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1. Fl Advanced Config H3 SYSTEM I O ANALOG OUTPUT Advanced Config System I O Analog Output CHANNEL 1to3 configuring each 4 to 20mA channel Pid to output Concentration Transmission Gas Temperature Gas Pressure or None WARNING MODE setting of mA output response during analyzer warnings Block Track Hold FAULT MODE setting of mA output response during analyzer warnings Block Track Hold BLOCK MODE LEVEL specifies the analog output level in block mode high 20mA or low 3 3m4 FIELD LOOP CHECK allows specified 4 20mA output levels to check and distinguish between the three analog output connections select analog output channel 1 2 or 3 to check and input new value to output and press enter to activate AO CH CALIBRATION Pre Calibrated at factory and not normally required Allows calibration of 4 to 20mA output channels follow onscreen instructions IM 11YO1B02 O1E A 4th Edition September 11 2012 00 6 BASIC OPERATION 6 9 Bl Advanced Config Oe SYSTEM I O ANALOG INPUT me Sane Contig Systom YOO Anaog input Pre calibrated at factory and not normally required Allows calibration of 4 to 20mA input channels follow onscreen instruction CH 1 Calibration CH 2 Calibration F Advanced Config Oe SYSTEM I O DIGITAL OUTPUT Advanced Config System I O Digital Output Setting of Digital Output assignments DO 1 3 CHANNEL 1 WARNINGS Setting of levels that will trigg
2. Result mon Check Gas 1 Local Initate Remote Initate control channel Time Initiate frequency Check Gas 2 Settings conc opl temp pres Check Gas 3 similar to Gas 1 Local Initiate Remote Initate control channel Time Initiate frequency Settings conc opl temp pres valves purge times AO mode Updated Relative Absolute Warning Fault User Data o o 172 Data Refresh Current Trend screen Min Max Minutes IM 11Y01B02 01E A 4th Edition September 11 2012 00 6 BASIC OPERATION 6 4 Optional Mini Display 4 line x 20 character Software Map oe Display Text Line 1 Measurement Measured gas and unit of measurement Line 2 Transmission or Sec Transmission xx x 96 Laser light transmission strength ond Gas Measurement 0 10096 range CHA xx x 96 Second measurement gas and unit Initializing shown during the power up and initialization of the analyzer WARNING Det Sig Low WARNING Conditions Line 3 Status FAULT Conditions Data Transfer Status TransferFaiture Transfer Failure YOKOGAWA TDLS220 Analyzer Name SN 76 1xxx 05 xx Analyzer Serial No AO1 CONC xx xx96 ppm ppb AO2 TRANS 9 Configured 4 20mA output for XX XX Yo AO1 AO2 amp AO3 AO3 TEMP xx xxF C K Bed sdntomdaion 10 0 0 35 Static IP Address TEMP Act Con Fix xx F C K Process Gas Temperature used for gas concentration calculation PRES Act Con Fix xx x PsiA Process Gas Pressure used for gas con
3. The trend will not update automatically use STDEV1 23 000 B STDEV2 looo MAN 20 4 VM A A A aad A M the refresh button to update the trend GAS 1 analyzer reading of gas 1 concentration STDEV1 the standard deviation of 25 consecutive concentration readings of Gas 1 GAS 2 analyzer reading of gas 2 concentration STDEV2 the standard deviation of 25 consecutive concentration readings of Gas 2 ea TRANS transmission 96 of laser light through the 12 10 2008 14 02 24 process LTS analyzer laser temperature set point LT analyzer laser temperature PCP peak center position for the absorption peak TEMP process gas temperature PRES process gas pressure Alongside the selection buttons the current value is displayed When selecting the information to trend user will be prompted to enter minimum value maximum value and time to trend advanced confie H3 ADVANCED CONFIGURE MENU gt gt PROCESS PATH LENGTH DO NOT ADJUST factory set typical 40 distance laser beam is exposed to m Asia ae decane a ede PROCESS PRESSURE allows selection of FIXED value entered into software ACTIVE analyzer fed pressure value from external transducer or CONTROL cell pressure controlled at a desired value with a proportional valve and pump In Active mode a Back Up value can be entered in case of active input failure TEMPERATURE allows selection of FIXED value entered into software ACTIVE INPUT ana
