2
Leak Tests .........................................................................................................................10-2
Chapter 5
Chapter 6
Chapter 7
Chapter 8
Chapter 9
Chapter 10

Contents
Thermo Fisher Scientific SOLA II User Guide ix
Flow Rate Checks........................................................................................................... 10-3
The Rotary Valve ........................................................................................................... 10-4
The Mixing Chamber.................................................................................................... 10-4
Replacing the Pyrolyzer Heater................................................................................. 10-5
The Pyrolyzer Reaction Tube.................................................................................... 10-13
Replacement ............................................................................................................... 10-13
Decoking ...................................................................................................................... 10-15
General Troubleshooting............................................................................................ 10-15
Contact Information ....................................................................................................10-19
Warranty.........................................................................................................................10-20
Items not Covered under Warranty .................................................................. 10-20
Watlow EZ-ZONE®PM6 Series..................................................................... A-1
Controller Description ................................................................................................... A-1
Hardware Setup ............................................................................................................... A-1
Display & Keys.................................................................................................................. A-1
Software Configuration................................................................................................. A-3
Pyrolyzer Settings....................................................................................................... A-3
Oven Settings...............................................................................................................A-11
The Lockout Menu ........................................................................................................A-18
Rotary Valve Service..................................................................................... B-1
Initial Precautions.............................................................................................................B-1
Valve Disassembly ...........................................................................................................B-2
Cleaning the Valve Body ...............................................................................................B-3
Cleaning the Rotor......................................................................................................... B-4
Rotor Assembly ............................................................................................................... B-4
Conditioning Procedure for High Temperature Valves ......................................B-5
Two-Position Air Actuator O-ring Replacement.................................................. B-6
Disassembly .................................................................................................................. B-6
Replacement ................................................................................................................. B-8
Assembly........................................................................................................................ B-9
Valve Alignment............................................................................................................. B-10
Rebuild the Assembly.................................................................................................... B-11
Dinfa Valve Service....................................................................................... C-1
Overview............................................................................................................................. C-1
Troubleshooting .............................................................................................................. C-5
TCP/IP Bridge................................................................................................ D-1
Hardware Configuration................................................................................................D-1
Software Configuration.................................................................................................D-2
The Browser Interface...................................................................................................D-3
24 Hours Chart ...........................................................................................................D-4
24 Hours Table Format ............................................................................................D-4
Appendix A
Appendix B
Appendix C
Appendix D

Contents
xSOLA II User Guide Thermo Fisher Scientific
Configuration ...............................................................................................................D-4
At Line Sample ............................................................................................................D-8
Version 1.20 Modbus Registers................................................................... E-1
Coils (0)0001 to (0)0040 ...............................................................................................E-1
Status Inputs (1)0001 to (1)0025.................................................................................E-3
Input Registers (3)0001 to (3)0040...........................................................................E-4
Holding Registers (4)0001 to (4)0049 .....................................................................E-5
The Workstation.............................................................................................F-1
Installing Workstation Software ..................................................................................F-1
Workstation Operation..................................................................................................F-3
Statistics..........................................................................................................................F-5
Density Values & Trend ............................................................................................F-5
Cal Validation History................................................................................................F-5
Stream Plot ....................................................................................................................F-5
Detector Status.............................................................................................................F-6
Alarms Status................................................................................................................F-6
Remote Controls ..........................................................................................................F-7
Analyzer Status.............................................................................................................F-8
Configuration ....................................................................................................................F-8
The X-Purge System......................................................................................G-1
Description......................................................................................................................... G-1
X-Purge Specifications...................................................................................................G-3
Installation.........................................................................................................................G-4
AC Power ......................................................................................................................G-4
Alarm Signal.................................................................................................................G-5
Startup ...............................................................................................................................G-5
Shutdown ..........................................................................................................................G-6
Power or Purge Loss Shutdown ............................................................................G-7
Maintenance .....................................................................................................................G-7
Timer Adjustment ..........................................................................................................G-8
Software Menu Tree ......................................................................................H-1
PUVF Optical Bench........................................................................................I-1
Dual PMT Supply Option................................................................................J-1
Overview............................................................................................................................... J-1
Menu Changes for Dual PMT Supply Option......................................................... J-2
Calibration Setup.......................................................................................................... J-2
AutoCal Setup................................................................................................................J-3
Stream Setup..................................................................................................................J-3
Appendix E
Appendix F
Appendix G
Appendix H
Appendix I
Appendix J

