Pulsar EX Carbon Dioxide Monitor: Training Manual

Training Manual
Pulsar EX
Carbon Dioxide
Monitor
Rec 4217 Rev A

Part NO: 074808
Pulsar EX System Overview
Technical Support for the Pulsar EX

Technical Support Available via:
• Telephone: (763) 783-2500
• Modem
o Please close down the pcAnywhere application on your Remote LabPC when
modem supported is required.
On-site Repair
• Monday – Friday
• 8:00 am to 5:00 pm
• Excludes Local Holidays
What is a Pulsar EX?

The Pulsar EX from Thermo Electron is a continuous CO2 on-line analyzer designed to
improve quality by detecting the following impurities in carbon dioxide:
• Sulfurs – regulatory, also affects product taste and smell

• Hydrocarbons - regulatory
• Aromatic Hydrocarbons - regulatory
The Pulsar EX includes four analysis subsystems, also known as benches or analyzers, to
test for these impurities. Three of the benches rely on pulsed ultra-violet fluorescence
(PUVF) to measure impurities; one (Total Hydrocarbons) uses non-dispersive infrared
technology (NDIR).
The type and amount of impurities in CO2 depends upon the source and the quality control
of the suppliers. ISBT has determined the maximum levels allowed for each of these
impurities. The Certificate of Analysis from the CO2 supplier and the results of the Pulsar
EX will ensure the maximum amount of protection.
Upon receipt of a delivery of CO2, the “streams” at the following locations will be analyzed:
• Delivery Truck, to prevent out-of-specification loads from being added to the

storage tank
• Pre-Filter, to measure the amount of impurities coming from the storage tank
• Post-Filter, to measure the amount of impurities making it through the filter
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Sampling Points
Pulsar
Pressure-reducing
Regulators
Dynamic Static
Sampling Sampling Pre-Filter Post-Filter
Delivery Vaporizing Storage Vaporizer Filters

Truck regulator Tank
Tank
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Pulsar EX
Benches
Remote Truck Panel

(Shown in optional pre-
assembled enclosure)
Remote Lab PC
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What Are the Key Features of the Pulsar EX?

The Pulsar EX has the following features:
• Fully automated operation
• Self diagnostics
• Self calibration
• Operator touch screen
• Remote PC monitoring
• Interface for truck delivery
• Remote modem support
• Data download to Microsoft Excel or Lotus 1-2-3
How Does the Pulsar EX Take Samples?

The Pulsar automatically monitors the Pre- and Post-Filter streams as follows
• Samples are taken automatically from the Pre- and Post-Filter streams every
three minutes.
• The four benches report the results after each cycle.
• Results are displayed on the monitor, and on one remote PC, which is usually in
the QA lab.
• In the event of an out-of-specification reading on the Total Aromatics analyzer,
an additional test is performed to specify the compounds.
How Does the Pulsar EX Test CO2 Delivery Trucks?

To test delivery trucks, the system does the following:
• Prepares the Truck Sample Valve system to properly purge the tubing and set
the correct flow paths
• Reports results from the analyzers continuously as the truck off-loads
• Displays results on the monitor and on the remote PC
• Prints a Certificate of Analysis (COA)
How Can I Access the Pulsar Software?

The Pulsar ProLink software can be accessed from the touch panel on the Pulsar system
and from the remote (lab) PC connected to the system. The menu buttons along the bottom
of the Pulsar screen pop up when activated (touch or mouse click) and allow the operator to
select various functions from the menu. If a selection is not made within three seconds, the
menu disappears.
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What information is displayed on the Pulsar EX results view?
• Results for the active streams including Pre-Filter, Post-Filter and Truck
• Status of the stream such as delay or sampling
• Activity Log of most recent actions
• Alarm, if active
• Access to menus for configuring and calibrating the system as well as viewing
data
To display the Pulsar Results View
1. Select the VIEW button from the bottom of the screen.
2. Select RESULTS from the menu.
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How will I know if the analysis failed?

The bright red alarm screen will appear. Click OK to close the alarm screen.
Although the alarm screen has been closed, the problem that caused the alarm is not fixed.
The results view will continue to flash Alarm (yellow) in the upper right-hand corner.
How do I start the ProLink for Pulsar software?
Select the ProLink icon on the Windows Desktop or from the Windows Start
Menu, Programs, ProLink folder and then the ProLink icon to start the ProLink
software.
How do I start the Remote Lab PC software?

The pcAnywhere program on the remote lab PC will allow you to control the Pulsar system
from the QA laboratory. Using the pcAnywhere program, you will see the same display that
is on the Pulsar unit and have the same access to software settings and activity logs as if
you were at the Pulsar.
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1. Select the pcAnywhere icon on the Windows Desktop or from the Windows
Start Menu under Programs.
2. In the pcAnywhere interface, click on Remote button in the icon bar.
3. Click on Network, Cable, DSL icon in the pcAnywhere window.

A dialog will launch indicating that the remote PC is attempting to connect to the
Pulsar system. When the connection is made, pcAnywhere will display look identical
to the display on the Pulsar.
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Typical Display at the Remote Lab PC
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Pulsar EX System Monitoring
Overview
The Pulsar EX system including analysis results and indicators on the unit should be
monitored routinely. The following Single Point Lesson (SPL) covers:
• Start-up
• Routine System Monitoring
• Results
• Activity Log
• Extended Shut Down
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Start Up
When the Pulsar has been properly shut down for an extended period, the operator must
restore all of the flows to the correct levels, turn on the system and allow it to stabilize before
analyzing CO2.
1. Turn the Pulsar power ON.

The power switch is on the lower rear panel of the Pulsar EX.
2. Open the utility air supply.

The utility air supply is often referred to as the “house” air.
3. Verify that the external pressure gauges for pre-filter and post-filter samples
and the truck vaporizing regulator read 60 psi.
4. Open the flows to both pre-filter and post-filter samples.

These flows should always be open.
5. Adjust the Sample, Air, and Zero pressure gauges, shown circled below, to 30
psi.
6. Allow the instrument to stabilize for 1-2 hours.
7. Begin the analysis.
System Monitoring
There are several key parameters that must be monitored routinely to ensure proper
operation of the Pulsar EX system.
• External pressure gauges
• Internal pressure gauges
• Pyrolyzer temperature gauge
• External air filter
• Pulsar display screen
1. Verify that the following external pressure gauges are set to 60 psi, adjust if
required.
o Pre-filter
o Post-filter
o Vaporizing Regulator
2. Verify that status window on the external air filter is NOT red.
If the external air filter status window is red and displays the change message, then
follow the instructions for replacing the air filter in the Maintenance training module.
3. Verify that the following internal pressure gauges are set to 30 psi; adjust if
required:
o Sample
o Air
o Zero
Pyrolyzer gauge
Sample
Air
Zero
4. Verify that the Pyrolyzer temperature gauge reads above 1200 ºC (± 10 ºC).
5. On the Pulsar display screen, verify that no alarm conditions exist.

