DPA-4.1 e 20071016 v4

Distillation Process Analyzer DPA-4.
1
Operating Instructions
Version 5
16.10.2007
Doc. No.: D3 1200 001 EM

Read these operating instructions carefully before installation and startup of the
instrument and observe the safety precautions. BARTEC BENKE cannot accept liability for
injuries or damages caused by failure to observe the operating instructions and safety
precautions.
We have checked the information in this document carefully to ensure its completeness
and correctness. However, as alterations may occur due to technical improvements, we
cannot accept liability for complete consistency. These operating instructions do not
constitute any obligation or guarantee of performance on the part of BARTEC BENKE.
These operating instructions were completed according to the specifications in ATEX

Directive 94/9/EC, Appendix II.
For translations of these operating instructions into other languages, the German version is
to be regarded as the original document.
If you have any problems or questions, please contact:
BARTEC BENKE GmbH

Borsigstraße 10
21465 Reinbek/Hamburg
Germany
Tel.: +49 (0) 40 - 72703 - 0

Fax: +49 (0) 40 - 72703 - 363
E-Mail: service@bartec-benke.de
© 2005 BARTEC BENKE GmbH, Reinbek. All rights reserved.
These operating instructions are subject to copyright laws. This document may not be
reproduced or transmitted, neither whole nor in parts, by any electronic, mechanical or
other means, without prior written permission from BARTEC BENKE GmbH. Nor is
production of the entire instrument or individual components permissible on the basis of
these operating instructions without our written approval.
Contents I
Contents
1 Introduction.........................................................................................3
1.1 Intended Use .......................................................................................................4
1.2 Analysis of Distillation Characteristics.................................................................4
1.3 Measuring Principle of the Distillation Process Analyzer ....................................5
2 Safety...................................................................................................7
2.1 General Safety Precautions ................................................................................8
2.2 Explosion Protection..........................................................................................12
3 Design and Function ........................................................................13

3.1 Overview............................................................................................................14
3.2 Media Conduction in the Analyzer.....................................................................16
3.3 Analyzer housing ...............................................................................................19
3.4 Control Unit........................................................................................................20
3.5 Functional Principle of Pressurized Enclosure System.....................................21
3.6 Explosion-proof chiller for liquids (optional) ......................................................21
3.7 Sample conditioning system (optional)..............................................................22
3.8 Further Options..................................................................................................23
4 Assembly, Installation and Disassembly........................................25

4.1 Safety 26
4.2 Transport ...........................................................................................................26
4.3 Intermediate Storage .........................................................................................27
4.4 Operating Area Requirements...........................................................................28
4.5 Installation .........................................................................................................28
4.5.1 Tubing Connections ...............................................................................29
4.5.2 Electrical Connections............................................................................31
4.6 Disassembly ......................................................................................................32
5 Initial Operation ................................................................................35

5.1 Safety during Startup.........................................................................................36
5.2 Checking Vent-Slop System and Recovery System .........................................37
5.3 Opening the Nitrogen Supply ............................................................................37
5.4 Opening the Cooling Water Supply ...................................................................38
5.5 Feeding In Product ............................................................................................38
5.5.1 Flushing the Product Feed Line .............................................................39
5.5.2 Preparing Sample Conditioning System (Optional) ...............................39
5.5.3 Feeding in Product .................................................................................41
5.6 Starting Up the Pressurized Enclosure System ................................................41
Version 4, 16.10.2007 Distillation Process Analyzer DPA-4.1

II
6 Operation .......................................................................................... 43
6.1 Switching on the Analyzer ................................................................................ 44
6.2 Switching off the Analyzer ................................................................................ 46
7 Maintenance and Troubleshooting................................................. 47

7.1 General Maintenance Instructions .................................................................... 48
7.2 Safety during Maintenance ............................................................................... 48
7.3 Routine Maintenance........................................................................................ 52
7.3.1 Visual Inspection of the Analyzer .......................................................... 52
7.3.2 Visual Inspection of the Analyzer Housing ............................................ 52
7.3.3 Maintenance Intervals and Tasks for Components............................... 55
7.4 Removing and Reinstalling the Distilling Flask................................................. 56
7.5 Cleaning the Distilling Flask.............................................................................. 60
7.6 Removing and Reinstalling the Heating Cartridges.......................................... 62
7.7 Cleaning the Condenser ................................................................................... 65
7.8 Servicing the Inlet-Valve and the Fill-Valve ...................................................... 69
7.9 Servicing the Flask-Valve ................................................................................. 73
7.10 Servicing the Receiver-Valve............................................................................ 76
7.11 Cleaning the Flame Arrester "Flamex Fuel" ..................................................... 79
7.12 Replacing a Fine Filter in the Sample Conditioning System (Optional) ........... 81
7.13 Replacing the Filter Element in the Water Separator ....................................... 82
7.14 Checking the Buret Dosing Volume.................................................................. 84
8 Troubleshooting............................................................................... 87
9 Technical Data.................................................................................. 91
9.1 Technical Data – Distillation Process Analyzer ................................................ 92
9.2 Technical Data – Control Unit Housing ............................................................ 95
Distillation Process Analyzer DPA-4.1 Version 4, 16.10.2007

Introduction 3
1 Introduction

4 Introduction
1.1 Intended Use
The Distillation Process Analyzer (DPA) is designed for automatic analysis of the distillation
characteristics of liquid petrochemical products at atmospheric pressure. Up to three
product streams, with one calibration stream each, can be connected to the online
analyzer. It is intended to monitor the quality of production in the process and also the
compliance with mandatory specifications for petrochemical products.
The Distillation Process Analyzer is technically laid out for analysis of the products specified
in the order. The system is intended exclusively for stationary operation in an analysis
building.
1.2 Analysis of Distillation Characteristics
The distillation characteristics of a liquid petrochemical product must be analyzed in order

to gather information about its behavior during use and storage. The DPA is designed for
monitoring and controlling the production process and the composition of blends, e.g. for:
• gasoline
• products used for petrochemical processes (e.g. naphta)
• aviation fuels (kerosene)
• fuel oil
• diesel
• paraffin products
• hydrocarbons with a maximum boiling point temperature below pyrolysis.
Analysis of the distillation characteristics of petrochemical products in the laboratory is

defined by national and international standards, for example:
• ASTM D-86
• DIN EN ISO 3405
• IP 123

Introduction 5
1.3 Measuring Principle of the Distillation Process

Analyzer
Distillation is a thermal separation process used to separate homogeneous mixtures

(solutions) of different liquids. During distillation, the original substance is heated. The
resulting vapor contains different components of the mixture, depending on the
temperature. The vapor is cooled in a condenser. The liquid condensate is collected.
In laboratory analysis, the distillation characteristics of a sample are determined according

to the standards listed in chapter 1.2. The analog Distillation Process Analyzer carries out
measurements automatically.
Flushing
At the start of the analysis cycle, the distilling flask is flushed and cooled down with fresh
product. The entire system which carries product is flushed.
Dosing / Gauging
With a buret (overflow container), a defined sample volume is measured out and the
density of the sample is analyzed. To do this, the sample is fed into the receiver. The
receiver is a container in which the hydrostatic pressure of the sample liquid column is
measured. Nitrogen is fed into the receiver from below at a low flow rate (bubbling-
through measurement). The pressure in the nitrogen feed line corresponds to the
hydrostatic pressure of the sample liquid column. From the measured pressure, the
density of the sample can be calculated for a known volume, and vice versa.
After the density measurement, another volume quantity of sample is measured out and
fed into the distilling flask.
Distillation
In the distilling flask, the sample is heated. As the temperature increases, the different
components of the sample evaporate slowly. The current vapor pressure is measured in
the head of the distilling flask. The vapor reaches the cooled condenser, where the vapor
precipitates. By means of a sensor (optional), the initial boiling point (i.e. the first liquid
drop at the condenser outlet, IBP) can be detected. The condensed sample flows into the
receiver, where the current volume is measured. When the distillation process is finished,
a new analysis cycle begins.

6 Introduction
Note: For a detailed description of the analysis cycle, please refer to the software
manual.
The analyzer is controlled, monitored and visualized with the aid of the PACS (Process
Analyzer Control System) process software. The results are transmitted via analog outputs.
A digital output indicates whether the measuring results are valid. The following results
can be transmitted (partly optional):
• initial boiling point (IBP)
• final boiling point (FBP)
• vapor temperature at a defined recovery rate (%) and vice versa
• % of loss, calculated as input volume minus % of recovered volume
• any combination of the results above
• any calculable parameter or correlation which is based on distillation or boiling points

and other variables, for example:
• Calculated Cetane Index according to ASTM D-976
• % of evaporated components
Further outputs are available as an option, as well as a MODBUS interface which also
allows to control the analyzer. An optional remote maintenance interface (e.g. analog
modem, ISDN) can be supplied for diagnosis, maintenance, and service purposes.