4. 11 2012 00 Blank Page IM 11YO1B02 O1E A 4th Edition September 11 2012 00 Blank Page IM 11YO1B02 O1E A 4th Edition September 11 2012 00 Yokogawa Corporation of America Yokogawa has an extensive sales and North America TAE 2 Dart Road Newnan GA 30265 1094 USA distribution network Phone 800 258 2552 Fax 770 254 0928 Please refer to the website www yokogawa com us to contact your nearest 12530 West Airport Blvd Sugar Land TX 77478 Phone 281 340 3800 Fax 281 340 3838 representative Mexico Melchor Ocampo 193 Torre C Oficina 3 B Veronica Anzures D F C P 11300 Phone 55 5260 0019 55 5260 0042 Yokogawa Canada Inc A Bay 4 11133 40th Street SE Calgary AB Canada T2C2Z4 e R YOKOGAWA e Phone 403 258 2681 Fax 403 258 0182 IM 11Y0O1B02 01E A 04 1209 A I Subject to change without notice Printed in The USA Copyright 9 IM 11YO1B02 O1E A 4th Edition September 11 2012 00
5. 40 Concentration of the target gas inside the gas flow cell Press Enter to proceed Wait for the reading to stabilize Press 9 to proceed AUTOMATIC OFFLINE VALIDATIONS The Offline Validations can also be automatically configured Refer to section 5 5 3 for details Local Initiate will start the automatic online validation sequence when selected It will use the existing Settings See below for details on Settings Remote Initiate will enable disable monitoring of the selected Remote Initiate contacts on TB 2 within the Launch Unit When enabled the analyzer will detect the chosen contact closure and automatically start the online validation sequence Time Initiate will allow input of a specified time to automatically start online validation sequence once every day every week every 2 weeks or every 4 weeks IM 11YO1B02 O1E A 4th Edition September 11 2012 00 7 ROUTINE MAINTENANCE 7 13 Advanced Calibrate amp Validate PRI AUTOMATIC OFFLINE VALIDATION SETTINGS Advanced Calibration amp Validation Offline Validation Settings _ Please see below for detailed explanations of Validation Settings Check Gas Concentration Check Gas Pathlength Check Gas Temperature There are several critical parameters that must be preconfigured in the TDLS220 software when using the automatic validation sequence These parameters MUST be correctly set otherwise the analyzer will report false incor
6. Calibration amp Validation Span Calibration Manual Restore old span calibration result Press 9 to restore previous span calibration press 8 to restore factory span calibration or press ESC to cancel Ensure analyzer is purged with nitrogen IM 11YO1B02 O1E A 4th Edition September 11 2012 00 8 TROUBLESHOOTING 8 1 8 Troubleshooting The TDLS220 TDL Analyzer troubleshooting is fairly simple for a process analyzer First virtually all components used in the system have a long Mean Time Between Failures MTBF with rated life of components typically exceeding 10 years when operating within their stated specifications Second most probable failures and problems are diagnosed by the system generating internal warning and fault conditions The intent of this guide is to provide common troubleshooting steps it does not detail specific repair procedures such as laser module replacement as these are unlikely and are detailed in other sections of the manual Routine maintenance procedures are also detailed in other sections of the manual The most common issues are divided into two categories Warnings These are conditions which will affect the analyzer reading but not cause complete loss of measurement integrity An example would be reduction of transmission amount of laser power at the detector which could indicate window fouling where the measurement is still being made but further loss of transmission will caus