• Verify that no alarm conditions exist by viewing the results screen alarm button
and icon colors.
• Check the activity log to ensure no alarms have occurred.
• Check the instrument status screen.
6. If any of these parameters are incorrect, determine the type of alarm and
respond as defined in the alarm handling training lesson.
Pulsar Display
The Pulsar display provides several ways to determine if an alarm condition exists including:
• Alarm button
• Icon colors
• Instrument status
• Activity log.
Alarm Screen and Button

The bright red alarm screen will appear. Click OK to close the alarm screen.
Although the alarm screen has been closed, the problem that caused the alarm is not
fixed. The results view will continue flash Alarm (yellow) in the upper right-hand
corner if an alarm is active.
Note: If the alarm has been silenced, the ALARM warning in the upper right-hand corner of
the screen will not be flashing yellow. However, the activity log, instrument status
and icon colors can be used to confirm the presence of an alarm.
Icon Colors
The following tables describe the meanings and colors of the icons. The icons are
displayed when, on the main screen, you select VIEW and RESULTS.
ICON MEANING
Stream Status OK
Stream Results Unknown
Stream Result(s) in Alarm
Stream Delay
Stream Disabled
Stream Pre-Purge
Calibration Check
Stream Selection in Progress
Review the individual stream results as follows:
READING MEANING
Reading OK
(Green on black background)
Warning Exceeded
(Black on yellow background)
Hi Alarm Exceeded
(Black on red background)
Trend Alarm Exceeded
(Red on black background)
Calibration Check Reading
(Black on turquoise background)
Calibration Check Failure
(Red on turquoise background)
Instrument Status
Instrument Status can be used to help troubleshoot Pulsar EX alarms in the event of
an analyzer or system fault. It indicates the status of each analyzer, the pyrolyzer as
well as the sample, air and zero pressures. The Thermo Electron Technical Support
Group will require the information in Instrument Status when you call the technical
support phone line. If there is a hardware failure, the Instrument Status screen will
provide a brief description of the analyzer failure.
1. Press the STATUS Button.
2. Select the INSTRUMENT STATUS menu item.
3. Confirm that all instrument status items read OK.

If the analyzers, pressures or pyrolyzer are not operating properly, you will see a red
display next to the parameter description.
Activity Log
The Pulsar EX system has an Activity Log feature that logs the time and date that events
such as alarms and system faults occur, system start-ups and shut-downs, and demand
requests. By adding a note, the activity log can also be used to keep track of other changes
to the system, which are not automatically recorded. The system logs user information such
as who silenced an alarm, performed a truck analysis, or even changed a parameter. This
log stores two days worth of information and can be reviewed in the event this type of
information is needed. After two days, the information is archived to a file.
1. Press the VIEW button in the ProLink software.
2. Select the ACTIVITY LOG menu item.
3. Review activity log information by using the up/down scroll bar on the right
hand side of the window.
4. To add a note to the activity log, press the Add Note button and enter a note on
the pop-up keyboard.
The note remains with the data from that time forward.
5. Return to the main screen by pressing the VIEW button and then RESULTS.
Extended Shut-Down
Note: When the plant is expected to shut down for more than 24 hours, the Pulsar EX
should be shut down as well.
1. Select the START button in the lower left corner of the display to close the
Windows® operating system.
2. Select Shut Down from the menu.
3. Select Shut Down from the dialog box, and then select OK.
4. Wait until the display indicates that it is okay to turn off power to the system.
5. Close the sample flow.
6. Close the CO2 flow.
7. Close the utility flow (air).
8. Turn off power to the Pulsar.
9. Turn off the circuit breaker to the Remote Truck Panel.
10. Turn off the circuit breaker to the Vaporizing Regulator.
Pulsar EX Truck Delivery
Overview
The following single point lesson (SPL) is designed to train operators on the procedure used
to test a CO2 delivery truck. This SPL covers:
• Setting Up the Valves for the Truck Test

• Analysis start via Loading Dock Interface (LDI) or Remote Truck Panel (RTP)
• Analysis complete – Delivery Acceptance or Rejection
• Restore Valve Conditions
• Printing an Analysis from a Remote (Lab) PC
Loading Dock Interface Display with keypad
Setting Up the Valves for the Truck Test
By setting up the valves for the truck test, you can assure the proper purge and sample flow
for analyzing the CO2 in the delivery truck.
Each valve can either be CLOSED or OPEN according to the following figures:
Valves Closed
When the valve handle is perpendicular to the tubing, the valve is closed.
Valve Open
Valve handle is parallel to the tubing when the valve is opened.
There are four valves associated with the Delivery Truck Sample System. Each valve is
marked A, B, C, D according to the plumbing diagram below and the following table.
Valve Configuration Chart – Dynamic Truck Test During Off-loading (3

Discrete Tests) Only
Valve Normal Run
Valve Truck Purge Truck Sample
Description Condition
A CO2 supply Closed Open Open
B Static Sample Closed Closed Closed
C Constant Purge Open Closed Closed

D Blow Down Closed Open Closed
Analysis Start via Loading Dock Interface (LDI)
Before the truck delivery testing is started the valves should be in the following positions. A,
B and D are closed. Valve C is open.
Dynamic (3 Discrete Tests) Sample Procedure

This procedure describes the actions required when testing during truck off-loading.
The test performs 3 discrete measurements on carbon dioxide delivery. If any of the
results from the 3 tests is out of specification, the test will terminate.
1. Ensure that the RTP screen is prompting for your Operator ID. If not, press
any key. The screen should then display the Operator ID screen.
Pulsar EX
Enter User ID:
Waiting for User ID
2. Enter your Operator ID and press the Enter key.

Enter Key
Use the keypad below the display to enter your User ID.
3. Enter the Tanker ID, press the Enter key.
Pulsar EX
Enter User ID: 586940

Enter Tanker ID:
Waiting for Tanker ID
4. Ask the truck driver to blow-down the fill line.
5. Close valve C.
6. Open Valve A.
7. Open Valve D. The CO2 should begin exhausting from the blow-down vent.
8. Allow the blow-down to continue until you see 15 seconds worth of solid
snow.
9. Close valve D.
10. Have the truck driver begin his offload.
11. Wait 60 seconds (1 minute) to ensure good flow to the Pulsar monitor.
12. Press the Enter key to start the analysis. This will initiate the test.
Pulsar EX
Enter User ID: 586940

Enter Tanker ID: 549961
Press Enter to Analyse
13. Wait for the RTP to display a result for the test. This will take approximately 3
minutes.
Pulsar Ex
User ID: xxxxxx

Tanker ID: xxxxx
Status: Analysing
Results: (17-Jan-03 11:30)

Total Sulfur xx.x ppb
THC xx.x ppm
Acetaldehyde xx.x ppb
Total Aromaticsxx.x ppb
Press Esc to Abort
Note: To manually stop the test, press the Esc key on the RTP.
14. The Pulsar is configured to automatically repeat this test 3 times. A result will
be displayed every 30 seconds. Please observe the results.
The complete test sequence takes approximately 4 minutes 30 seconds. If any
results from the 1st or 2nd discrete test are out of specification (alarm level), the
truck test will automatically stop. The results for the truck test can be located in the
data files.
Pulsar Ex
User ID: xxxxxx

Tanker ID: xxxxx
Status: Analysis PASS Results of truck delivery test

Results: (17-Jan-03 11:30)
Total Sulfur xx.x ppb
THC xx.x ppm
Acetaldehyde xx.x ppb
Total Aromaticsxx.x ppb
Press Esc to Abort
15. When the tests are complete, close valve A.

The complete test sequence takes approximately 4 minutes 30 seconds.
16. Open Valve C.
17. Ensure that the valves are in the proper positions.
18. Test completed.

.
Handling a High Truck Sample Result
If you obtain an out-of-specification result during truck testing, the following steps should be
followed to confirm that the high result is legitimate.
1. Did you wait 60 seconds before beginning the analysis (hitting the enter key) at
the Loading Dock Interface?
If you did not wait 60 seconds before starting the analysis, adequate gas flow to the
Pulsar unit was not established. Low flow to the instrument will cause high results
and alarms due to out-of-specification results. Repeat the truck test and wait at least
60 seconds before starting the analysis.
2. Was the Loading Dock Interface properly blown-down (Step 8)?
3. Confirm with the truck driver that the truck lines were properly blow-down.
4. Confirm that the sample, air and zero gas pressures are 30 psi.
5. Confirm that the external pressure gauges at Pre-filter, Post-filter and Truck
vaporizing regulators read 60 psi.
6. Confirm the pyrolyzer temperature reads 1200 °C.
7. Check the Instrument Status screen.