Safety 7
2 Safety

8 Safety
2.1 General Safety Precautions
The following safety instructions are mandatory for all tasks on the Distillation
Process Analyzer and must be followed at all times! In addition, also observe
the safety instructions in the supplied operation manuals of all built-in
equipment and components!
Furthermore, always follow the company's safety regulations and the particular safety
procedures for explosive areas!
In addition to the safety instructions in this manual, it is necessary to observe and follow
the current legal regulations for general safety and accident protection. Please also
observe the presently applicable regulations on “Environmental protection and noise
protection”.
In addition to the safety precautions described here, the safety precautions listed
separately in the individual chapters also apply.
The analyzer may be started up, operated, serviced and/or repaired only by personnel
trained by the operator or by BARTEC BENKE GmbH. The analyzer can pose hazards when
not operated and/or serviced properly by trained personnel. It can present an accident risk
as a result of operating errors.
Observe the safety and hazard information on the analyzer and keep them in a legible
state. Immediately replace warning plates which have been damaged or are missing.
Ensure that the operating personnel working with the analyzer has been instructed
regarding possible hazards when operating the analyzer.
The analyzer is equipped with safety and protective devices based on the present state of
the art and applicable laws. It is the responsibility of the operator to ensure that the
analyzer is operated only in a technically safe, proper and functional condition as intended
under observance of these operating instructions.
If the original state of the safety equipment (e.g. protective covers or changes in explosion
hazard area) changes during operation ensure that the analyzer is properly shut down
immediately and secured against being started up improperly.
Never start up an analyzer which is not functionally safe or on which the safety devices are
not operating properly! Never remove or circumvent safety and protective devices or
render them ineffective or inoperative!
It is not permissible to make any technical modifications to the analyzer without written
authorization from BARTEC BENKE. Any unauthorized modification can impair the safety of
the analyzer and lead to accidents.

Safety 9
Caution!
An explosive atmosphere can be a danger to your life!
Before you switch on the analyzer, and while the analyzer is operating, make
sure (e.g. by de-airing the lines carefully) that the product feed lines and all
lines carrying product contain only the specified product. Also make sure
that the product properties correspond to the specification defined at the
time of ordering the analyzer.
Make sure that no other gases (e.g. hydrogen or nitrogen used by other
analyzers) and no other vapors or liquids can reach the analyzer through the
vent-slop-system.
While the EEx p system is under electric current, it must be opened by
specially qualified and instructed personnel only! To do this, a hot-work
permit is strictly required!
The EEx d housing contains components which will heat up during
operation. Before opening the housing, wait for 30 minutes after switching
off the analyzer.
Keep the door of the EEx p cabinet closed during operation and also for 5
minutes after switching off the voltage to allow electric charges and high
temperatures to dissipate. The closure of the EEx p cabinet is secured with a
screw.
Follow the safety regulations for explosive areas at all times!
When performing work with the purging universal system switched off (key
switch “Explosion Protection On - Off” in position “Off”), take suitable
measures to ensure that the development or presence of an explosive
atmosphere is recognized within due time! If a hazard from an explosive
atmosphere exists, IMMEDIATELY switch off the circuit breaker or main
switch for the Distillation Process Analyzer!
Never replace the nitrogen with a different gas, e.g. pressurized air.
In case of a faulty lithium battery of the industry standard PC: The battery
should be replaced by an identical spare part. Please notice the user manual
of the PC.
In order to avoid electrostatic charge and spark formation, use only a damp
cloth to clean the window in the main door of the EEx p cabinet.

10 Safety
Caution!
Electric currents can be a danger to your life!
The Distillation Process Analyzer contains components under electrical
power. Work on these components may be performed only by qualified
personnel trained specifically for this purpose!
Before starting work on electrical components, always observe the
5 safety rules of electrical engineering:
1. Disconnect.
2. Secure to prevent the system from being switched on again.
3. Ascertain that the system is not live.
4. Earth and short-circuit the system.
5. Cover or cordon off any neighboring live parts.
The analyzer must not be operated without protective earthing!
Caution!
Pressurized nitrogen can be a danger to your life!
The analyzer contains lines and components carrying nitrogen. Some of
these lines are pressurized. Work on these lines may be performed only by
qualified personnel trained specifically for this purpose!
Before starting work on pressurized components, ensure that the system is
depressurized. Do not loosen or tighten any pipe connections as long as the
equipment is under pressure. If work on pressurized systems is carried out
improperly, this can lead to serious accidents!
To avoid the risk of suffocation by nitrogen, ensure that the room is
sufficiently ventilated. Always wear your personal protective equipment
when working on lines carrying nitrogen!
Caution!
Compressed air can cause serious injuries!
The EEx p system contains compressed air pipes and components. Work on
compressed air systems may only be carried out by specially qualified and
instructed personnel!
Always wear your personal protective equipment, especially protective
goggles!

Safety 11
Caution!
Pressurized chemicals and poisonous vapors can be harmful to your
health!
The product can escape from the Distillation Process Analyzer or the sample
conditioning system, and volatile constituents in the product can evaporate.
The product and its vapor can form an explosive gas mixture if in contact
with air, can be highly flammable, poisonous, harmful to your health, and
may cause skin irritation! For more detailed information on hazards and
further safety precautions, refer to the safety data sheet and the safety
instructions for the product.
Some of the lines and components carrying product are pressurized. Do not
carry out work on lines or components while they are pressurized. This can
lead to serious accidents!
When working on lines and components carrying product, always wear eye
protection, suitable protective gloves and protective equipment suitable for
the product! Observe the safety data sheets and safety precautions for the
product!
Caution!
Chemical detergents can be harmful to your health!
Detergents and solvents used to clean the analyzer and its components can
be dangerous. The detergent or solvent and its vapor can form an explosive
gas mixture if in contact with air, can be highly flammable, poisonous,
harmful to your health, caustic, and may cause skin irritation! For more
detailed information on hazards and further safety precautions, refer to the
safety data sheet and the safety instructions for the detergent or solvent.
When handling these chemicals, always wear eye protection, suitable
protective gloves and protective equipment suitable for the chemicals!
Observe the safety data sheets and safety precautions for the detergent or
solvent.
Caution!
Hot surfaces can cause serious injuries!
operation. If you must touch any components, wait for at least 30 minutes
after switching off the analyzer before you open the housing. Please follow
the instructions and the warning notices on the labels. Before touching a
component, check that the component has cooled down sufficiently. Always
wear protective gloves and your personal protective equipment when
performing maintenance work!

12 Safety
2.2 Explosion Protection
The liquid hydrocarbon mixtures which can be analyzed with the aid of the Distillation
Process Analyzer are classified in explosion category IIA.
In terms of explosion protection, the Distillation Process Analyzer is built according to the
latest knowledge and standards in the European Union and represents a protective system
for intended use in explosion hazard areas. The Distillation Process Analyzer complies with
the requirements of the following flame protection class:
• II 2 G EEx dp IIA, IIB or IIB+H2 T5
• or II 2 G EEx dp[ib] IIA, IIB or IIB+H2 T5
The component tested parts of the Distillation Process Analyzer and their respective flame
protection classes are listed below:
Component Flame Protection Class
Analyzer housing (EEx d) II 2G EEx d IIC

Control unit housing (EEx p) II 2G EEx p II T4
Line duct type A2F II 2G EEx d/e IIC
Junction box (EEx e) II 2G EEx e II T6 or II 2G EEx e [ia] IIC T6
Differential pressure transmitter II 2G EEx ia IIC T6
Level-Valve II 2G EEx ia IIC T5
Bartec cradle relay II 2G de IIC
Sensor module II 2G EEx ib IIC T4/T6
Overpressure control system EEx p II 2G EEx ed ib [iap] IIC T4/T6
Bypass-Valve II 2G EEx m II T4/T5 orII 2G EEx me II T4/T5
Bartec Ex fuse II 2G EEx de IIC
Optional : Ex transformer EEx e II T4
Safety barriers EEx [ia/ib] IIC
Flame arrester "Flamex Fuel" II 2G EEx d IIA; IIB
Caution!
Never perform any unauthorized modifications to the Distillation Process
Analyzer. Modifications not carried out by authorized personnel can lead to
personal injury and property damage and endanger the ATEX approval
certificate for the equipment.

Design and Function 13
3 Design and Function

3.1 Overview
The following figure shows an overview of the Distillation Process Analyzer:
12 B 13 9 10
2 5
6
13
A 7
F
8
14
1
11
4
D
C
Fig. 3.1: Overview of the Distillation Process Analyzer

1 Frame A Product inlet
2 Analyzer housing (EEx d) B Vent
3 Control unit housing (EEx p) C Slop
4 Junction box (EEx e) D Instrument air inlet for
5 Display overpressure control system with
6 Mouse maintenance unit
7 Overpressure control display E Nitrogen inlet for analyzer with
8 Key switch maintenance unit
9 Transport eye F Connections for cooling water
10 Differential pressure transmitter
11 Receiver
12 Buret
13 Flame arrester
14 Nitrogen flow control

The pressure-resistant casing for the analyzer (2) contains the main components of the
measuring system.
The pressurized housing (3) contains the analyzer control unit, die overpressure control
system, and, if present, the control unit for the optional explosion-proof chiller for liquids.
The junction box (4) contains the power supply terminals for input and output signals.
You operate the analyzer with the display (5) and the mouse (6).
The overpressure control display (7) provides information on current operating states and
parameter settings of the overpressure control system.
By means of the key switch (8) ("bypass switch"), you can activate or deactivate the
explosion protection (overpressure monitoring) for the pressurized control unit
housing (3).
By means of the differential pressure transmitter (10), you can determine the volume or
density of the sample in the receiver (1).
In the buret (12), the sample is gauged.
The flame arresters (13) ensure that an event (explosion, deflagration) inside the analyzer
housing (2) cannot be carried outside the housing.
The following options are not shown:

• Sample conditioning system
• Explosion-proof chiller for liquids
• Validation system
• Cooling of the control unit housing
• Recovery system
• Automatic sampling
• Automatic product stream switching
• Trace heating

3.2 Media Conduction in the Analyzer
19 12 7 28 8 5
29
25
27 15 16
14
26
9
23 10
11 17
24
13 3
29
4
22 21
18 20
1
2
Fig. 3.2: Media Conduction in the Analyzer

1 Product inlet 16 Water-Valve

2 Bypass-Valve 17 Initial boiling point sensor
3 Analyzer housing (optional)
4 Slop 18 Receiver
5 Vent 19 Differential pressure transmitter
6 Inlet-Valve 20 Receiver-Valve
7 Fill-Valve 21 Nitrogen inlet
8 Buret 22 Nitrogen maintenance unit
9 Distilling flask 23 Nitrogen pressure switch
10 Heating cartridges 24 Nitrogen flow control
11 Temperature sensors at bottom of 25 Level-Valve
flask 26 Pilot valves
12 Vapor temperature sensor 27 Condenser cleaning
13 Flask-Valve 28 Component water cooler
14 Condenser (optional)
15 Cooling water temperature sensor 29 Flame arresters
The product is fed into the analyzer at the product inlet (1). Via the Bypass-Valve (2) the
product is channeled either through the analyzer housing (3) or to the slop (4). The
system which carries product is ventilated through the vent (5).
By means of the Inlet-Valve (6), the product feed line into the analyzer housing is opened
or closed. The Fill-Valve (7) directs the product stream into the buret (8) or into the
distilling flask (9).
By means of the buret (8), a defined product volume can be measured out.
In the distilling flask (9), the sample is evaporated. The flask is heated by heating
cartridges (10). The temperature at the bottom of the flask is controlled by two
temperature sensors (11). In the upper part of the flask, a temperature sensor (12)
measures the vapor temperature. During the heating phase, the sample is agitated by
nitrogen in order to avoid delay in boiling. The Flask-Valve (13) allows to empty the
distilling flask (9) during flushing.
In the condenser (14), the vapor precipitates. The temperature sensor (15) measures the
temperature of the cooling water in the condenser, which is controlled by the valve (16).
An optional sensor (17) allows to detect the initial boiling point (IBP).
The condensate now flows into the receiver (18). The receiver is a container in which the
hydrostatic pressure of the sample liquid column is measured. Nitrogen is fed into the
receiver from below at a low flow rate (bubbling-through measurement). The pressure in
the nitrogen feed line, which is measured by means of the differential pressure
transmitter (19), corresponds to the hydrostatic pressure of the sample liquid column.
From the measured pressure, the volume of the sample can be calculated for a known
density, and vice versa. The receiver can be emptied by means of the valve (20).
The analyzer is supplied with nitrogen via the nitrogen inlet (21) and the maintenance
unit (22). The pressure switch (23) allows to monitor whether the nitrogen supply and
pressure is sufficient. The nitrogen stream required for agitating the sample in the distilling
flask, and for measuring the pressure in the receiver, is controlled via the flow

control (24). The valve (25) directs the nitrogen flow either into the distilling flask (9) or
into the receiver (18).
By means of the pilot valves (26), the pneumatic valves (6), (7), (13) and (20) are
actuated with nitrogen.
Before distillation starts, nitrogen is fed into the condenser via the purging connection (27)
in order to flush out any remaining sample.
Optionally, depending on the product that is analyzed, the buret, the receiver and the
vent-slop-line (28) are cooled.
The flame arresters (29) ensure that an event (deflagration or explosion) inside the
pressure-resistant casing cannot be carried outside the casing.

3.3 Analyzer housing
The following figures show the components inside the analyzer housing:
8
4
6
2 10
9 11
7
Fig. 3.3: Inside of analyzer housing
Fig. 3.4: Opened distilling flask housing

1 Distilling flask 6 Cooling water temperature sensor

2 Distilling flask housing 7 Inlet-Valve
3 Heating cartridges and 8 Fill-Valve
temperature sensors at bottom 9 Flask-Valve
of flask 10 Pilot valves
4 Vapor temperature sensor 11 Pressure switch for N2-supply
5 Condenser
3.4 Control Unit
The control unit housing (EEx p) contains all electrical and electronic components which
are needed to control the Distillation Process Analyzer. These are, for example:
• Industry standard PC (Analyzer Control Unit) running the PACS Software, which
provides the user interface, controls and monitors all processes, and handles
external communication.
• Controller and components for the overpressure control system of the housing
• I/O board for processing internal and external digital and analog inputs and
outputs
• Power supply units
• Transformers to adapt the power supply voltage for the Distillation Process
Analyzer
• Controller components for the explosion-proof chiller for liquids (optional)
• Automatic circuit breakers, motor protection switches and error relays, filters,
and contactors
• Measuring transmitters and amplifiers
• Cooler for the housing (optional)
Note: For a detailed description of the analysis cycle, please refer to the software
manual.

3.5 Functional Principle of Pressurized Enclosure

System
The capsule design in conjunction with the protective gas, "instrument air", allows
components which are not explosion-proof to be used inside the housing.
In order to prevent an explosive mixture from entering the interior of the housing, the
pressure inside must be higher than the surroundings. A controller takes care of building
up and maintaining the necessary operating pressure inside the control unit housing.
When the pressure of the instrument air inside the housing falls below a defined value, the
safety system, a combination of a pressure monitor and a controller, operates to switch off
all electrical operations inside the housing and to separate all external signal connections
(DI, DO, AO, Modem) using the EEx-d cradle relay.
Before each instrument start, the interior is flushed with instrument air. During this
process the controller initiates a purging cycle with a defined minimum of air so that any
traces of explosive gas previously inside the housing are diluted and expelled. The digital
valve is opened for a configurable period of time.
To maintain the overpressure inside the electronic housing and to compensate for possible
leaks during operation, an adjustable needle valve (continuous feed) is used. This valve
allows sufficient instrument air to pass so as to make up for leakage losses. The needle
valve and the digital valve are integrated into one assembly.
By means of the key switch, you can activate or deactivate the explosion protection
(overpressure monitoring) for the pressurized control unit housing for servicing purposes.
To do this, a hot-work permit is strictly required!
Note: For further information on the function of the overpressure system, please
refer to section 5.6 and to the separate manufacturer’s manual.
3.6 Explosion-proof chiller for liquids (optional)
For smooth operation, the Distillation Process Analyzer requires clean cooling water with a
defined temperature (depending on the product to be analyzed). An appropriate
Explosion-proof chiller for liquids is available as an option. For more detailed information
on the explosion-proof chiller for liquids, please refer to the corresponding separate
operation manual.

3.7 Sample conditioning system (optional)
The sample conditioning system is located on a stainless steel front panel below the
combination cabinet. The standard sample conditioning system consists of the following
components listed here in the sample flow direction:
• Inlet valve
• Pressure reducer
• Laboratory sampling point
• Pressure gauge
• Fine filter
• Heat exchanger
• Thermometer
• Water separator (coalescer)
• Product flow meter
• Flow meter for water separator outlet
• 3/2-port directional control valve for validation product
Fig. 3.5: Sample conditioning system (exemplary layout)
Note: The description given here refers to the standard system. For a detailed
description of your sample conditioning system, please refer to the technical
documents supplied!

3.8 Further Options
Automatic sampling
The analyzer can be equipped with additional valves, switches and sensors which allow
automatic taking of samples. The PACS process control software controls the sampling
system, which fills a sampling container with a sample of the current product on request.
Cooling of the control unit housing
In order to avoid abnormally high temperatures in the inner chamber of the control unit
housing at a high ambient temperature, the analyzer housing can be equipped with a
cooler, e.g. a Vortex cooler.
Automatic stream switching
To allow the switching of streams, the analyzer can be equipped with additional valves.
These are controlled via the PACS process software.
Validation system
For validating the analyzer, it can be equipped with a tank. Product switching is carrried
out via valves which are controlled by the PACS process control software.
Recovery system
A recovery system collects the product which flows into the slop line of the analyzer, for
further processing. The system consists mainly of a container, a pump, valves, sensors
and a separate control unit.
Trace heating
For certain products, it is necessary to equip the lines and components that carry product
with electrical trace heating in order to avoid solidification and clogging of the lines.


Assembly, Installation and Disassembly 25
4 Assembly, Installation and

Disassembly

26 Assembly, Installation and Disassembly
4.1 Safety
Ensure that the equipment is set up and put into operation according to the
following rules and regulations:
• national and international safety regulations
• regulations for the prevention of accidents
• assembly and construction regulations (e.g. IEC 60079-14)
• generally recognized rules of engineering
• safety precautions in these operating instructions
• data on the rating plates
• data on additional information plates
Caution!
Damage to the system or its components can impair the explosion
protection! Therefore, always ensure that the system is not damaged during
transport, assembly and installation!
4.2 Transport
The analyzer is delivered in a packing unit which, unless specified otherwise in the
contract, satisfies the packing guidelines of the German Federal Society for Wood, Pallet
and Export Packaging.
Check the delivery for completeness on the basis of the delivery slip immediately after
receipt, and check the analyzer for any external damage before removing the packing.
Note: Report any damage or shortage immediately in writing to the transport

company and to BARTEC BENKE. Claims can only be considered for settlement
if they are reported immediately to BARTEC BENKE GmbH.
Caution!
Standing under a suspended or supported load is dangerous!
When loading and transporting the analyzer, make sure that suitable lifting
tackle is used! The lifting machinery must be capable of supporting the load.