7. Connection Protected Name amp IP Delete Select Bu Connection Connection Config VNC Options Connection Options Menu Enter New Password password Return to Exit Main Menu About Confirm Shutdown Shudu Return to Main Menu Return to Main Menu Shutdown Return to Main Menu IM 11Y01B02 01E A 4th Edition September 11 2012 00 6 BASIC OPERATION 6 22 6 5 6 OPTIONAL Virtual Analyzer Controller VAC Operating Software Guide ANALY TIC AN jp specialties Virtual Analyzer Controller 10 Main l Connect F2 Copy Data F3 Configurahion F4 Help Ctri F1 Shutdown Esc a ANALYTICAL Ti specialties Virtual Analyzer Controller vio Select Analyzer LTAL BESP be eed Shue Arles Lerdsoler 5 ien IP Address Oxygen TOL Tag 1 TELES Connect Fz Quit Esc s ANALY TICAL specialties Virtual Analyzer Controller Select ipiam ICTFILsBKSP to end Virtual Analyzer Controller Serion Analyzer Osygen TOL lag 1 IITTES Quil Esc Once an Ethernet connection has been established the VAC software can be started To load the software on to a laptop or desktop PC follow these steps Create folder under c asiini Copy all files from the CDROM to this folder Create a shortcut from the desktop by browsing for the ASI VAC exe file Test the shortcut by double clicking on it and the VAC software should open Once the software is open fol
8. Figure 11 Safe Area General Purpose I A Analyzer Purge Schematic I A Purge Inlet N Purge Inlet General Purpose or Safe Area N Purge Vent I A Purge Vent ELECTRONICS CONTROLLER Figure 12 Safe Area General Purpose Dual Split N amp I A Analyzer Purge Schematic IM 11YO1B02 O1E A 4th Edition September 11 2012 00 lt 5 INSTALLATION AND WIRING 5 7 N Purge Inlet Hazardous Area Div 2 BCD ATEX CAT3 ELECTRONICS CONTROLLER N Purge Vent Figure 13 Hazardous Area N Analyzer Purge Schematic I A Purge Inlet Hazardous Area Div 2 BCD ATEX CAT3 Purge Pressure Switch with Indicator Div 2 BCD ATEX CAT3 ELECTRONICS CONTROLLER I A Purge Vent Figure 14 Hazardous Area I A Analyzer Purge Schematic Note Please also refer to any separate Purge System Original Manufacturers Operating Instructions and Manuals in conjunction with this Instruction Manual IM 11YO1B02 O1E A 4th Edition September 11 2012 00 6 BASIC OPERATION 6 1 6 Basic Operation Only the numerical keys arrow keys ENTER ESC and BACKSPACE keys are used to control the analyzer Their functions are determined by the context sensitive menus of the analyzer software The misuse of keys is not possible rejected by software 6 1 Menu Structure Map Online Menu Level 1 Menu Level 2 Menu Level 3 Menu Level 4 Menu Level 5 Menu Select A O Mode Configure Process Path Length Old Block New Track Pressure Hold
9. IM 11YO1B02 O1E A 4th Edition September 11 2012 00 lt 5 INSTALLATION AND WIRING 5 5 5 4 Purge Gas Requirements and Hazardous Area Systems The TDL S220 Analyzer requires a continuous nitrogen optionally instrument air gas purge to prevent ambient oxygen ingress to the optical path when oxygen is the measured gas The flow rate can be minimized as long as it prevents any ambient oxygen ingress to the measurement optical path Other purge gases may be used as long as they do not contain any of the measured gas and a clean dry etc For hazardous area operation the same nitrogen purge gas is used to purge the entire analyzer including non optical path sections such as the electronics Refer to purge diagrams below In some applications Instrument Air I A may be used as the purge gas Special software configurations must be set up under the Configure section called Non Process Parameters refer to software section of this manual for further details The flow rate can be minimized as long as it prevents any ambient oxygen ingress to the measurement optical path Other purge gases may be used as long as they do not contain any of N Purge Inlet FLOW CELL N Purge Vent ELECTRONICS CONTROLLER Figure 10 Safe Area General Purpose N Analyzer Purge Schematic IM 11YO1B02 O1E A 4th Edition September 11 2012 00 lt 5 INSTALLATION AND WIRING 5 6 I A Purge Inlet I A Purge Vent ELECTRONICS CONTROLLER