All analyzers should be on-line and with the status “Analyzer OK” displayed. Gas
pressures and the pyrolyzer should also read “OK”.
8. Check the activity log.

Confirm that no alarms occurred and that the system did not lose power or air
supply. If alarms did occur prior to the truck test, refer to the Alarm Handling and
Troubleshooting single point lessons for additional information.
9. Confirm that a calibration was successfully completed in the last 24 hours.

If a calibration did not occur in the past 24 hours or an alarm occurred during
calibration, the Pulsar may not be producing reliable results. The Pulsar should be
re-calibrated to ensure accurate results are obtained.
Printing an Analysis from a Remote (Lab) PC

If you have a local printer connected to the remote (Lab) PC, the monitor unit is configured
to print reports and COA (Certificate of Analysis).
Configuring the Printer to Print on Demand

The following steps allow you to configure the ProLink software so a report will print
automatically anytime a truck delivery test is run.
1. Select the SETUP button, then Report Setup menu item in the ProLink
software.
2. In the Report Configuration dialog, touch the Generate Report on Demand

Stream selection and the Generate Report on Manually Requested Process
Stream selection.
3. If you would like to preview the report prior to printing when printing a
manually requested Process Stream, select the Preview Report Prior to
Printing option.
4. Click OK to exit the Report Configuration dialog box.

The report will be printed automatically every time a truck test is run.
Example Truck Delivery COA
Pulsar EX Alarm Handling
Overview
The Pulsar EX monitor provides an easy to detect visual display anytime the CO2 is out of
specification, there is a hardware alarm or other system failure. The following Single Point
Lesson (SPL) will train operators on how to interpret and respond to Pulsar alarms.
• View Alarms
• Interpret Alarms
• Respond to Alarms
• Read Activity logs
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How Will I Know If There Is An Alarm?

The Pulsar will produce a visual alarm when the CO2 sample is out of specification or when
there is a hardware failure. If there is an alarm, you will see a
• Bright red alarm screen
• Flashing yellow Alarm box at top right-hand corner of results screen.
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Viewing Alarms
At any time even when there may not be an active alarm you may view the recent alarms.
1. Touch the Alarm button at the bottom of the screen.
2. Touch Show Alarms in the menu.

The last active alarm will be displayed.
If the alarm is a component alarm (the CO2 is out of specification), you will return to
the Results view.
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The red or yellow colored results box can identify the out of specification component
and stream. The readings are color coded to indicate if the results are in or out of
specification. The following table identifies the displays you may see.
READING MEANING
Reading OK
(Green on black background)
Warning Exceeded
(Black on yellow background)
Hi Alarm Exceeded
(Black on red background)
Trend Alarm Exceeded
(Red on black background)
If the alarm is a hardware or analyzer alarm, the activity log will be displayed. The
activity log will provide details on the source of the alarm.
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If there are no active alarms, a message pops up “NO active alarms”. The activity
log will be displayed by default.
Alarm Types
There are two basic types of alarms, component and hardware.
Component Alarm
Indicates that the sample (CO2) is out of specification.
Hardware and Analyzer Alarm
Indicates that there is a failure or problem with a component in the Pulsar system.
Responding to an Alarm
Component Alarm
Consult your company’s policy for handling out-of-specification results.
Hardware Alarm
Verify that all pressure and temperature gauges are reading properly. Consult the
Basic Troubleshooting and System Monitoring sections for further details.
Low Pressure
Verify that all internal and external pressure gauges are reading properly. For details
on how to verify the pressure settings, refer to the Basic Troubleshooting Single
Point Lesson (SPL).
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Pyrolyzer Failure
Check the pyrolyzer temperature setting. For details on troubleshooting the
pyrolyzer alarm, refer to the Basic Troubleshooting Single Point Lesson (SPL).
Auto Calibration Failure
Follow the procedure described in the Basic Troubleshooting Single Point Lesson.
Other Hardware Alarms
Contact Thermo Electron technical support.
Note: When you call the Thermo Electron technical support line, please be ready to tell the
representative the entire alarm message displayed in the activity log available.
Silencing Alarms
When you silence an alarm, you acknowledge that the alarm occurred. Silencing an alarm
does not correct the alarm. It stops the Alarm display on the results from flashing yellow.
1. Touch the Alarm button at the bottom of the screen.
2. Touch Silence Alarm in the menu.

The ALARM display at the upper right of the main ProLink display will stop flashing.
Note: Silencing a component or hardware alarm does not change the status of the alarm.
Check the Activity Log to view the alarm and silencing history.
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If a component alarm is silenced, the stream results will still indicate that the sample
is out of specification.
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Activity Logs
such as alarms and system faults, system start-ups and shut-downs, and demand requests
occur. The system also logs user information such as who silenced an alarm, performed a
truck analysis, or even changed a parameter. This log stores two days worth of information
and can be reviewed. After two days, the information is archived to a file.
2. Select the ACTIVITY LOG menu item
4. To add a note to the activity log, press the Add Note button and enter a note on
the pop-up keyboard.
The note remains with the data from that time forward.
5. Return to the main screen by pressing the VIEW button and then RESULTS.
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Instrument Status
Instrument Status can be used to help troubleshoot Pulsar EX alarms in the event of an
analyzer or system fault. It indicates the status of each analyzer, the pyrolyzer as well as
the sample, air and zero pressures. The Thermo Electron Technical Support Group will
require the information in Instrument Status when you call the technical support phone line.
If there is a hardware failure, the Instrument Status screen will provide a brief description of
the analyzer failure.
1. Press the STATUS Button.
2. Select the INSTRUMENT STATUS menu item.

The instrument status window will be displayed.
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Pulsar EX Data Retrieval and Interpretation
Overview
The Pulsar EX multiple ways to interpret and view data including the activity log and Data
Review tool. The following single point lesson (SPL) will explain how to:
• Transfer data to the Remote Lab PC

• Back up data
• View past and current activity logs
• View data in trend and numerical format
• Print results
Note: All data retrieval and interpretation tools may be accessed at the remote lab PC or
the Pulsar. To access the data via the Remote Lab PC, you must open the
connection via the pcAnywhere software. Refer to the Overview SPL for details on
how to open pcAnywhere.
Data Transfer to the Remote Lab PC

Data can be transferred directly from the Pulsar EX to the Lab PC whenever the
communications link is established.
Each file is organized into folders by year and month. Each filename is generated by the
Stream ID and date. Multiple files can be transferred at once. Once transferred to the Lab
PC, the files can be opened into spreadsheet programs such as Microsoft Excel or Lotus 1-
2-3.
Two types of sample streams are distinguished in the Pulsar EX system. Process streams
are for continuous monitoring. In normal operation, Pulsar EX cycles through the analysis of
process streams continuously in a sequence defined by the user. Alternatively, truck
samples (demand streams) may be designated for analysis on demand.
1. Select the File Transfer button in the pcAnywhere window.