A ring screw is provided in the upper part of the carrying frame for transport of the
analyzer with a crane or hoisting equipment. After attaching the transport belt, ensure that
it is attached tightly to prevent damage from concussions when unloading.
To move the analyzer across short distances, suitable lifting machinery can be used. Only
the lower frame is appropriate for lifting the analyzer. Please consider the substantial
weight of the analyzer, and the asymmetrical distribution of its weight. Due to its high
center of gravity, the analyzer may topple over. Therefore ensure that the analyzer does
not overbalance during transport. To prevent the analyzer from slipping, use intermediate
layers of wood.
Remove the packing on the system carefully at the installation site and dispose of it in an
environmentally sound manner. Pay attention to the notes on the packing material.
4.3 Intermediate Storage
The analyzer is delivered ready for installation. If it is necessary to store the system
intermediately before installation, make sure that it is kept in the closed transport packing
in a dry place. Furthermore, there must be no large temperature variations and no strong
vibrations in the storage area.
Note: Damage due to incorrect storage is not covered by the BARTEC BENKE terms
of warranty.

4.4 Operating Area Requirements
The analyzer is intended exclusively for stationary operation in a weather-protected

analysis building.
For information on environmental conditions at the operating location, please refer to the
technical data in this manual.
The analyzer building must be ventilated sufficiently. For better maintenance, the analyzer
shelter should be equipped with heating or air-conditioning facilities.
The operating area must be selected to provide adequate lighting at the front and the
sides of the system. Good lighting is essential for identifying and correcting malfunctions
quickly, and for carrying out maintenance tasks.
Moreover, when installed against a wall, the analyzer must remain accessible from the
front and from the left and right sides to ensure unimpeded access for later maintenance
or disassembly work. Observe the external dimensions of the system, so as to ensure
sufficient clearance around it (see also the supplied technical diagrams and
documentation). The floor in the operating area must be even and level, and capable of
supporting the weight of the analyzer.
A line power connection with the appropriate fusing must be available in the vicinity.
During startup and operation, please also observe the applicable regulations for
environmental protection and avoiding noise.
4.5 Installation
Note: This manual contains the information necessary to install and use the analyzer.
However, it is not a substitute for training by the BARTEC BENKE GmbH service
and training personnel before initial operation.
To install the analyzer, proceed as follows:
Align the analyzer horizontally and fasten it with four M 12 mounting bolts. Note that the
slop outlet connection on the analyzer must be higher than the highest inlet point on the
slop line of the analyzer building.

4.5.1 Tubing Connections
Caution!
Make sure that the product feed lines can contain only the specified product,
and that the product properties correspond to the specification defined at
the time of ordering the analyzer.
vent-slop-system.
Caution!
Caution!
The analyzer contains lines and components carrying compressed air. Work
on compressed air systems may only be carried out by specially qualified
and instructed personnel!
goggles!

Caution!
health!
The product can escape from the analyzer or the sample conditioning
system, and volatile constituents in the product can evaporate.
product!
The pipelines leading to the system must be laid as shown in the setup plan. For particular
information on connection assignment, connection types, and pipe diameters, please refer
to the installation diagram. All feed lines must be equipped with a manual shut-off valve.
The vent and slop lines must be pressure-free and open to the atmosphere. Make sure
that the lines always run downwards to the slop. Do not use pipes and connections with a
smaller diameter than the minimum stated in the supplied installation diagram.
Make sure that the minimum bending radius is observed for all pipes, and that there are
no kinks.
Before starting up pressurized equipment, check all pipe connections for leakage and
ensure that all incoming pipelines to be connected to the system are free of contamination
and metal chips.

4.5.2 Electrical Connections
Caution!
To install the electrical connections, a hot-work permit is strictly required!
Caution!
1. Disconnect.
All important information for installation can be found in the supplied electrical
documentation and in the wiring diagram.
Before starting work, make sure that the voltage of the power supply matches the
required voltage shown on the instrument type plate. If this is not the case, please contact
BARTEC BENKE immediately.
All external cable connections (analyzer power supply, measuring and signal outputs) must
be permanently wired in the junction box according to the supplied wiring diagram. Make
sure that only screened cable (single screening) is used for control connections. Check the
polarity of the signal cables.
The analyzer must be incorporated in the local equipotential bonding using

cable with at least 16 mm2 cross section.
Use only cable passages present on the cabinet.
Connect the power and signal cables according to the information in the wiring diagram.
Replace the protective covers on the terminals and close the junction box.

4.6 Disassembly
Caution!
Danger to your life!
Disassembly of the system must be carried out expertly by specially qualified
Always observe all safety precautions in Section 2 before and during work!
Before starting disassembly ensure that the system is switched off.
Removing Electrical Connections
Caution!
1. Disconnect.
• Make sure that all fuses at the main terminal have been removed or switched off and
secured, so that the system cannot be switched on accidentally.
• Remove the electrical connections and cable connections, as specified in the specific
connection and wiring diagrams.

Removing Tubing Connections
Caution!
The analyzer contains lines and components carrying compressed air. Work
on compressed air systems may only be carried out by specially qualified
goggles!
Caution!

Caution!
health!
product!
• Before starting work, make sure that all feed lines carrying compressed air or nitrogen
are depressurized!
• Make sure that the manual shut-off valve at the inlet to the analyzer / sample
conditioning system is closed and secured so that it cannot be opened accidentally!
Check the flow indicators and pressure gages to make sure that the product flow has
stopped.
• Remove the tubing connections, as specified in the supplied installation diagram.
Transport and Intermediate Storage
Note: For safe transport and intermediate storage, please observe the safety notes in
sections 4.2 and 4.3.
Disposal
• Make sure that the system is disposed of in an environmentally sound manner.

Observe the national and local regulations.

Initial Operation 35
5 Initial Operation

36 Initial Operation
5.1 Safety during Startup
Caution!
sure (e.g. by deairing the lines carefully) that the product feed lines and all
vent-slop-system.
off the analyzer.
Before opening Ex cabinets, observe the safety regulations in
DIN EN 60079-14.
Caution!
Risk of injury!
The cover on the analysis cabinet is not always fastened with hinges. When
loosened, it poses an injury hazard!
When opening the cabinet cover, always use the handles present and hold
on to the cover tightly.

Note: We recommend to have the system put into operation by BARTEC BENKE
service personnel, and to have your operators and maintenance staff instructed
and trained by BARTEC BENKE.
Note: To put the explosion-proof chiller for liquids into operation, please observe the
operating instructions delivered with the instrument. For the target
temperature of the thermostat, please refer to the supplied floor plan.
5.2 Checking Vent-Slop System and Recovery System
• Ensure that the vent-slop system and the recovery system, if installed, are ready for
operation.
5.3 Opening the Nitrogen Supply
• Make sure that the nitrogen supply inlet of the analyzer is connected to nitrogen, and
not to any other gas (e.g. pressurized air).
Make sure that the nitrogen satisfies the specifications (see technical data).
Open the nitrogen supply inlet to the analyzer.
• Using the pressure regulator at the maintenance unit (see pos. E in section 3
"Overview"), adjust the operating pressure to the specified value.
• Using the flow control (see pos. 14 in section 3 "Overview"), adjust the nitrogen flow
rate to the specified value.

5.4 Opening the Cooling Water Supply
Note: To put the optional explosion-proof chiller for liquids into operation, please
observe the operating instructions delivered with the instrument. Shut-off
valves are located on the water supply and return lines between chiller and
analyzer housing. For the target temperature of the thermostat, please refer
to the supplied floor plan.
• Make sure that the cooling water corresponds to the specifications (see technical data
in this manual and floor plan).
• Open the shut-off valves for the cooling water.
• If a flow meter with needle valve is supplied: Set the required flow rate by means of
the needle valve. Otherwise, set the required flow rate at the intended point. For the
target flow rate, please refer to the supplied floor plan. The system should
automatically be de-aired after a short interval.
• Check the water temperature. For the target temperature, please refer to the supplied
floor plan.
5.5 Feeding In Product
Caution!
health!
product!