Contents
Thermo Fisher Scientific SOLA II User Guide xi
4–20 mA Range Setup................................................................................................J-3
Diagnostics Display ......................................................................................................J-3
At Line-Grab Sample...................................................................................................J-4
Installation...........................................................................................................................J-4
Toxic & Hazardous Substances Tables....................................................... K-1
Connecting to a Sarasota FD910 Density Meter..........................................L-1
Purpose ................................................................................................................................L-1
Connections........................................................................................................................L-1
Connecting One Density Meter to a Dual Stream System............................L-3
Related Technical Bulletins..........................................................................M-1
Appendix K
Appendix L
Appendix M
Appendix NTrace Level Measurements ...............................................................................N-1
Appendix OVapour Sample Measurements.........................................................................O-1

Thermo Fisher Scientific SOLA II User Guide 1-1
Chapter 1
Safety Information & Guidelines
This chapter contains information that must be read and understood by all
persons installing, using, or maintaining this equipment.
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 perform the instructions and procedures in this manual
or other documents pertaining to this system correctly can result
in equipment malfunction, equipment damage, and/or injury to
personnel.
Safety
Considerations

Safety Information & Guidelines
Safety Summary
1-2 SOLA II User Guide Thermo Fisher Scientific
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. σ
Caution Cautions notify users of operating procedures, practices, conditions,
etc. which may result in equipment damage if not carefully observed or
followed. σ
Caution Static sensitive component. Appropriate handling precautions
required to prevent damage. σ
Note Notes emphasize important or essential information or a statement of
company policy regarding an operating procedure, practice, condition, etc. σ
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. σ
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.
Safety Summary
Safety Operating
Information

Safety Information & Guidelines
Electrical Power
Thermo Fisher Scientific SOLA II User Guide 1-3
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. σ
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.
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). σ
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. σ
Electrical Power

Thermo Fisher Scientific SOLA II User Guide 2-1
Chapter 2
Product Overview
The Thermo Scientific SOLA II 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.
Major components of the SOLA II include a sample injection valve, carrier gas
flow control system, mixing chamber, pyrolyzer, optional dryer, and a pulsed
ultraviolet fluorescence (PUVF) detector. Unlike the original SOLA instrument,
the PUVF is not a subassembly. The SOLA II is a single assembly with one
software program and one user interface.
The sample injection valve periodically transfers a small amount of sample
(approximately 1.0 µL) into an air carrier gas. The air/sample mixture passes
through the mixing chamber to ensure complete mixing and then flows to the
pyrolyzer. The pyrolyzer combusts all sample components to SO2, CO2, and
H2O at approximately 1100°C (2012°F). The optional dryer (application
dependent) removes water from the sample that is produced during
combustion. The PUVF detector accurately measures the amount of SO2
produced during combustion of the sample.
An appropriate sample conditioning system is mandatory for proper
functioning. The sample conditioning system should:
λRegulate sample pressure and temperature.
λProvide filtration to at least a 0.5-micron particle size. Staged filtration is
recommended (e.g. going from 10 micron to 5 micron to 0.5 micron). The
final filter should contain a hydrophobic element to remove undissolved
water.
λEnsure that a representative sample is transported to the analyzer in the
desired time.
λMaintain the sample in a single phase.
Function

Product Overview
Total Sulfur Measurement
2-2 SOLA II User Guide Thermo Fisher Scientific
Note Liquid samples with high vapor temperatures such as naphthas and
gasolines will require sample backpressure regulation +0 25–35 psig. σ
λRemove undissolved water.
Sample should be delivered to the sample conditioning system using a sample
probe. The sample probe should be designed and fabricated so that sample is
extracted from near the center of the process pipe, preventing the
unnecessary introduction of pipe scale and other particulate that tend to
accumulate along the process pipe walls.
Figure 2–1. Functional block diagram
Total sulfur measurement is based upon the precise measurement of the SO2
concentration produced from a wide variety of compounds containing sulfur,
such as H2S, COS, methyl mercaptan, benzothiophenes, dibenzothiophenes,
sulfides, disulfides, and thiols. Consider the measurement of a sample of
diesel, gasoline, or another common petroleum fraction such as naphtha for
liquid phase samples. For liquid phase samples, the analyzer periodically
injects a very small quantity of sample (1.0 µL) of the petroleum fraction into
a hot oven (110°C to 220°C / 230°F to 428°F) where it is vaporized and mixed
with air. Analysis of gas phase samples requires sample sizes of 0.1 to 1.0 cm3.
After thoroughly mixing with air, the sample enters the pyrolyzer, where all
components of the sample are combusted at 1100°C (2012°F) to CO2, H2O, or
SO2. The quantity of SO2formed during the combustion process is directly
proportional to the total sulfur content of the petroleum fraction.
The analyzer is equipped with a PUVF detector that accurately measures the
quantity of SO2formed during the combustion process. The SO2molecules
Total Sulfur
Measurement