The data transfer operation must be performed at the remote lab PC with
pcAnywhere running. The file transfer window will pop up.
2. On the right hand side of the window (shows Pulsar EX windows explorer
view), select C:\Pulsar_EX\ProLink\Data
3. Double-click the appropriate year folder.
4. Double-click the appropriate month folder.
5. Click the file(s) to be transferred.
6. On the left-hand side of the file transfer window, select the destination on the
remote lab PC where you want the files to be saved to.
7. Click the TRANSFER button in the middle of the file transfer window.
8. Verify that the file(s) were transferred to the desired location on the remote Lab
PC by using Windows Explorer on the Lab PC.
9. You can now open the files in Excel.
Note: pcAnywhere software must closed for service support via modem.
Data Back up
Data can be backed up to CD using the CD writer on the Pulsar system. To copy data to a
CD, use the full ROXIO EZ CD Creator software and select the files you want to copy.
Activity Log
such as alarms and system faults, system start-ups and shut-downs, and demand requests
occur. By adding a note, the activity log can also be used to keep track of other changes to
the system or unusual observations. The system logs user information such as who
silenced an alarm, performed a truck analysis, or even changed a parameter. This log
stores two days worth of information and can be reviewed in the event this type of
information is needed. After two days, the information is archived to a file.
Accessing the Current Activity Log (Last 48 hours)
2. Select the ACTIVITY LOG menu item
Accessing Old Activity Logs

Activity logs (messages) older than 2 days are transferred to text files, which are
stored in the date-structured folders. The text files are in Comma Separated Values
(CSV) format, which can be read by any text file editor and most spreadsheet
programs such as Microsoft Excel.
The folder name for storing the old Activity Logs is \Messages. The Messages folder
will have subfolders for each year. The activity log file names are composed of 4
digits corresponding to the month and the day, e.g. 2803.CSV corresponds to the
28th of March.
1. Open Windows Explorer from the Start Menu.

The old activity logs are stored on the Pulsar hard drive. The files can be accessed
from either the Pulsar or the Remote Lab PC when the pcAnywhere software is
running.
2. Select C:\ProLink\Messages folder.
3. In the messages folder, select the folder with the year that corresponds to the
data you are interested.
4. Select the activity log file.

The activity log file names are composed of 4 digits corresponding to the month and
the day, e.g. 2803.CSV corresponds to the 28th of March.
The archived activity logs can be opened with any text editor or spreadsheet
program like Microsoft Excel.
Example Activity Log opened in Microsoft Excel

Date Time Message
16-Jan-03 11:32:30 AM --- System Started ---
16-Jan-03 11:32:30 AM User 'Default User' logged in
16-Jan-03 11:32:33 AM D300 Remote Truck Panel Installed, COM2,9600,n,8,1
16-Jan-03 11:32:45 AM Manual request of stream 'POST FILTER'
16-Jan-03 11:32:52 AM --- System Shutdown ---
16-Jan-03 4:39:38 PM --- System Started ---
16-Jan-03 4:39:38 PM User 'Default User' logged in
16-Jan-03 4:39:39 PM D300 Remote Truck Panel Installed, COM2,9600,n,8,1
16-Jan-03 4:48:42 PM --- System Shutdown ---
Viewing Data
You can view historical data using the Pulsar EX Data Wizard. The Data Wizard software
provides both trend and numerical displays of the data from one or more streams.
The folders displayed by the Data Wizard contain data from each stream (pre-filter and post-
filter), truck tests and calibration results. The type of data contained in the file is denoted by
the first words or characters in the filename such as Cal, PRE FILTER and POST FILTER.
Loading Data into the Data Wizard
1. Click the VIEW button from the main Pulsar screen.
2. Click the DATA REVIEW menu item to start the Data Wizard program.
3. Double-click the appropriate year folder.
4. Double-click the appropriate month folder.
5. Select the file(s) to be opened.
6. Press the LOAD icon (shown circled below) to load the data.
7. Select the View menu in the toolbar.
8. Select either Trend or Numeric view.

Trend provides a graphical representation of the data. Numeric shows the selected
data in a table arranged by data and time.
Numeric Display Trend Display
Trend display
The trend display allows you to view and interpret data in a graphical format. Plant
personnel can review the graphical trend set for a specified time limit to see the
fluctuations in the level of impurities.
Note: If you want to switch to numeric view, select the View menu from the toolbar and
numeric.
Cycle Through Traces

• Changes the y-axis scale and units to match the
contaminant (trace) of interest such as Total aromatics
or THC.
Trend Configuration
• Specify the duration (x-axis limits). Duration can be set
in minutes, seconds, hours or days.
• Max duration is 48 hours
Traces Configuration
• Set the color
• Set y-axis type
• Set if trace will be visible
• Add and delete traces
Show Cursor Values

• Displays the numerical results for each trace at the
point where the green horizontal cursor is placed.
Link Cursor to Scan/Numeric Display

• Useful only if the Numeric display is also open.
• When the cursor is moved on the trend display, the
cursor in the numeric display will be moved to the
corresponding data point.
Cursor Positioning Tools

• Moves the cursor on the trend display.
• Use the arrow buttons to move the cursor to the next
data point in the plot.
Cursor
The Cursor, is the green vertical line present in the trend view. The cursor is moved
by selecting the cursor line with the mouse and dragging the cursor to any position
on the graph. The cursor can also be moved by using the Cursor Positioning Tools
in the Trend view toolbar.
Note: The trend display with limited functionality can be accessed by selecting VIEW, then
TREND DISPLAY from the main Pulsar window. Because this version of trend
display has limited functionality and does not allow you to view the numerical data,
we recommend that you work with the Trend Display available in the Data Review
tool.
Numeric Display
Numeric display provides a view of the data in a tabular format. Information
contained in the numeric display include:
o Date and time
o Alarms (flags)
o Analyzer results and errors
The numeric display is best used in conjunction with the Trend display when the
Link Cursor to Numeric Display is active.
Printing Trend or Numeric Display

Any screen in the ProLink software and the Data Review application including the numeric
and trend displays can be printed by pressing ALT-Print Screen or Print Screen button.
The display will be printed automatically.
Printing a Certificate of Analysis (COA)

If you have a local printer connected to the remote (Lab) PC, the Pulsar is configured to print
reports and COA (Certificate of Analysis).
Set up to Print Manually

The following steps allow you to configure the ProLink software so a report will print
when a stream is manually selected.
1. Select the SETUP button, then REPORT SETUP menu item in the ProLink
software.
2. In the Report Configuration dialog, touch the Generate Report on Demand

Stream selection and the Generate Report on Manually Requested Process
Stream selection.
3. If you would like to preview the report prior to printing when printing a
manually requested Process Stream, select the Preview Report Prior to
Printing option.
4. Click OK to exit the Report Configuration dialog box.
Print COA on Manually Selected Process Stream
1. Select the REQUEST ANALYSIS button.
2. Select the stream of interest.

You may select Post Filter, Pre Filter or Truck streams.
3. Select the report title and filename from the dialog box.
The name selected in the dialog box will be the filename and title that appears on the
report.
4. Select the PRINT button.

The report will print after the OK button is selected.
Note: If you selected the Print Preview option in the Report Setup menu, a preview screen
will be displayed. Select the PRINT REPORT button in the preview screen to initiate
printing.
Pulsar EX Software Configuration
Overview
The ProLink for Pulsar software is used to monitor results, display and retrieve data,
calibrate and configure the analyzer and other options including reports and analysis
streams.
The following single point lesson (SPL) will teach QA and plant managers how to setup and
configure:
• Analyzers (Sulfur, Total Hydrocarbons, Aromatics)

• Reports
• Trends
• Analysis streams
• Calibrations
• Alarms
Note: Changes made to the Analyzer Setup, Stream Setup, Calibration Setup and Alarms
Setup may modify the analysis and display of results.
Accessing the Software Configuration Menus
Access to the Software Configuration menus is limited to users who are members of the
Supervisor and Engineering security groups. You will be required to enter a Username and
Password to enter the setup functions of the Pulsar software.
Note: See the Pulsar System Security training module for details on setting up Pulsar
system security and access levels.
1. Click on the SETUP button at the lower left-hand corner of the screen.
2. Select the setup menu item you would like to view.
3. At the security dialog, enter your user name.
4. At the second security dialog, enter your password.
Analyzer Setup
• Enabling and disabling the analyzers.

• Analyzer parameters (purge time, span and zero information)
Enabling/ Disabling Analyzers
1. Click on the checkbox next to the analyzer name.