10. PCs desktop ready for use when connecting with the analyzer From Control Panel Network Connections make sure Ethernet Local Area Connection is set to Enabled status Disable wireless and any other networking connections Connect crossover or on most 2008 onwards PC s a crossover is not necessary Ethernet cable from client system to Analyzer e On the computer go to Control Panel Network Connections Local Area Connection Internet Protocol TCP IP Properties O Set IP to 10 255 255 254 amp Subnet Mask to 255 0 0 0 Select OK to accept changes on Internet Protocol TCP IP and Local Area Connection Properties O Start Ultra VNC software running from Desktop using the Guide below Ethernet Connection on Single Board Figure 16 Connecting External Computer to the analyzer IM 11YO1B02 O1E A 4th Edition September 11 2012 00 6 BASIC OPERATION 6 20 6 5 2 Using Ultra VNC Software Start the Ultra VNC software by double clicking on the vncviewer exe ICON as shown below Within the VNC Server field enter the correct IP address for the analyzer to which you are connecting then click on Connect button If a successful connection is established then use the default password for entering the VNC connection screen is 1234 see screen below that shows an example IP address of 10 0 200 2 TDLS220 analyzer Serial number 220 XX 1402 XX etc N WARNING DO NOT attempt to change of the Quick Options or any
11. Start Preparation Carefully un pack and check equipment for any obvious damage Ensure the appropriate utilities are available and ready for connection These may include electri cal power nitrogen purge gas instrument air validation gas etc Make sure the sample handling and conditioning system meets the sample inlet and outlet requirements for TDLS220 Refer to Section XX Installation for details Ensure you comply with any local and or site specific safety requirements Read the appropriate sections of the Instruction Manual BEFORE starting any installation work Contact Yokogawa Laser Analysis Division or Local Agent if any doubts Installation Ensure there is sufficient physical space to mount the analyzer and allow suitable space for any future maintenance access Mount the analyzer panel to a secure vertical surface using appropriate style shake proof fasteners Avoid areas prone to vibration to ensure long term reliability the analytical mea surement itself is not affected by vibration Ensure that all wiring will meet local codes and site requirements Connect protective ground wire to the protective ground terminal of TDLS220 Use minimum 14 AWG wire or equivalent Connect the appropriate single phase AC electrical power supply 110 240 50 60 Hz to the terminal block located in the power Temperature Controller box Refer to Part 2 Electrical Hazard of the Safety section in this manual A suitable mains disco
12. TI II To ti Grip area The analyzer should be always transported either in a vertical position as shown in the picture or in a horizontal position with the mounting plate facing down If transported horizontally it must be held by the mounting plate only In vertical position it is acceptable to hold the analyzer by the elements in the grip area Never hold the analyzer by applying force to the elements in the Do not grip zone or to the conecting cables and tubes If a winch or another hoisting device is used it can be hooked to the upper mounting holes 2 Electrical hazard The areas of potentially hazardous voltage are labeled with this sign The analyzer is powered by either a 220V 50 Hz or 120V 60 Hz model specific During normal operation this voltage is not accessible from outside of the enclosure However end user is responsible for connecting the mains to the analyzer terminals in the Power Temperature Controller box right bottom block in the diagram above THE WIRES BEING CONNECTED MUST BE DISCONNECTED FROM ANY VOLTAGE SOURCES DURING THIS PROCEDURE PROTECTIVE GROUND WIRE MUST BE CONNECTED TO THE DESIGNATED TERMINAL LABELED BY THE CORRESPONDING SYMBOL DO NOT OPEN THE POWER MODULE ENCLOSURE WHEN THE ANALYZER IS ENERGIZED Some maintenance and troubleshooting operations require opening the Electronics Controller box left bottom block in the diagram above while the analyzer is powered The highest voltage presen