Note: The product can be supplied without the analyzer being switched on.
• Make sure that the product satisfies the specifications (see technical data).
• Product pressure at inlet
• Product flow rate
• Product temperature
5.5.1 Flushing the Product Feed Line
Before the analyzer is put into operation, or after maintenance work on the product feed
line or on the sample conditioning system have been carried out, the feed line must be
flushed with product and de-aired.
• Make sure that the manual shut-off valve in the product feed line is closed, otherwise
close it.
• Open the screw connection that connects the product feed line to the analyzer (A in
Fig. 3.1) or, if present, to the optional sample conditioning system (1 in Fig. 5.1), and
remove any leaking product.
• Install a collect vessel at the end of the open feeding line.
• Carefully open the manual shut-off valve upstream of the sample inlet and make sure
that the sample is collected into the vessel.
• Flush the sample line with product until you are sure that that any possible dirt,
particles or other types of contamination is removed.
• Close the shut-off valve upstream of the sample inlet.
• Reconnect the product feed line to the analyzer or, if present, to the optional sample
conditioning system. Make sure that the connection is leakproof.
5.5.2 Preparing Sample Conditioning System (Optional)
If the analyzer is equipped with an optional sample conditioning system, put this system
into operation as follows (only required before first operation or after maintenance work,
e.g. filter change):

• Ensure that the sample conditioning system is ready for operation (check filter
elements, etc.). Please also read the supplied technical documentation and operation
manuals for the components of the sample conditioning system.
• Open the shut-off valve upstream of the sample inlet.
3 2 1
5 6 7 8 9 10 4
Fig. 5.1: Sample conditioning system (exemplary layout)
Note: The delivered sample conditioning system may be different to the described
one. In case of doubt please consult BARTEC BENKE.
• Open the inlet valve (2) of the sample conditioning system, and turn the knob at the
pressure reducer (3) clockwise to adjust the pressure. Ensure that the pressure does
not exceed 6 bar during the adjustment. The required setting is specified on the label
that is located near the pressure gauge (4). While the sample is flushing the sample
conditioning system (this will take a couple of minutes) the pressure may fluctuate.
• Adjust the needle valves (5) and (6) and, if present, the needle valve (7) for the
coalescer (8). The settings are specified on the related labels. The adjustment may
affect the pressure adjustment. In this case readjust the pressure and flow alternately
until all readings are satisfactory.
• Flush the sample conditioning system for about 5 minutes. In the case that a second
fine filter (9) is installed (the second fine filter serves a spare for quick filter change)
switch over the valves for flushing it after half of the time.

• After flushing, check the gauges again and , if necessary, readjust the settings. Check
the temperature of the sample indicated by the thermometer (10).
5.5.3 Feeding in Product
• Open the shut-off valve upstream the sample inlet (if it is not yet open).
• Ensure that the parameters specified on the rating plate and on other information
plates are maintained:
• Product pressure at inlet
• Product flow rate
• Product temperature
5.6 Starting Up the Pressurized Enclosure System
When starting up the analyzer, always observe the operating instructions for
the EEx p cabinet and the instructions given there for starting up the
pressurized enclosure system!
To start up the pressurized enclosure system, proceed as follows:
• If intrinsically-safe operating equipment which is not part of the analyzer (e.g. for
signal transfer) is supplied with power from the cabinet, ensure that all capacities and
inductivities are below the specified limits.
• Ensure that all transport packaging inside the cabinet has been removed, and that all
transport arrests for the components and built-in devices have been released.
• Make sure that the instrument air satisfies the specifications (see technical data).
• Using the pressure regulator at the maintenance unit (see pos. D in section 3
"Overview"), adjust the operating pressure to the specified value.


Operation 43
6 Operation

44 Operation
6.1 Switching on the Analyzer
Caution!
vent-slop-system.
off the analyzer.
DIN EN 60079-14.

Operation 45
Caution!
1. Disconnect.
To switch on the analyzer, proceed as follows:
• Ensure that instrument air, nitrogen and product correspond to the technical data
specified in the appendix and that the pressure reducers and flow controls are
adjusted as specified on the related labels. Readjust them if necessary.
• Ensure that all circuit breakers, ground fault switches and, where applicable, motor
protection switches in the control unit housing are switched on.
• Close the door of the control unit housing. Ensure that the door gasket is seated
properly and that all locks are closed.
• Move the key-operated switch in the main door on the control unit housing to the
"ON" position and remove the key before leaving the system.
• Switch on the circuit breaker or main switch in the electric distribution for the analyzer
in the analysis building.
• This starts the purging cycle in the control unit housing.
• The system-specific purging time is specified on the rating plate. The remaining purge
time is indicated in the sensor module display on the main door for the control unit
housing. During the purging cycle, all electrical equipment that does not meet the
specification of the required protection class remains switched off. The analyzer is not
yet ready for operation during this purging phase.
• When the system has completed the purging cycle, the power supply in the control
unit housing is switched on. The analyzer is started automatically, the computer boots
and the operating system as well as all applications are started.

46 Operation
• After the PACS process software has started by itself, measurement is started
automatically as a rule.
The analyzer is now ready for operation.
Note: The entire analysis sequence is controlled, monitored and evaluated with the
aid of the PACS (Process Analyzer Control System) process software. A detailed
description of the process sequence and a list of the parameters is given in the
enclosed software manual for the PACS process software.
6.2 Switching off the Analyzer
To switch off the analyzer, proceed as follows:
• In the process software PACS, select File – Exit in the menu and click on the
Shutdown button. For further information, please consult the PACS software manual.
The computer for data analysis is shut down.
Note: If there is no optional product inlet valve installed which can be controlled by
the PACS process software, the product flow through the Bypass-Valve will
remain open.
• In the junction box of the analyzer shelter, switch off the main fuse or main control
switch for the analyzer.
• If you want to carry out maintenance or repair work on the analyzer, always observe
the 5 safety rules of electrical engineering:
1. Disconnect.
The analyzer is now switched off.
• If required, you can now stop the product flow and the purging air and nitrogen
supply.

Maintenance and Troubleshooting 47
7 Maintenance and Troubleshooting

7.1 General Maintenance Instructions
Note: We recommend having the entire system serviced by BARTEC BENKE at least
every 2 years!
If the maintenance work is not accomplished by trained personnel from the
manufacturers during the guarantee phase, it is necessary to note that claims
against the manufacturer for subsequent damage resulting from irregular
and/or improper maintenance work, as specified in this manual, are voided.
Use only original spare parts supplied by BARTEC BENKE!
Always keep the operating instructions together with all other technical documents and
circuit diagrams included with the equipment in the vicinity of your system to allow any
problems which could occur to be solved quickly.
If the system is equipped with an optional Explosion-proof chiller for liquids, please refer
to the supplied operation manual for maintenance.
7.2 Safety during Maintenance
Caution!
Danger to your life!
Always observe all safety precautions in section 2 before and during
maintenance work!
All maintenance tasks must be carried out expertly by specially qualified and
instructed personnel! To do this, a hot-work permit is strictly required!

Caution!
vent-slop-system.
off the analyzer.
DIN EN 60079-14.

Caution!
1. Disconnect.
Caution!
Caution!
The EEx p system contains compressed air pipes and components. Work on
compressed air systems may only be carried out by specially qualified and
instructed personnel!
goggles!

Caution!
health!
product!
Caution!
solvent.
Caution!

7.3 Routine Maintenance
Routine maintenance tasks should be planned by means of a maintenance plan and be

documented in a suitable way.
7.3.1 Visual Inspection of the Analyzer
We recommend to carry out a daily visual inspection of the analyzer. The following
aspects should be checked:
• Parameter values of product and auxiliary substances (pressures, temperatures,
flow rates, liquid levels) which can be read in the instrument displays or
observed by other visual means. The target value ranges can be found on the
respective information plates.
• Leakages
• Exterior damage
• Error messages from the PACS process control software (see software manual)
• Plausibility of the displayed information in the PACS process control software
(see software manual)
7.3.2 Visual Inspection of the Analyzer Housing
We recommend to carry out monthly checks for leakages inside the analyzer housing. To
do this, proceed as follows:
• Switch the analyzer to the process step "Ready". For further information on
preparatory steps for maintenance, please refer to the software manual.
• Switch off the analyzer, as described in section 0.

Caution!
1. Disconnect.
Caution!
health!
product!
Caution!

Caution!
Caution!
Risk of injury!
• Open the analyzer housing.
• If there are leakages, stop the product flow and the nitrogen and cooling water
supply.
• Remove the cause of the leakage.
Caution!
solvent.

• Carefully remove all traces of product, cooling water, solvents and detergents.
• Close the analyzer housing.
You can now switch the analyzer back on, as described in sections 5 und 6.
7.3.3 Maintenance Intervals and Tasks for Components
Some analyzer components require regular maintenance. The maintenance intervals may
vary considerably, depending on the analyzed product and on whether distillation is carried
out to the final boiling point. The intervals given below are intended as a general
overview. In case of malfunctions before the end of an interval, the intervals should be
shortened appropriately.
Maintenance Tasks Maintenance Interval

Clean the distilling flask every 6 months in case of gasoline and if
distillation is carried out to the final boiling
point
Clean the condenser every 12 months
Clean the flame arresters every 12 months
Replace the heating cartridges every 24 months
Service the Flask-Valve and the Receiver- every 24 months
Valve
Change the filter element of the fine filter in depending on product type and amount of
the optional sample conditioning system particles in the product
Change the filter element of the coalescer in depending on water content and on type
the optional sample conditioning system and amount of particles in the product

7.4 Removing and Reinstalling the Distilling Flask
For maintenance, you will need a gasket set (see spare parts list) which comprises all
required gaskets.
To remove the distilling flask, proceed as follows:
• Stop the nitrogen supply and the product flow into the analyzer.
Caution!
1. Disconnect.

Caution!
health!
product!
Caution!
Caution!