An enabled analyzer has the checkbox checked. The default configuration is all
analyzers enabled.
Note: A disabled analyzer will not be calibrated or used in measuring components. Any
component measured by a disabled analyzer will by flagged as being ‘off-line’.
Configuring Analyzer Parameters
1. Click on the analyzer name in the table.

The selected analyzer will be highlighted in yellow. The right side of the screen will
show the configuration parameters applicable to the selected analyzer.
2. Enter desired changes to analyzer parameters.
Note: Changes made to the Analyzer Setup may affect results.
3. To save changes made to an analyzer configuration, click the SAVE button at

the bottom of the screen.
4. To change the parameters for another analyzer, select the analyzer name in the
table.
Repeat steps 2 – 4 to make changes to other analyzer parameters.
5. Click the OK button to exit the Analyzer configuration window and return to the
Results display.
Reports Setup
• Preview reports
• Define when reports will be printed
• Define if report will be converted and saved to HTML file
A report can be generated upon the analysis results of a demand stream such as the truck
or when the user manually requests that a stream be analyzed.
Note: A printer must be connected locally to the Pulsar or to the Remote Lab PC when
changing report configuration options or printing a report.
Generate Report On Demand Stream

If this option is enabled then a report is generated automatically at the end of every
analysis of a demand stream such as the truck.
Generate report on manually requested process stream

If this option is enabled then a report will be generated manually when the process
stream is requested manually. The operator will be prompted to select the title for
the report
Note: Click on the REQUEST ANALYSIS button at the bottom of the Pulsar Results
screen and then selecting the desired stream to manually request analysis of
a stream.
Preview report prior to printing

If this option is enabled then a window is displayed showing a preview of the report.
The preview window gives further options to print the report or to select another
report format file.
Number of copies to produce

This value defines the number of copies of the report to be printed.
Generate HTML format disk file

If this option is enabled, an HTML file of the report will be saved to the Pulsar hard
drive under /Prolink/Reports. The reports are given a filename based on the report
format chosen in the dialog that is displayed. The reports are numbered
sequentially. A typical report filename would be Pulsar(2).htm where 2 is the second
report produced and Pulsar is the title that was selected from the dialog.
Trend Setup
• Graph duration
• Display parameters (color, label) for each stream and analyzer
Graph Duration
The default graph duration is 24 hours. It can be adjusted as required.
Trace Label
This shows the label that is attached to the trace on the graphical display. To
change the label, double click in the label field. When the label is highlighted, type in
the new label.
Trace Color
The trace color can be selected by pressing on the colored block. A form is
displayed allowing selection of a trace color.
Auto Scale
If auto scale is enabled then the Y-axis minimum and maximum for the trace is
recalculated when a new data point is plotted. If the new data point value is greater
than the existing Y-axis maximum then the maximum value on the Y-axis is adjusted.
If the new data point value is lower than the existing Y-axis minimum then the
minimum value on the Y-axis is adjusted.
Min
Sets the minimum display for the Y-axis for the corresponding trace.
Max
Sets the maximum display for the Y-axis for the corresponding trace.
Trace Enabled
This entry allows traces to be enabled/disabled. A disabled trace will not be
recorded on the trend display and will not be available for trend alarms. By default,
only traces for non-demand streams are enabled. Changing the enabled value for a
trace will cause the graph display to be reset.
Trace Visible
This entry allows traces to be made visible or to be hidden. The data for all enabled
traces is still maintained. The visible value can be toggled at any time without
causing a loss of the displayed data. A trace will still be included in the trend alarm
calculations even though it may be hidden.
Trend Alarm Enabled

Sets the trend alarm for any trace to be enabled or disabled.
Trend Alarm Level

Sets the alarm level for trending alarms. Refer to the next paragraph on Trend
Alarms for more information.
Trend Alarms
The rate of change of any trended components can be monitored. If the rate of
change (in a positive direction) over a 1 hour time period exceeds the entered limit
the alarm is activated.
The alarm limit is defined in the units of the component. For example, a value of 5
on the total aromatics component would be defined as raising an alarm if the rate of
change of the total aromatics reading exceeds 5 ppb per hour. A minimum of 2
minutes worth of data for the component must be recorded before the trend alarms is
monitored.
Streams Setup
• Streams analyzed
• Stream parameters including delay and purge
• Order of stream sampling (schedule)
• Demand stream analysis parameters
Stream Name
Identifies each stream by a user-defined name. The name for each stream should be
unique and can consist of any alphanumeric combination of characters.
By definition, Pulsar EX defines the stream at the uppermost position on the Pulsar
results display as stream 1, regardless of its user-defined name. The second stream
from the top is stream 2, and so on down the screen to stream 3 at the lowest
position. The numbers to the left of the stream names identify their permanent
number assignment.
Delay
Defines the length of the time (in minutes) that the stream is purged after the system
switches to this stream from another stream. This purge time ensures that any
previous sample is flushed from the system before a new reading is taken. Minimum
purge time is one minute.
PrePurge
The length of time (in minutes) that the system will flow sample to the vent after the
stream is selected. This prepurge time ensures adequate time to fill the sample lines
to the system with representative sample before switching the valve to select the
stream. During PrePurge time, analysis readings continue on the previously
monitored stream.
Pre Run Cal Check

If selected, the system performs a calibration check prior to performing an analysis
on the stream.
Stream Enabled
If selected, the stream is analyzed. If the Stream Enabled option is not checked, It
allows a stream to be temporarily disabled without having to explicitly remove it from
the Stream Schedule (see below).
Storage Enabled
If selected, the results for this stream are stored to disk.
Running Average
This value determines the number of results to average for each component on the
stream. A running average of 5 would mean the last 5 results are averaged and this
value would be displayed, checked for alarms if required, displayed on the graph and
optionally stored to disk. If there are less than the required number of results, i.e.
only 4 results have been taken then these are averaged. For demand streams (but
not continuous process streams) repeated analysis of the stream is conducted until
the specified number of measurements has been recorded for the running average
before moving on to the next stream.
Process Stream Analysis Interval

The frequency (in seconds) at which the stream readings are taken when the system
is continuously monitoring only a single stream such as the truck test. The Stream
Analysis Interval is also invoked when a running average greater than 1 is entered
for a stream.
Stream Schedule
The stream schedule defines the sequence for analyzing process streams. The
sequence need not be in numerical order and some streams may be repeated or
missed. When the end of the given sequence is reached, the sequence is repeated.
Some examples (assuming maximum of 3 process streams) are as follows:
o 1, 2, 3
o 1, 2, 1, 3
o 2, 3
Demand Stream Analysis

Defines the parameters for the truck delivery tests.
Sampling Type
Dynamic sampling provides a continuous analysis of the CO2 while the truck is
unloading into the tank. Dynamic sampling should be the selected sampling type.
Static sampling analyzes the truck sample prior to unloading the sample. Static
sampling ensures that potentially contaminated sample is not charged to the holding
tank.
Dynamic Sampling Timeout
Defines the duration of the dynamic sampling truck test. The Timeout should be less
than the average truck off-load time. If the Timeout is set to 0, the truck test will
continue until an operator manually stops the test.
Calibration Setup
• Calibration type
• Calibration schedule
• Action to be taken on calibration check failure
Calibration Type
No Auto Calibration
The Pulsar EX software will not perform a full calibration or a calibration check on
scheduled basis.
Note: A full calibration can be requested manually, at any time, via the Calibrate; Calibrate
Now menu option. The calibration check can be performed prior to any stream
analysis by setting the appropriate Pre Run Cal Check flag on the Stream Setup
page.
Full Calibration
A full calibration is performed according to the calibration schedule. Full calibrations
are recommended.
Calibration Check Only