13. Temperature Similar to Process Path Password Protected IP Address Serial No Version View Spectra Raw Detect Spectrum Spectrum Capture Absorption Spectrum Spectrum Capture Alarm History View Data on screen Cal History View Data on screen Record Data User data Factory data Gas 1 Concentration Min Max STDEV of Gas 1 Concentration Minutes Gas 2 Concentration STDEV of Gas 2 Concentration Transmission Laser Temp Setpoint Peak Center Position Gas Temperature Gas Pressure Similiar to Gas 1 Concentration ADVANCED Configure Process Path Length Current Confirmation of Change Password New Confirmation of Change Protected Current New Confirmation of Change 4 20 mA amp Backup Confirmation of Change Desired Range Center of Confirmation of Change Pressure control Active Control similar to Fixed Temperature Current New Confirmation of Change 4 20 mA amp Backup Confirmation of Change Offset Confirmation of Change Range of second peak option Confirmation of Change Desired range of tem control Confirmation of Change Active Input Active Ambient Active Peaks Control similar to Fixed Non Process Parameter Path Length Current New Pressure Concentration similar to Path Length Temperature Fixed or Active value or offset Path Length Select from in ft cm m Select from psiA barA kPa torr atm Tempterature Select from F C K IM 11YO1B02
14. allow the introduction of appropriate calibration gases 1 With the appropriate user interface go to either Basic Menu to Check Zero or Span or Advanced Menu to Check Zero or Span and or perform actual Calibration Follow the detailed on screen instructions 3 We do not recommend calibrating the Zero If the Zero reading appear incorrect then ensure all data results and spectra have been stored and send the files to Yokogawa Laser Analysis Division for further evaluation k3 Advanced Calibrate Advanced Calibrate Zero Calibration Zero Calibration Ensure calibration cell is purged with nitrogen Ensure reading Is stable for at least one minute Press 9 when ready to calibrate or press ESC to cancel this calibration H20 Concentration ppm ELM When an acceptable zero has been established follow the on screen instructions for Span calibration ENSURE all parameters are correct for the actual TDLS220 flow cell conditions IM 11YO1B02 O1E A 4th Edition September 11 2012 00 7 ROUTINE MAINTENANCE 7 15 Span Calibration Enter calibration cell pressure psiA 4 7 Enter calibration cell temperature F Enter calibration cell length in Calibrated Concentration 0 9 Span Calibration Ensure reading is stable before calibration Analyzer will be span calibrated to 20 90 concentration Press 9 to proceed or press ESC to cancel O2 Concentration Advanced
15. and ready for service If the window does not appear to clean up well then replace the window assembly with a new one If the window appears to have an etched or pitted surface then it has probably been contaminated with HF or other similar corrosive gas A new window should be installed Check and replace if necessary the window o ring IM 11YO1BO2 O1E A 4th Edition September 11 2012 00 lt 7 ROUTINE MAINTENANCE 7 9 Window o ring Once the window has been thoroughly cleaned it should be re installed using a reverse procedure as above CAUTION Ensure the window is installed in the correct orientation with the stainless steel ring clamping the window onto the o ring Note the window holder holes a distinct hole pattern and can only fit in one rotational position on the cell Carefully install the window onto the cell and rotate such that the holes align with the threads hand tighten the fasteners with lock washers in position with 7 64 Allen key Using the 7 64 Allen key wrench carefully hand tighten each screw using a diagonal pattern and gradually increase each screw incrementally do not fully tighten one screw at a time tighten them down evenly and incrementally to a maximum of 18 Ib in torque When the window is fully fastened check the transmission level to see if normal levels have been restored and if the measurements now appear normal If so replace the enclosure cover and allow 30 minutes for temperature stabi