Product Overview
Total Sulfur Measurement
Thermo Fisher Scientific SOLA II User Guide 2-3
enter the cell of the PUVF detector where they are exposed to ultraviolet (UV)
light. Absorption of UV light by SO2molecules results in an excited state of
the SO2molecules. The excited state SO2molecules exist at a higher energy
state (due to absorption of energy in the form of UV light) and rapidly relax
to their original energy level or ground state through the emission of light.
This process is called fluorescence. The intensity of the light emitted by SO2
fluorescence is directly proportional to the SO2concentration. Pulsing the UV
light allows more energy (UV light) to be delivered to the sample, increasing
the fluorescence intensity for a given SO2concentration. This results in
increased overall sensitivity of the instrument.
At the PUVF detector, it is important to ensure that the measured light is
representative of only the SO2concentration and not some other species. SO2
molecules emit light through fluorescence at a specific wavelength, and the
PUVF detector utilizes bandpass filters to ensure that only light from SO2is
measured. Once the proper wavelength of light is selected, its intensity is
measure by a photomultiplier tube (PMT). The PMT converts light energy to
electrical energy through manipulation of the photoelectric effect. The
electrical signal generated by the PMT is finally processed by the analyzer
electronics and software to determine and report the concentration of total
sulfur in the liquid petroleum fraction or gas sample.
The analyzer can be configured to report total sulfur in parts per million
(ppm), parts per billion (ppb), or milligrams per liter (mg/L).
λWhen using the ppm or ppb units of measure, you can choose to calibrate
the analyzer in terms of ppm (w/w), ppm (v/v), ppm (w/v), ppb (w/w),
ppb (v/v), or ppb (w/v).
λWhen using density compensation and the ppm or ppb units are selected,
the display shows ppm/weight or ppb/weight.
Units of concentration calculated on a weight/weight basis are sensitive to
sample density. If the density of the calibration standard is significantly
different from the density of the sample, a density correction should be
applied.
λIf the sample density varies significantly, a density correction is also
necessary when using concentration units of ppm (w/w) or ppb (w/w).
λIf using mg/L, ppm (w/v), ppm (v/v), ppb (w/v), or ppb (v/v), a density
correction is not required.

Product Overview
Principle of Operation
2-4 SOLA II User Guide Thermo Fisher Scientific
The detector is based on the principle that SO2molecules absorb UV light and
become excited at one wavelength, then decay to a lower energy state
emitting UV light at a different wavelength. Specifically,
The sample inlet bulkhead draws the sample into the analyzer. The sample is
mixed with air and passes through a pyrolyzer furnace that oxidizes the sulfur
molecules in the sample to produce SO2. The sample then flows into the
fluorescence chamber where pulsating UV light excites the SO2molecules. The
condensing lens focuses the pulsating UV light onto a mirror assembly. The
mirror assembly contains four selective mirrors that reflect only the
wavelengths that excite SO2molecules.
As the excited SO2molecules decay to lower energy states, they emit UV light
that is proportional to the total sulfur concentration in the sample. The
bandpass filter allows only the wavelengths emitted by the excited SO2
molecules to reach the PMT, which detects the UV light emission. The photo
detector, located at the back of the fluorescence chamber, continuously
monitors the pulsating UV light source to provide compensation for
fluctuations in the UV light source. The measured SO2concentration
(representing total sulfur in the sample) is processed, displayed on the front
panel display, and sent to the analog outputs.
Figure 2–2. Typical functional flowdiagram
Principle of
Operation