A calibration check is performed according to the calibration schedule. The
calibration check performs a calibration, however it does not apply the newly
calculated factors to the system. The system is not updated.
Calibration Schedule
This applies to both full calibration and calibration check. A calibration is performed
at the specified time and repeated every N hours. In the above example, a full
calibration is defined to run at 3:00 am and repeat every 24 hours.
It is also possible to prevent an automatic calibration starting within N hours of the

Pulsar EX system starting up. This is useful where the analyzers require time to get
to the correct operating temperature.
The Abort Scheduled Calibration following a Hardware Alarm checkbox should be

checked to ensure that potentially incorrect calibration results obtained when there
was a failure is not applied to the system.
Action to take on Calibration Check Failure
Note: Calibration checks are NOT recommended. Calibration checks do not apply the
calculated calibration factors that are required to ensure the highest confidence in
the results.
Continue
The global alarm is activated and a message is placed in the activity log. The
scheduled or manually requested analysis continues.
Calibrate
The global alarm is activated and a message is placed in the activity log. A full
calibration is invoked.
Stop Analyzing
The global alarm is activated and a message is placed in the activity log. All analyses
are stopped until a successful manual calibration has been performed.
Pre Run Calibration Check Options

Perform Zero & Span Check
If Calibration check is selected, the Pulsar will perform a check on the zero and span
values for each analyzer.
Perform Zero Check Only
If Calibration check is selected, the Pulsar will perform only a check on the zero values
for each analyzer.
Alarms Setup
• Define the alarm set point for warnings and alarms

• Enable / disable an alarm
Concentration values for Warning and Hi alarms can be set for each component on each
stream on each Analyzer. Only the SetPoint and Enabled fields may be changed. To
change a set point, touch the desired value on the screen and enter the new value.
To disable an alarm, click the checkbox under the enabled column. The alarm is enabled
when the check mark is present.
Alarm Type
Warn
Defines the first-level or warning limit for the substance of interest (e.g., sulfur,
hydrocarbon, or aromatics). A unique warning level can be set for each stream. The
unit of measure for the alarm setting is specified on the display screen.
Alarm
Defines the second-level or maximum limit for the substance of interest (e.g., sulfur,
hydrocarbon, or aromatics). A unique maximum limit can be set for each stream. The
unit of measure for the alarm setting is specified on the display screen.
Pulsar Security – Name and Password
For distribution to QA manager or system administrator only!
Prolink Security Software requires a Name and Password to access the software. When
installed, the ProLink is setup with a default name and password. The name and password
are case sensitive.
Username: Security Manager

Password: password
ProLink Software Users and Passwords
Default login has operator privileges. DO NOT change the password or username for the
default login.
Username: default
Password: <blank password. Hit the enter key.>
Supervisor login has Supervisor privileges.

Username: supervisor
Password: <blank password. Hit the enter key.>
Engineer login has Engineer privileges.

Username: engineer
Password: prolink
Thermo login provides the privileges and software access required by Thermo Electron
service technicians.
Username: thermo
Password: thermo
Revision 2.0 1 of 1
Pulsar EX System Security
Overview
The ProLink Security software is used to define user levels and other security features. It
allows the system administrator to change the permissions for any number of operator levels
of the system. Security is managed in terms of Functions, Groups, and Users.
The following single point lesson (SPL) will train system administrators and managers how
to set up security using the ProLink Security software.
• Defining Access Levels

• Defining Groups and Allocating Functions
• Creating Users and Assigning Users to Groups
Note: System administrators must have the full keyboard installed when working at the
Pulsar monitor. System security can be setup from the Remote Lab PC or Pulsar.
Opening ProLink Security Software

ProLink Security software requires the user to enter a password and username to access
the software.
1. Select the Windows Start menu.
2. Under Programs choose the ProLink folder
3. Select the ProLink Security Menu item.
4. In the security log in dialog, enter the system administrator username and
password.
Note: The ProLink Security username and password were provided to the system
administrator or QA manager at installation. For security reasons, the logon
information is not included in this training module. If you lost the username and
password, please call Thermo Electron Technical Support.
Navigating ProLink Security Software
Group Details
• Create and delete groups
• Change available functions for each group
• View users in group
User Details
• Create and delete users
• Define usernames and passwords
• Assign users to a group
System Options
• Set the time when the logged in user will automatically be logged
out.
After the time defined as the auto-logout time in the System Option,
the ProLink software will automatically log the current user out of the
software and return control to the default user. The user will have to
re-enter their username and password to obtain access to selected
functions.
File Menu
• Exit command
Edit Menu
• Group details
• System options
• User details
Security Menu
• Passwords. Change username and password for ProLink
Security administrator.
Help Menu
• About ProLink Security. Version and copyright information.
Defining Access Levels

ProLink Security software uses groups to define the privileges and functions available to a
user. By default, the software provides three access levels, Operator, Supervisor and
Engineer with defined privileges. The Operator is able to perform only basic functions and
cannot change any system settings. The Engineer has full access to all functions. The
Supervisor has an intermediate level of privileges and is able to access the setup functions.
Operator Functions Supervisor Functions Engineer Functions

Acknowledge alarm Acknowledge alarm Acknowledge alarm
Any on-demand analysis Any on-demand analysis Any on-demand analysis
Perform manual calibration Perform manual calibration Perform manual calibration
Exit Program Exit Program Exit Program
Setup trends Setup trends
Setup analyzers Setup analyzers
Setup reports Setup reports
Setup alarms Setup alarms
Setup calibration Setup calibration
Setup streams Setup streams
Perform manual cal check Perform manual cal check
Override auto cal delay Override auto cal delay
Engineering Functions
Analyzer Mode Switch
.
Changing Group Privileges
1. Open the Group Details dialog by clicking on the icon.

The Group Details dialog box will open.
2. Select the group you want to change from the drop down list.
3. Use the “<” and “>” symbols in the middle of the dialog box to add and remove
functions available to the group.
The functions listed under the “Allocated” box are the functions the group will have
access to. The functions listed under the “Available” box are functions that the group
does not have privileges to use.
4. Click on the Save button at the upper right corner of the box.
5. Repeat steps 1-3 until all changes to group privileges are made.
Creating a New Group

The Group Details dialog box will open.
2. Select the New Group button.

The Group Name will change to New Group and no functions will be allocated to the
new user.
3. To change the group name, highlight the group name in the dropdown box and
type in the new name.
4. Click the Save button to the right of the Group Name box.
5. Add functions to the new group by selecting the desired function from the
Available list and clicking the to move the function to the Allocated list.
6. Click on the Save button.
Deleting a User Group
1. Select the user group you want to delete from the Group Name drop down.
2. Click the Delete Group button to delete the group.
3. Respond Yes to the prompt confirming you want to delete the group.
Note: To view the users assigned to a group, click on the button. You can
hide the view of users in a group by clicking on the Hide Users in Group button.
Managing Users
In the User Dialog , usernames and passwords can be created, deleted or changed.
The new user’s privileges are defined by assigning them to a group.
Creating a New User

The User Details dialog box will open.
2. Click on the New User button.
3. Click on the Select User dropdown box to highlight the name.
4. Type in the new user name.
5. In the Login Name text box, type in the login name.
6. Use the Group dropdown box to assign the user to a group.
7. Type in the password for the new user.
8. Retype the password in the Confirm Password textbox.
9. Click on the Save button at the upper right corner of the User Details dialog.
Deleting a User
1. Select the user to be deleted from the Select User dropdown list.
2. Click on the Delete User button at the bottom of the User Details screen.
3. Click Yes when the confirmation dialog appears.
Changing a User Password
1. Select the user from the Select User dropdown list.
2. Highlight the Password field.
3. Type in the new password.
4. Retype the new password in the Confirm Password textbox.
5. Click on the Save button
Note: Remember to click the SAVE button after making any changes in the User Details
screen.
Setting the Auto Log-out Time