16. are possible with correct analyzer configuration at the following conditions Gas temperatures up to 120 C 248 F Gas pressures up to 4 BarG 75psig Each application may differ in maximum limitations depending upon the combination of gas temperature gas pressure and concentration of the gas being measured The standard analyzer is designed for operation in a Safe Area General Purpose The addition of a Purge System facilitates operation in Hazardous Areas The basic TDLS220 analyzer comprises a mounting panel with three units attached the Controller housing the Power Supply Heating enclosure and Flow Cell or optional heated flow cell Several ap may be added to the standard analyzer such as Mini Display 4 line 20 character or 6 5 screen and keypad Hemote Interface Unit not required for normal operation Insulated and Heated flow cell Hazardous Area purge systems Other options may also be added 2 1 Functional Description Tunable Diode Laser or TDL measurements are based on absorption spectroscopy The TDLS220 Analyzer is a TDL system and operates by measuring the amount of laser light that is absorbed lost as it travels through the gas being measured In the simplest form a TDL analyzer consists of a laser that produces infrared light optical lenses to focus the laser light through the gas to be measured onto a mirror and back through the gas and then on to a detector the detector and electronics that control the lase
17. face of the enclosure They are typically 34 Myers hubs that have 34 NPT female threads Each has a ground lug to facilitate the grounding of cable shields to the analyzer chassis as needed When an analyzer has been supplied with the optional Mini Display 4x20 VFD the normally blank blind door has a different configuration The center of the door has a cut out measuring approx 3 W x 1 H 75mm x 25mm A clear laminated safety glass window is mounted to the inside of the door with stainless steel fasteners and a weather tight gasket This allows for external viewing of the actual VFD display without opening the door When an analyzer has been supplied with the optional integral 6 5 display and keypad then the normally blank blind door has a different configuration The left hand side of the door has a cut out measuring IM 11YO1B02 O1E A 4th Edition September 11 2012 00 4 ANALYZER COMPONENTS 4 2 approx 5 W x 4 H 130mm x 100mm A clear laminated safety glass window is mounted to the inside of the door with stainless steel fasteners and a weather tight gasket This allows for external viewing of the actual display without opening the door The right hand side of the door accommodates a keypad 30 keys stainless steel which is also operated externally without opening the door Backplane Circuit Board Large approx 10 H x 15 W printed circuit board that mounts inside the enclosure The board has several integral circuits
18. file formats The content can then be copied and pasted into Microsoft Excel spread Each Calibration and or Validation event is logged with the date MM DD YYYY and time that it occurred the Mode Calibration or Validation the specific type Transmission Calibration Zero Calibration etc and the K constant factor used for the event Example 11 14 2007 14 11 19 span calibrate 612814 89 9250 84 152665 88 11 14 2007 14 50 16 transmission cal 14 95 IM 11YO1B02 O1E A 4th Edition September 11 2012 00 9 DATA FILES AND FORMAT 9 3 Calibration History When the calibr his file exceeds 100KB size the contents is saved to this bak file and the his file is emptied This bak file is in the form of ASCII data files that can be opened with Microsoft Notepad as simple txt file formats The content Calibration History Back Up can then be copied and pasted into Microsoft Excel spread calibr bak A back up of historical log of analyzer Each Calibration and or Validation event is logged with the date calibrations MM DD YYYY and time that it occurred the Mode Calibration or Validation the specific type Transmission Calibration Zero Calibration etc and the K constant factor used for the event Example 11 14 2007 14 11 19 span calibrate 612814 89 9250 84 152665 88 11 14 2007 14 50 16 transmission cal 14 95 calibr Calibration Pick List Factory FACTORY PERSONNEL ONLY Use Only Chemometric Model File Pare