Caution!
Risk of injury!
1 A B
Fig. 7.1: Removing and Reinstalling the Distilling Flask
• Remove the connectors (A) and (B) from the terminal strips.
• If you also want to remove the temperature sensors in the bottom of the flask,
remove the respective connection cables from the connector.
• Loosen the screw connections (1), (2), (3) and (4) and remove any leaking product.
• Slightly tilt the distilling flask housing (5) and remove it from of the analyzer housing.

If you want to disassemble the distilling flask from its housing, proceed as follows:
E
G
H
C
D
Fig. 7.2: Disassembling the Distilling Flask from its Housing
• Open the distilling flask housing.
• Loosen the screws (C) and remove the upper section (2).
• Loosen the screw (E) and remove the plate (F).
• Loosen the screws (G) and remove the lower section (H).
You can now take the distilling flask out of its housing. Be careful not to damage the
connected lines.
To replace the distilling flask, proceed as follows:
• If the distilling flask has been taken out of its housing, reassemble it in the opposite
order as described above. While doing this, replace the gasket under the upper
section.
• Clean the sealing surfaces of the connections (1) to (4) and replace the gaskets.
• Tighten the screw connections (1) to (4) only hand-tight. You should be able to
replace the distilling flask without greater tension. Tighten the screw connections (1)
to (4) only 1/8 turn with a wrench. Use another wrench to hold the assembly in
position while doing this.
• If you have removed any connection cables from a connector earlier, replace them
now.
• Plug the connectors (A) and (B) back in to the terminal strips.

7.5 Cleaning the Distilling Flask
Depending on the analyzed product and on whether distillation is carried out to the final
boiling point, the bottom of the distilling flask may be coked. These residues will increase
continually, and this may cause malfunction and may impair the precision of the
measurements.
Coking should be removed only by means of blasting with glass beads. This method
requires a special jet nozzle. This cleaning process can be carried out by BARTEC BENKE.
Other residues and contaminations can be removed with suitable detergents and solvents.
To clean the distilling flask, proceed as follows:
• Remove the distilling flask as described in section 7.4. It is not necessary to

disassemble the distilling flask from its housing.
6
4
Fig. 7.3: Disassembled Distilling Flask

• Loosen the screws (1) and remove the upper section (2).
Caution!
solvent.
• Clean the inside of the distilling flask. Coking at the bottom of the flask should be
removed by blasting with glass beads.
• Clean the connection lines (3) and (4).
• Remove any clogged substances from the tube (5) and clean it.
• Carefully remove all remaining glass beads, detergents and solvents from all
components.
• Replace the gasket (6) and reassemble the distilling flask.
• Close the distilling flask housing.
You can now replace the distilling flask, as described in section 7.4.

7.6 Removing and Reinstalling the Heating Cartridges
If a heating cartridge is damaged, the entire set must be replaced.
To remove the heating cartridges, proceed as follows:
Caution!
1. Disconnect.

Caution!
health!
product!
Caution!
Caution!
Risk of injury!

Fig. 7.4: Removing and Reinstalling the Heating Cartridges
• Remove the connector for the heating cartridge cables from the terminal strip.
• Loosen the screws (1) and (2).
• Pull the holding plate (3) back to the connecting cables.
• Pull out the heating rods by using multigrip pliers.
In some cases, the heating rods may fit so tightly that they cannot be pulled out of their
bore holes. In this case, proceed as follows:
• Remove the distilling flask from the analyzer housing and from the distilling flask
housing, as described in section 7.4.
• Using a small hammer and a suitable pin punch, knock out the heating cartridges from
the back towards the front. Take care not to damage the distilling flask.

To replace the heating cartridges, proceed as follows:
• Clean the bore holes in the bottom of the flask thoroughly.
• Apply a very thin layer of copper paste to the heating zones of the heating cartridges.
The heating zone can be identified by its tarnish.
• Push the heating cartridges through the holding plate (3).
• Observe the installation position of the holding plate: fixing hole at the bottom.
• Push the heating cartridges into the bore holes in the bottom of the flask. Make sure
that the heating zone (recognizable by its tarnish) of the heating cartridges is centered
in the bottom of the flask.
• Mount the holding plate (3) with the screw (1).
• Secure the earth cable with the screw (2) and the corresponding washers.
• Reinstall the distilling flask as described in section 7.4.
• If it has not been reconnected yet, replace the connector for the heating cartridge
cables into the corresponding terminal strip.
7.7 Cleaning the Condenser
Depending on the analyzed product, residues will collect in the condenser. These residues
may cause malfunction and may impair the precision of the measurements.
To clean the condenser, proceed as follows:
• Interrupt the cooling water supply to the condenser.

(If the system is equipped with an Explosion-proof chiller for liquids: Please read the
operating manual for the chiller. The shut-off valves are located on the water supply
and return lines between the chiller and the analyzer housing.)

Caution!
1. Disconnect.
Caution!
health!
product!

Caution!
Caution!
Risk of injury!
6 1
2
5
3 4
Fig. 7.5: Clean the condenser

• Remove the connector (1) for the cooling water temperature sensor (2) from the
terminal strip.
• Remove the sensor.
• Loosen the screw connections (3) and (4) (the screw connections are hidden under
the insulation) and remove any spilled cooling water.
• Loosen the screw connections (5), (6), and (7) and remove any leaking product.
• Remove the condenser from the analyzer housing. To do this, it may be necessary to
disconnect some additional pipes.
• Clean the condenser, using suitable detergents and solvents.
• If the residues cannot be removed completely, you can use an ultrasonic cleaning unit
to clean the condenser. If you do this, remove the insulation before cleaning and
replace it with new insulation after cleaning.
• Remove all remaining detergents and solvents, also from inside the condenser.
To replace the condenser, proceed as follows:
• Clean the sealing surfaces of the screw connections, and replace the gasket for the
screw connection (5).
• Insert the condenser into the analyzer housing.
• Tighten all screw connections hand-tight. You should be able to replace the condenser
without greater tension. Tighten the screw connection (5) hand-tight, then turn it 1/8
turn with a wrench. Use another wrench to hold the assembly in position while doing
this. Tighten the remaining screw connections according to the manufacturer's
specification, as described in the supplied documentation.
• Install the cooling water temperature sensor (2) and connect the connector (1) to the
terminal strip.

7.8 Servicing the Inlet-Valve and the Fill-Valve
For maintenance, you will need a maintenance set (see spare parts list) which comprises
all wear parts for a valve.
Caution!
1. Disconnect.

Caution!
health!
product!
Caution!
Caution!

Caution!
Risk of injury!
• Loosen the screw connections for product and the nitrogen control line for the
respective valve.
• Remove the valve from the analyzer housing.
1
2
11
10
4
3
8
7
9
Fig. 7.6: Service the Inlet-Valve and the Fill-Valve

• Remove the control head by loosening the screws (1) and taking off the control
head (2).
• Pull the socket (3) together with its O-ring (4) out of the valve body (5).
• Pull the valve core (6) out of the valve body (5).
• Use a hook-shaped, blunt tool to pull the valve seat (7) together with its O-ring (8) out
of the valve body (5).
• Remove the O-ring (9) from the valve body (5).
Caution!
solvent.
• Clean the valve body and all parts which will be inserted in the valve body and will not
be replaced by new parts.
• Replace the O-rings (4), (8) and (9) and the valve core (6).
• Grease the parts slightly with lithium base grease and assemble all parts (except the
control head (2)) which will be inserted in the valve body.
• Pull the valve spool (19) together with the lip seal (11) out of the control head.
• Remove the lip seal (11).
• Clean the valve spool (10) and the inside of the control head (2).
• Replace the lip seal (11) with a new one.
• Grease the components slightly with lithium base grease and push the valve spool (10)
together with the lip seal (11) into the control head (2).

• Push the control head (2) into the valve body (installation position: vent nozzle
towards the product lines), and secure it with the screws (1).
• Insert the valve into the analyzer housing. Tighten the pipe connections according to
the manufacturer's specification, as described in the supplied documentation.
7.9 Servicing the Flask-Valve
all wear parts.
• Remove the distilling flask as described in section 7.4.
• Loosen the screw connections on the nitrogen control line and the product outlet to
the bottom of the analyzer housing. Remove any leaking product.
• Remove the valve from the analyzer housing.

9
3 7
4 6
8
2
10
Fig. 7.7: Servicing the Flask-Valve
• Clamp the valve body (1) in a vice at the spanner flat.
• For disassembly, please note that the spring (2) is under tension.
• Carefully unscrew the valve cap (3) from the valve body (1).
• Remove the spring pin (4) and the spring (2).
• Remove the bolt (5).
• Remove the guide assembly (6).
• Remove the O-rings (7) and (8) and the lip seals (9) and (10).

Caution!
solvent.
• Clean all parts which will not be replaced by new ones.
• Replace the O-rings (7) and (8).
• Replace the lip seals (9) and (10). Observe the correct installation position (see
figure).
• Replace the entire bolt (5) by a new one.
• Grease all components slightly with lithium base grease.
• Inserting one component after the other into the valve body (1), reinstall the guide
assembly (6), the bolt (5), the spring (2), and the spring pin (4).
• Apply some mounting paste for stainless steel threads to the thread of the valve
body (1).
• Screw the valve cap (3) onto the valve body and tighten it only until you notice some
resistance.
• Insert the valve into the analyzer housing. Tighten the two pipe connections according
to the manufacturer's specification, as described in the supplied documentation.
• Reinstall the distilling flask as described in section 7.4.