After the time defined as the auto-logout time in the System Options, the ProLink software
will automatically log the current user out of the ProLink software and return control to the
default user. The user will have to re-enter their username and password to obtain access
to functions the default user cannot access.
1. Click on the icon to open the System Options screen.
2. Change the Auto-Log out time by pressing the up and down arrows.
3. Click OK to exit.
Changing the Administrator Name and Password

There is only one administrator username and password to access the ProLink Security
software.
Note: Remember to write down the new administrator password and name. The
administrator password and name may be required by Thermo Electron to provide
technical support.
1. Choose Password from the Security Menu.
2. To change either the Name or Password, highlight the entry and type the new
name.
3. If you made a change to the password, you must confirm the new password by
entering the password into the Confirm New Password text box.
4. Click the Save button.
Pulsar EX System Maintenance
Overview
The Pulsar EX system requires minimal routine maintenance by plant personnel. The plant
responsible for maintaining the air filters at the Pulsar unit. Thermo Electron will perform
routine maintenance at 6- and 12-month intervals.
The following Single Point Lesson (SPL) explains how to:
• Monitor and maintain the air filters external to the Pulsar EX
It also outlines the routine maintenance schedule performed by Thermo Electron service
technicians.
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Air Filter Maintenance

The Air Filter unit external to the pulsar must be monitored daily to ensure the highest
quality air is supplied to the Pulsar system.
If the status window on the left air filter is red and displays the “Change”
message, then:
1. Turn off the facility air to the Pulsar.
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2. Disconnect the input to the air filters.
3. Rotate the air filter cover to the left and remove.

The air filter cover is removed by unscrewing the bottom of the canister.
4. Unscrew and remove the filter element.
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5. Screw in new filter element.
6. Replace the air filter cover.
7. Replace the two remaining air filters by following the procedure outlined in
steps #3-6 above.
8. Reconnect the input to the air filters.
9. Turn on the facility air pressure to the Pulsar.
Revision 2.0 4 of 5
Pulsar EX Routine Maintenance Schedule

• To be performed by Thermo Electron
Six Month Maintenance

• Visually inspect and clean the system
• Replace Total Hydrocarbons permeation tube
• Test the system for internal leaks
• Replace internal flow restrictors
• Replace the activated charcoal filter in internal scrubber
Annual Maintenance
• Visually inspect and clean the system
• Replace Total Hydrocarbons permeation tube
• Replace Total Aromatics permeation tube
• Replace Total Sulfur permeation tube
• Replace Acetaldehyde permeation tube
• Test the system for internal leaks
• Replace internal flow restrictors
• Replace the activated charcoal filter in internal scrubber
Maintenance on an as needed basis

• Replace sample particulate filters when flow rates are diminished
• Replace air scrubbers if contaminated or liquid buildup is observed
• Replace air filters
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Pulsar EX Basic Troubleshooting
Overview
Using the System Monitoring Single Point Lesson (SPL), confirm that the pressure and
temperature gauges are reading properly before consulting this basic troubleshooting guide.
The following SPL will assist operators in diagnosing basic Pulsar EX system faults.
• Low Pressure Alarm

• High Analyzer Stream Readings
• Auto Calibration Fault
• Pyrolyzer Failure
• Computer Not Responding
Note: When support is provided by Thermo Electron via modem, the pcAnywhere
application on the Remote Lab PC must be closed.
Revision 2.0 1 of 8
Pressure Low Alarm
The Pulsar EX requires proper air and CO2 pressure to operate correctly. These pressures
are monitored by an internal pressure sensor that is set to alert the operator if the air,
sample or zero gas pressures drop to zero.
Procedure
1. Verify that the external regulators for the pre-filter, post-filter and truck
vaporizing regulator are set to 60 psi.
2. Verify that the internal pressure gauges are reading 30 psi.

If the internal pressure gauges do not read 30 psi, adjust the pressure using the
corresponding knob.
Air
Sample
Zero
3. Verify that the isolation valves on the rear of the monitor are in the on position.
Isolation
Valves
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High Analyzer Stream Reading

Although the Pulsar EX detects actual impurities in CO2, plant anomalies that affect CO2 and
air pressure may cause higher than expected readings.
Procedure
1. Determine if high readings are on both the pre-filter and post-filter streams.
2. If the readings on the post-filter stream are higher than those on the pre-filter
stream, the problem is either associated with the sample line or some other
interference with the CO2 system.
The Benzene reading on the Post-filter is higher than the reading on the Pre-filter in
the above example.
3. Refer to your procedures for details on how to respond.
Revision 2.0 3 of 8
Auto Calibration Failure

Proper calibration is critical to the operation of the Pulsar EX system. When calibration fails,
the system generates a fault to alert the operator.
Note: If an alarm is generated during calibration, the calibration is aborted. If the alarm is
silenced during calibration, the calibration is still aborted. The Activity Log will
display a message similar to “Calibration aborted; hardware alarm”.
1. Check the activity log.
2. Has there been a system shutdown including loss of power in the past
two hours?
If YES If NO
• Wait for the system to stabilize, the time depends
on the down time.
• Perform a manual calibration.
3. Have there been any facilities failures during calibration, such as cycling
CO2 on/off, loss of vaporizer, etc.
If YES If NO
• Perform a manual re-calibration.
4. Are any of the internal pressure gauges reading under 30 psi?

If YES If NO
• Verify that the external pressure gauges read 60
psi.
5. Does the status window of the air filters display red “Change”?
If YES If NO
• Replace the air filters
• Allow the system to stabilize for 1 hour
• Initiate a manual calibration and make sure the pressures / temperatures
do not fluctuate during the entire calibration sequence.
6. Does the calibration fail on span low?

If YES If NO
Contact the Thermo Electron representative.
Revision 2.0 4 of 8
7. Does the calibration fail repeatedly on zero gas high?

If YES If NO
Contact the Thermo Electron representative to replace the The procedure is
zero gas scrubber. finished.
If you are unable to resolve the Auto Calibration failure, contact the Thermo Electron
technical support.
Revision 2.0 5 of 8
Pyrolyzer Fault
The pyrolyzer is internal to the sulfur analyzer and is responsible for converting all sulfur
compounds to sulfur dioxide, which is accomplished by heating the sample stream to over
1200 °C. If the temperature of the Pyrolyzer drops too low, this conversion will not take
place and an alarm will be generated.
Procedure
1. Check the Pyrolyzer temperature meter.

If the temperature gauge is not reading the correct value, make sure that the set
point value was not mistakenly changed. To check the pyrolyzer set point
temperature, press the left-hand button (Set Key) on the display. The display should
alternate between °C and 1200. To adjust the temperature, press and hold the set
key and then press the up and down arrow keys on the temperature gauge.
2. If the temperature meter display on the front of the Pulsar alternates between
“AL” and a temperature from 20 ºC to 40 ºC, call Thermo Electron support —
the Pyrolyzer has failed and needs to be replaced.
Pyrolyzer
Temperature
Gauge
Revision 2.0 6 of 8
3. If the temperature controller displays “inPt FAIL”, call Thermo Electron

support — the thermocouple has failed and needs to be replaced.
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Computer Lock-up
The Pulsar EX and the Remote Lab PC runs within the Microsoft Windows operating
System, which is prone to locking up and not responding from time to time, just like in a
normal PC. If this happens, the Pulsar EX or Remote PC must be re-booted to restore
operation.
Procedure
1. Shut off the power to Pulsar EX or the Remote PC.

The power switch on the Pulsar is located on the rear of the monitor near the center
bottom.
2. Wait 10 seconds.
3. Turn the power back on.
4. Allow the system to re-start.
5. Log back into the Pulsar EX or Remote PC.
Revision 2.0 8 of 8
Pulsar EX Frequently Asked Questions
What do negative numbers mean?