19. is un heated then the sample gas should be with 10 deg C of the ambient temperature Please ensure that the process gas entering the sample cell is above the dew point If necessary utilize membrane or coalescing type filter device on the inlet Lower gas temperatures generally lead to better measurements e Process Gas Pressure It is recommended that the analyzer be installed at a location where pressure fluctuations are minimized Generally as a guide if the temperature of the gas at the point where the analyzer is to be installed is to vary by more than 0 05Bar 0 725psi then an Active input signal should be used for compensation Ensure the analyzer has been selected and configured to suit the maximum operating gas pressure Ensure the process isolation windows have been selected and configured to suite the maximum design gas pressure Lower gas pressures generally lead to better measurements Process Dust Particulate Matter It is recommended that the process gas is filtered to 2u using pro cess analytical grade filtration systems IM 11YO1B02 O1E A 4th Edition September 11 2012 00 lt 5 INSTALLATION AND WIRING 5 3 5 3 Wiring Details Connect protective ground to the designated terminal of the analyzer Use minimum 14 AWG or equivalent The analyzer mains must be connected to an end user provided disconnect device a switch or circuit breaker with 250V 10 A ratings The disconnect device must be located with
20. occur Insert Yokogawa a Supplied SanDisk pE USB memory Part No 2000 1040 p1 LIA 2 Bock Pilone Boord x Storage Device TIE we a i 1 c E wun gta 1 Figure 19 USB Data Port Simply insert the memory device and wait for the Data Transfer to complete Do not remove the device before the transfer is complete The analyzer will advise via the user interface when Data Transfer is complete For totally blind units i e no user interface wait for the indicating LED to stop blinking flashing for at least 5 minutes to ensure the transfer is complete IM 11YO1B02 O1E A 4th Edition September 11 2012 00 REVISION RECORD i Manual Title Model TDLS220 Tunable Diode Laser Spectroscopy Analyzer Start up Manual Manual Number IM 11Y01B02 01E A Edition Date Remark s 1 April 2008 Newly Published one Feb 2012 Revisions Formatting was corrected 3 June 2012 Revisions 1 Format issues were corrected 2 Preface section was modified 3 Safety Precautions section was added 4 Quick Start section 1 was modified 5 General Specifications section updated 6 Section 7 Routine Maintience updated 7 Section 8 Troubleshooting updated 8 Section 8 4 removed 9 Corrected image numbers 4th Sept 2012 Revisions 1 Format issues were corrected 2 Preface section modified 3 Quick Start section 1 was modified 4 Section 5 3 was modified 5 Figure 9 was modified IM 11Y01B02 01E A 4th Edition September
21. on wires Warning E ia NN EL NC Closed contact on Warning Power off state Seem Gnmucniom wu ens C Common contact rated max 1A 9 24VDC NO Open contact on Warning Power off state IM 11YO1B02 O1E A 4th Edition September 11 2012 00 lt 5 INSTALLATION AND WIRING 5 4 Receive Detect Analog 1 output Analog Analog 3 output iin Os a 7 Internal connections only do not use Cal Val initiate signal loop SV 1 to Remote voltage free contacts switch Do not apply external power Cal Val initiate signal loop SV 2 to Remote voltage free contacts switch Do not apply external power Cal Val initiate signal loop SV 2 to Remote voltage free contacts switch Do not apply external power Factory and or Field Externally powered 4 20mA gas temperature signals are wired to 1 and 2 3 not used Loop powered temperature transmitter can be con nected to 1 and 3 24VDC 2 not used Gas Temperature Compensation Externally powered 4 20mA gas pressure signals are wired to 1 and 2 3 not used Loop powered pressure transmitter can be connected to 1 and 3 24VDC 2 not used Mini Display Internal connections only do not use Gas Pressure Compensation 1 4 HEAT TRACE TEMHEHA TURE CONTROLLER CYCLOPS MAINS TERMINAL E YH L N Figure 9 Internal Wiring Diagram including optional cell heating and optional purge unit