7.10 Servicing the Receiver-Valve
all wear parts.
Caution!
health!
product!
Caution!

• To simplify matters, leave the valve at the bottom of the receiver.
• Loosen the screw connections on the nitrogen control line and the product outlet.
Remove any leaking product.
2 9
7
4
6
3
8
10
Fig. 7.8: Servicing the Receiver-Valve
• To deinstall, use a suitable tool to hold the valve body (1) in position.
• For disassembly, please note that the spring (2) is under tension.
• Carefully unscrew the valve cap (3) from the valve body (1).
• Remove the spring pin (4) and the spring (2).
• Remove the bolt (5).
• Remove the guide assembly (6).
• Remove the O-rings (7) and (8) and the lip seals (9) and (10).

Caution!
solvent.
• Clean all parts which will not be replaced by new ones.
• Replace the O-rings (7) and (8).
• Replace the lip seals (9) and (10). Observe the correct installation position (see
figure).
• Replace the entire bolt (5) by a new one.
• Grease all components slightly with a thin coat of lithium base grease.
• Inserting one component after the other into the valve cap (3), reinstall the spring
pin (4), the spring (2), the bolt (5), and the guide assembly (6).
• Apply some mounting paste for stainless steel threads to the thread of the valve
body (1).
• To install, use a suitable tool to hold the valve body (1) in position.
• Screw the valve cap (3) onto the valve body and tighten it only until you notice some
resistance.
• Tighten the two pipe connections according to the manufacturer's specification, as

described in the supplied documentation.

7.11 Cleaning the Flame Arrester "Flamex Fuel"
To clean a flame arrester Flamex Fuel, proceed as follows:
• Switch off the analyzer, as described in section 6.2.
• Stop the product flow to the analyzer.
Caution!
Please read the separately supplied operating instructions carefully. Make
sure that the flame arrester is reinstalled in the same instrument from which
it was removed.
Make sure that the flame arrester is reinstalled in the same analyzer from
which it was removed (there are flame arresters for different explosion sub-
groups).
Caution!
health!
product!
• Unscrew the pipe connections of all connected pipes (depending on the type of flame
arrester, this may be the vent pipe, the slop pipe or the product inlet pipe), and
remove the pipe. Remove leaking product with a suitable cloth.
• Remove the flame arrester.

Caution!
solvent.
• Disassembling, cleaning and assembling of the flame arrester is described in the

separately supplied operating instructions.
• Reinstall the flame arrester. Tighten the screw connections according to the
manufacturer's specification, as described in the supplied documentation.

7.12 Replacing a Fine Filter in the Sample Conditioning

System (Optional)
To replace a filter, proceed as follows:
• Stop the product flow to the filter in which you want to replace the filter element. To
do this, either stop the product flow to the analyzer or, if two fine filters are installed,
switch the product stream to the second filter, using the valves mounted immediately
in front of and behind the filter.
Caution!
health!
product!
• Place a suitable container below the filter element. Loosen the filter element with a
suitable tool and place it in the container in which you collect leaking product.
• Apply a thin coat of grease to the gasket of the new filter element, screw on the filter
element and tighten it hand-tight.
• For de-airing, let the product flow through the new filter and the sample conditioning
system via the Bypass-Valve into the slop for at least five minutes. Afterwards, switch
the product stream back to the older fine filter, if required.

7.13 Replacing the Filter Element in the Water Separator
To install a new filter element, proceed as follows:
• Stop the product flow.
Caution!
health!
product!

Fig. 7.9: Replacing the Filter Element in the Water Separator
• Loosen the T-screw (1).
• Take off the cap (2). If the cap sits tightly, carefully tap on its rim (2) from below to
loosen it.
• Pull the filter element out slowly by rotating it slightly.
• Insert a new filter element.
• Make sure that all gaskets are in their correct positions.
• Replace the cover and tighten the bolt hand-tight.
• For de-airing, let the product flow through the new filter and the sample conditioning
system via the Bypass-Valve into the slop for at least five minutes.

7.14 Checking the Buret Dosing Volume
On delivery, the buret is adjusted to a volume of 103 ml. The nominal volume for the
distilling flask is 100 ml, the remaining 3 ml correspond to the volume between the
position of the Flask-Valve and the bottom of the flask.
It is recommended that two persons carry out this check, because some steps must be
carried out simultaneously or in quick succession.
As the following sequence makes it necessary that you open the screw connections, thus
effectively opening the analyzer housing, please observe the following safety precautions.
Caution!
vent-slop-system.
off the analyzer.
DIN EN 60079-14.

Fig. 7.10: Underside of the Analyzer Housing
To check the dosing volume, you will need a measuring cylinder or a similar instrument for
measuring volumes (in this section referred to as the measuring cylinder) which is suitable
for measuring the required volume with the necessary precision. The measuring cylinder
should be designed so that it allows you to collect the product which will drain from the
screw connection (1) at the bottom of the analyzer housing. Futhermore, keep suitable
tools ready for loosening the screw connections (1) and (2).
Caution!
health!
product!

• Keep the software manual ready for reference.
• Manually activate an existing stream, and deactivate it again as soon as the

corresponding button changes its color to green.
• Wait until the process step "Gauge Buret 2" is displayed.
• Stop the product flow to the analyzer.
• Wait until the process step "Filling Flask" is displayed.
• Loosen the screw connections (1) and (2) and remove the pipe (3). Remove any
leaking product.
• Place the measuring cylinder below the opened screw connection (1).
• Without clicking yet, position the mouse arrow over the button "Break" in the PACS
main window.
• As soon as the process step "Start Heat" is displayed, click on the button "Break"
immediately.
The product flows from the distilling flask into the measuring cylinder, as soon as the
program step "Start Heat" is displayed.
• Install the pipe (3) by tightening the screw connections (1) and (2) according to the
manufacturer's specification, as described in the supplied documentation.
You can now open the product flow to the analyzer again.
The measured dosing volume should be 103 ml ± 1 ml. If the tolerance range is exceeded,
repeat the check. If the second check has the same result, please contact the BARTEC
BENKE service department.

Troubleshooting 87
8 Troubleshooting

88 Troubleshooting
The PACS process software continuously monitors operation of the system and outputs
error messages in the event of a malfunction. For detailed information on the causes of
malfunctions and their elimination, please refer to the software manual.
In the event of malfunctions on individual pieces of equipment or assemblies within the

system, please first check whether the malfunction can be remedied with the aid of the
enclosed operating instructions. If this is not possible, please contact BARTEC BENKE
immediately:
BARTEC BENKE GmbH

Borsigstraße 10
21465 Reinbek/Hamburg
Germany
Tel.: +49 (0) 40 -72703 0

Fax: +49 (0) 40 -72703 363
E-Mail: service@bartec-benke.de
Error Cause / Result Troubleshooting

Analyzer is switched off / does not start
a) Display of overpressure Power supply of the analyzer Check and restore power
control is not present is interrupted (e.g. broken or supply
blown fuse)
Fusing of overpressure Remove the cause of the
control system is faulty (only malfunction.
present in some versions)
a) Display of overpressure Overpressure control system Please refer to operating
control is present has switched off the analyzer manual of the overpressure
/ cannot start the analyzer control system.
Internal fuses are faulty / Remove the cause of the
blown malfunction.
Power supply of the Remove the cause of the
I/O board interrupted or malfunction.
I/O board faulty
Instrument air supply is Remove the cause of the
interrupted malfunction.
No Ready signal / measuring result over a longer period of time
Analyzer is switched off. see above
No stream selected; "Reset" Please refer to the software
is activated; PACS is not manual.
operating; PACS is in the
state "Shutdown"

Troubleshooting 89

Unsuitable parameter settings Adjust the parameters (see
software manual).
Cable connection to the Remove the cause of the
analyzer is interrupted malfunction.
Measuring value output signals an unusual or implausible value /
reproducibility of measuring results decreases
Sudden significant changes in
product properties
An alarm has caused the Remove the cause of the
measuring value output to be alarm. Carry out a reset (see
reset to the initial value. software manual).
Error in sample conditioning Make sure that the product
system (contamination, is conditioned as specified in
water, temperature, gas in the technical data.
product...)
Distilling flask is soiled. Clean the distilling flask
Condenser is soiled. Clean the condenser
A product valve is clogged / Clean / repair / replace the
soiled / does not close tightly. respective valve.
Slop and/or vent is blocked Remove the cause of the
malfunction.
System alarm (digital output)
A configured alarm has Remove the cause of the
occurred. alarm. If required, carry out
a reset (see software
manual).
Insufficient / no heating of the distilling flask
Heating cartridge is faulty Replace the heating
cartridges.
Incorrect installation Install the heating cartridges
according to the installation
instructions.
Unsuitable software Check the parameter values,
parameters see software manual.

90 Troubleshooting

A product valve does not Clean / repair / replace the
close tightly. respective valve.
Fuse or residual current Find and remove the cause
circuit-breaker of the heating of the malfunction, change
cartridges has blown. the heating cartridges, if
required.
Temperature fuse blown Find and correct the cause
(overtemperature) of the overtemperature.
Then release the system lock
by operating the push-
button "SH-2" inside the
control unit housing.
No product flow in the analyzer
Malfunction in the sample Remove the cause of the
conditioning system malfunction. Make sure that
the product is conditioned as
specified in the technical
data.
A product valve is clogged or Clean / repair / replace the
soiled; actuation is respective valve.
interrupted.