Negative numbers occur when the amount of a particular contaminant is below the
limit of detection of the analyzer. The negative numbers are not displayed on the
main results screen but will be visible in the numeric and trend display and when a
data file is opened in spreadsheet programs such as Microsoft Excel.
If the magnitude of the negative number is greater than:

• 2 ppb on the sulfur analyzer
• 0.5 ppm on the THC analyzer
• 0.5 ppb on the aromatics analyzer or
• 20 ppb on the acetaldehyde analyzer
there may be a problem with your unit. Contact Thermo Electron technical support.
How do I print a COA (Certificate of Analysis)?

Refer to the Single Point Lesson (SPL) on Truck Testing for instructions on printing
the COA during truck delivery. The SPL on Data Retrieval and Interpretation has
instructions on how to print reports on manually selected streams.
What should I do if there is a temporary loss of power to the Pulsar?

If there is a temporary loss of power to the Pulsar system, follow the Start-up
procedure in the System Monitoring training module. Let the system stabilize before
starting data collection or a calibration. Length of time required to stabilize the
system will depend on the amount of time the power was off. If the system was
without power for more than 15 minutes, it will take 1-2 hours for the unit to re-
stabilize.
What happens if the air supply to the Pulsar EX is shut off?

If the air supply to the Pulsar EX is disrupted or shut-off while the Pulsar is still
running, the low-pressure alarm will be triggered. A full alarm (red screen) will occur.
DO NOT silence the alarm if there is a loss of air to the system. If the alarm is not
silenced, when the air supply is restored the system will automatically enter into a
20-minute delay before it begins analyzing any stream. If a calibration was
scheduled to occur during the period when the air supply was shut off, the system
will then start a calibration. The Pulsar will be purged for an additional 20-minutes as
part of the calibration routine.
If the alarm is silenced before the air supply is restored, after an initial 20-minute
delay, the Pulsar will automatically begin an analysis or calibration. The calibration
and stream results will be inaccurate because the Pulsar did not have time to
stabilize after the air supply was restored. In this situation, the analysis should be
aborted. Allow the system to stabilize for 60 minutes and then initiate the calibration
routine manually.
Revision 2.0 1 of 3
Does the Pulsar analyze gas or liquid carbon dioxide?

The Pulsar analyzes gas phase carbon dioxide. If liquid carbon dioxide were to
reach the Pulsar monitor, the check valves inside the unit would be triggered
preventing damage to the instrument.
How do I back-up the Pulsar data?

Data can be backed up directly from the Pulsar system using the CD/RW drive or on
the Remote Lab PC by transferring the files to the lab PC using the pcAnywhere
automatic file transfer feature. The files can be transferred to a CD using the CD
burner.
In the event that the Pulsar system has a complete computer failure, Thermo
Electron will reinstall all the necessary software including operating system and
restore your monitor to proper operating status. It may not be possible to restore lost
data that resided on the Pulsar hard drive and was not backed previously.
How do I know if the Pulsar switched to benzene-only mode?

Any time a result on the Total Aromatics analyzer is greater than or equal to 20 ppb,
the Pulsar will automatically switch to benzene-only mode. The analyzer will enter
into a purge sequence and then a result will be displayed in the Benzene results
column as shown below.
Revision 2.0 2 of 3
How does calibrate work?

Calibration is performed every 24 hours by establishing a zero reference and a span
level. In ensure accurate and reliable results, calibration should be performed daily.
The zero reference uses scrubbed post-filter CO2 gas. The span level is generated
using permeation devices (tubes) installed in each bench. The zero and span define
a two-point linear calibration curve. A calibration factor/coefficient is generated and
applied to all results until the next calibration occurs.
How long does a calibration take?

Calibration takes approximately one (1) hour to complete.
What should I do if a truck delivery occurs during a calibration?

To ensure the most accurate and reliable results, a calibration should not be aborted.
Do your best to schedule a truck delivery during a time when the calibration is not
scheduled to occur. In the event that a truck delivery and calibration occur
simultaneously, it is highly recommended that the calibration be allowed to continue
and the truck driver asked to wait until the calibration is complete. Once the
calibration is completed, the truck testing may be initiated.
What happens when there is an alarm during calibration?

If an alarm occurs during calibration, the calibration will be terminated and the
calibration is NOT completed. A message such as “Calibration aborted; hardware
alarm” will appear in the Activity log. Silencing an alarm that occurs during
calibration acknowledges that the user is aware of the alarm. If an alarm occurs
during calibration, consult the Auto Calibration Fault section in the Basic
Troubleshooting module. Once the cause of the alarm is corrected, initiate a manual
calibration by selecting “Calibrate Now” in the Calibrate menu.
How does the system determine if a calibration is good?

At installation and each time a new permeation tube is installed, the system is
calibrated. These calibration results are used as the baseline reference for all future
calibrations. Each subsequent time the system is calibrated (every 24 hours), the
new calibration results are compared to the original calibration. The results
(calibration coefficient) from the daily calibration must be within a pre-defined
acceptance level, generally set at 20%. If the results differ from the original values
by more than 20%, the calibration is rejected and an alarm is signaled.
Revision 2.0 3 of 3

Pulsar EX Carbon Dioxide Monitor: Training Manual

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Training Manual

Rec 4217 Rev A

Technical Support for the Pulsar EX

What is a Pulsar EX?

• Sulfurs – regulatory, also affects product taste and smell

• Delivery Truck, to prevent out-of-specification loads from being added to the

Delivery Vaporizing Storage Vaporizer Filters

Remote Truck Panel

What Are the Key Features of the Pulsar EX?

How Does the Pulsar EX Take Samples?

How Does the Pulsar EX Test CO2 Delivery Trucks?

How Can I Access the Pulsar Software?

What information is displayed on the Pulsar EX results view?

To display the Pulsar Results View

1. Select the VIEW button from the bottom of the screen.

2. Select RESULTS from the menu.

How will I know if the analysis failed?

How do I start the ProLink for Pulsar software?

How do I start the Remote Lab PC software?

2. In the pcAnywhere interface, click on Remote button in the icon bar.

3. Click on Network, Cable, DSL icon in the pcAnywhere window.

Typical Display at the Remote Lab PC

1. Turn the Pulsar power ON.

2. Open the utility air supply.

4. Open the flows to both pre-filter and post-filter samples.

6. Allow the instrument to stabilize for 1-2 hours.

7. Begin the analysis.

5. On the Pulsar display screen, verify that no alarm conditions exist.

Alarm Screen and Button

Stream Results Unknown

Stream Result(s) in Alarm

Stream Selection in Progress

Review the individual stream results as follows:

1. Press the STATUS Button.

2. Select the INSTRUMENT STATUS menu item.

3. Confirm that all instrument status items read OK.

1. Press the VIEW button in the ProLink software.

2. Select the ACTIVITY LOG menu item.

2. Select Shut Down from the menu.

5. Close the sample flow.

6. Close the CO2 flow.

7. Close the utility flow (air).

8. Turn off power to the Pulsar.

9. Turn off the circuit breaker to the Remote Truck Panel.

10. Turn off the circuit breaker to the Vaporizing Regulator.

• Setting Up the Valves for the Truck Test

Loading Dock Interface Display with keypad

Setting Up the Valves for the Truck Test

Valve Configuration Chart – Dynamic Truck Test During Off-loading (3

A CO2 supply Closed Open Open

B Static Sample Closed Closed Closed

C Constant Purge Open Closed Closed

Analysis Start via Loading Dock Interface (LDI)

Dynamic (3 Discrete Tests) Sample Procedure

Enter User ID:

Waiting for User ID

2. Enter your Operator ID and press the Enter key.

3. Enter the Tanker ID, press the Enter key.

Enter User ID: 586940

Waiting for Tanker ID

4. Ask the truck driver to blow-down the fill line.

10. Have the truck driver begin his offload.

Enter User ID: 586940