Technical Data 91
9 Technical Data

92 Technical Data
9.1 Technical Data – Distillation Process Analyzer
Technical Data
General
Type DPA-4.1
Method according to ASTM D 86, DIN EN ISO 3405, IP123
Repeatability limit ≤ DIN EN ISO / ASTM
Reproducibility ≤ DIN EN ISO / ASTM
Measuring cycle discontinuous, according to the standardized method
Cycle time 30..50 minutes, depending on the product and on
whether distillation is carried out to the final boiling point
Ambient temperature 5.0.40°C
Humidity max. 70%, non-corrosive
Measuring range 25..400°C
Sample at analyzer (clean and water-free according to quoted standards)
Flow rate 20..40 l/h
Pressure 1..3 bar
Temperature at inlet according to ASTM D 86
Viscosity max. 50 cSt at inlet temperature
Outlet / Vent open to atmosphere
Auxiliary media
Power supply see specification for control unit housing
Cooling water clean, free of particles, temperature depends on product
20..60 l/h / 1..3 bar
Instrument air see specification for control unit housing
Nitrogen min. 3 bar; consumption approx. 25 Nl/h
Electrical Signals
Measuring value output 1 x 4..20 mA; 800 Ω out; active (optionally potential-
(analog) free) *
System alarm digital output 24 VDC; max. 0.5 A *
Ready signal digital output 24 VDC; max. 0.5 A *
Auxiliary power supply 24 VDC; max. 800 mA
output

Technical Data 93
Technical Data
Communication
Display Color LC display 800 x 600 pixels
Mouse / keyboard Virtual keyboard, operated via mouse in EEx p housing
Software MS Windows 2000, PACS Software,
Remote control software (optional)
Test certificates
Flame Protection Class II 2 G EEx dp IIA, IIB or IIB+H2 T5 or
II 2 G EEx dp[ib] IIA, IIB oder IIB+H2 T5
Test certificate number TÜV 98 ATEX 1297
Standard connections
Pipe fittings 6 mm / 12 mm
Cable inlets M20 / M25
Weight approx. 325kg (without optional equipment)
Dimensions 1140 x 2250 x 710
(W x H x D) in mm
Optional electrical signals and interfaces

Outputs
Measuring value outputs up to 7 x 4..20 mA; 800 Ω out; active (optionally
(analog) potential-free) *
Identification validation digital output 24 VDC; max. 0.5 A *
cycle
Identification of streams 2x digital output; binary coded; 24 VDC; max. 0,5 A *
Warning digital output 24 VDC; max. 0.5 A *
Error: bottom of distilling digital output 24 VDC; max. 0.5 A *
flask is coked
Identification measuring 5x digital output; binary coded; 24 VDC; max. 0,5 A *
value (property)
Valid time measurement digital output 24 VDC; max. 0.5 A *
value available
Identification time 5x digital output; binary coded; 24 VDC; max. 0,5 A *
measurement value
Automatic Sampling: digital output 24 VDC; max. 0.5 A *
sample taken
Automatic Sampling: ready digital output 24 VDC; max. 0.5 A *

94 Technical Data
Optional electrical signals and interfaces

Inputs
Analog Inputs max. 2 x 4..20 mA; 200 Ω (e.g. for density)
Activation of reset Digital input / potential-free; reference potential 0 V;
high: 15..28 VDC; low: 0..4 VDC
Activation of individual 2x digital input; binary coded; potential-free; reference
streams potential 0 V; high: 15..28 VDC; low: 0..4 VDC
Activation of automatic coded via digital inputs / potential-free; reference
stream switching potential 0 V;
Deactivation of all streams coded via digital inputs / potential-free; reference
and of automatic stream potential 0 V;
switching high: 15..28 VDC; low: 0..4 VDC
Activation of validation Digital input / potential-free; reference potential 0 V;
Stream selection for Digital input / potential-free; reference potential 0 V;
validation high: 15..28 VDC; low: 0..4 VDC
Interfaces
Field bus interface RS485 / RS422 or fiber optic cable
(Modbus)
Remote maintenance Analog modem or ISDN, Ethernet
interface
* The sum of the streams of all analog and digital outputs must not exceed a maximum
of 0.8 A.
Note: The analyzer is subject to continuous improvements, so that technical changes

are possible.

Technical Data 95
9.2 Technical Data – Control Unit Housing
Technical Data
System version PAGS 96-1 (Prozess Analyzer Housing System)
Version number 96 0200
Explosion protection class II 2 G EEx p II T4
Test certificate number TÜV 96 ATEX 1132X
Cabinet volume approx. 200 dm3
Dimensions 515 x 470 x 800
(L x D x H)
Protection class IP65 (if equipped with a Vortex cooler: IP 54)
Operating voltage 230 VAC/50Hz; or according to customer specification
Connection power approx. 2 kW (analyzer approx. 700 W / optional water chiller
approx. 1100 W)
Max. power loss 515 W
Protective gas Instrument air (dry, oil-free)
Instrument air dew point ≤ - 40°C (quality of pressurized air according to ISO8573.1:
class 2 or better)
Initial instrument air 2..5 bar
pressure
Operating pressure inside 3..4 mbar
cabinet
Switch-off pressure 0.8 mbar
Instrument air min. 1.4 Nm3 per purging phase (7-fold cabinet volume)
consumption
during operation only compensation for leakage
Note: The analyzer is subject to continuous improvements, so that technical changes

are possible.

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Distillation Process Analyzer DPA-4.

Doc. No.: D3 1200 001 EM

These operating instructions were completed according to the specifications in ATEX

If you have any problems or questions, please contact:

BARTEC BENKE GmbH

Tel.: +49 (0) 40 - 72703 - 0

© 2005 BARTEC BENKE GmbH, Reinbek. All rights reserved.

3 Design and Function ........................................................................13

4 Assembly, Installation and Disassembly........................................25

5 Initial Operation ................................................................................35

Version 4, 16.10.2007 Distillation Process Analyzer DPA-4.1

7 Maintenance and Troubleshooting................................................. 47

Distillation Process Analyzer DPA-4.1 Version 4, 16.10.2007

Version 4, 16.10.2007 Distillation Process Analyzer DPA-4.1

1.1 Intended Use

1.2 Analysis of Distillation Characteristics

The distillation characteristics of a liquid petrochemical product must be analyzed in order

Analysis of the distillation characteristics of petrochemical products in the laboratory is

Distillation Process Analyzer DPA-4.1 Version 4, 16.10.2007

1.3 Measuring Principle of the Distillation Process

Distillation is a thermal separation process used to separate homogeneous mixtures

In laboratory analysis, the distillation characteristics of a sample are determined according

Version 4, 16.10.2007 Distillation Process Analyzer DPA-4.1

• initial boiling point (IBP)

• final boiling point (FBP)

• vapor temperature at a defined recovery rate (%) and vice versa

• % of loss, calculated as input volume minus % of recovered volume

• any combination of the results above

• any calculable parameter or correlation which is based on distillation or boiling points

Distillation Process Analyzer DPA-4.1 Version 4, 16.10.2007

Version 4, 16.10.2007 Distillation Process Analyzer DPA-4.1

2.1 General Safety Precautions

Distillation Process Analyzer DPA-4.1 Version 4, 16.10.2007

Version 4, 16.10.2007 Distillation Process Analyzer DPA-4.1

Distillation Process Analyzer DPA-4.1 Version 4, 16.10.2007

Version 4, 16.10.2007 Distillation Process Analyzer DPA-4.1

2.2 Explosion Protection

• II 2 G EEx dp IIA, IIB or IIB+H2 T5

• or II 2 G EEx dp[ib] IIA, IIB or IIB+H2 T5

Component Flame Protection Class

Analyzer housing (EEx d) II 2G EEx d IIC

Distillation Process Analyzer DPA-4.1 Version 4, 16.10.2007

3 Design and Function

Version 4, 16.10.2007 Distillation Process Analyzer DPA-4.1

The following figure shows an overview of the Distillation Process Analyzer:

Fig. 3.1: Overview of the Distillation Process Analyzer

Distillation Process Analyzer DPA-4.1 Version 4, 16.10.2007

In the buret (12), the sample is gauged.

The following options are not shown:

Version 4, 16.10.2007 Distillation Process Analyzer DPA-4.1

3.2 Media Conduction in the Analyzer

Fig. 3.2: Media Conduction in the Analyzer

Distillation Process Analyzer DPA-4.1 Version 4, 16.10.2007

1 Product inlet 16 Water-Valve

Version 4, 16.10.2007 Distillation Process Analyzer DPA-4.1

Distillation Process Analyzer DPA-4.1 Version 4, 16.10.2007

3.3 Analyzer housing

Fig. 3.4: Opened distilling flask housing

Version 4, 16.10.2007 Distillation Process Analyzer DPA-4.1

1 Distilling flask 6 Cooling water temperature sensor

3.4 Control Unit

Distillation Process Analyzer DPA-4.1 Version 4, 16.10.2007

3.5 Functional Principle of Pressurized Enclosure