22. span gas and follow manual Manual Zero Span procedure via user interface Calibrate Off Line Manual or automatic introduction of Zero and Span gases for Manual Zero Span validation or calibration when equipped with appropriate hard ware valves etc 7 4 1 Off Line Manual Automatic Checking Validation S Advanced Calibrate amp Validate mm MANUAL OFFLINE VALIDATIONS Advanced Calibration amp Validation Check Gas 1 Esisrutodbed dua6d Menu Calibrate amp Validate section Off Line Validations Choose Check gas 1 2 or 3 and select Manual Validation Automatic Ensure analyzer is purged with nitrogen IM 11YO1B02 O1E A 4th Edition September 11 2012 00 F Advanced Calibrate amp Validate Offline Validation Check Gas1 Enter validation cell pressure psiA 4 7 Enter validation cell temperature F Enter validation cell length in 9 6 Validation Concentration ppm F Advanced Calibrate amp Validate Offline Validation Check Gas 1 When reading stabilized press 9 to validate or press ESC to cancel H2O Concentration ppm E 3 F Advanced Calibrate amp Validate xX Advanced Calibrate amp Validate Automatic Local Initiate Remote Initiate Time Initiate 7 ROUTINE MAINTENANCE 7 12 Following the on screen directions enter in the Pressure Cell Pressure Temperature Cell Temperature Cell length
23. that can be cali brated The analyzer with a clean sample flow cell is calibrated at 100 transmission when leaving the factory Spectrum Noise High This is based on a measurement of the noise standard deviation of the absorption peak baseline regions Process Pressure out of range The gas pressure range for the application is programmed into the analyzer Clean window and or mirror Contact Yokogawa if fault cannot be cleared Check pressure transducer feed to analyzer Check to ensure software setting Advanced Menu Configure is correct IM 11YO1B02 O1E A 4th Edition September 11 2012 00 8 TROUBLESHOOTING 8 4 quem Process Temperature out of range The gas temperature Check temperature transducer feed to analyzer from the range for the application is programmed into the analyzer heat trace controller Check to ensure software setting Advanced Menu Con figure is correct If operating outside of temperature range a re calibration may be required contact Yokogawa Concentration out of range The process pressure range for Check to ensure software setting Advanced Menu Con the application is programmed into the analyzer figure is correct L or D unit temp out of range The Controller Unit has two Check purge system flows and excessive heat output from built in temperature sensors backplane and detect board SBC and or other electronic components This diagnostic is triggered if they sense the ambient t
24. 2 O1E A 4th Edition September 11 2012 00 4 ANALYZER COMPONENTS 4 3 Calibration Valve Relays There are three calibration valve relay circuits on the board These are capable of actuating Form C SPDT relays The common pole is connected to 24VDC power and the normally open pole is routed to the field terminal block Digital ground is also routed to the terminal block TB3 as shown below Relay Coil Drive Circuit Relay Coil Relay Contacts 24VDC to C and to NO NOTE Use ferrite coil or direction diode on TB6 wired outputs to prevent switching spikes 24VDC 12W max to external solenoid valve when relay is energized Figure 3 Calibration Valve Relay Diagram Connections of each relay Common and Normally Open are routed through the board to field terminals The contacts are rated for a maximum of 1A 24VDC or 0 5A 125VAC The pluggable field terminals are mounted on the lower edge of the board just to the left side of the DC power input terminals The appropriate relay s is actuated when a calibration gas check valve is to be initiated Laser Temperature amp Current Control The board has two main laser control function circuits temperature control and laser current control Board Temperature The board has a temperature sensing chip circuit that monitors temperature of the board inside the main electronics enclosure The sensor is located on the top edge of the Back Plane Analog I O Board outputs the anal
25. 3 User Alarm Field Loop Check Tag MDLVENT 02 SN 76 1205 08 EXA 12 19 2008 19 04 34 CTRL BKSP to ond Virtual Analyzer Controller Session IM 11YO1B02 O1E A 4th Edition September 11 2012 00 8 TROUBLESHOOTING 8 2 3 Advanced Config ij 15 4 T Advanced Data Ls Obed Advanced Config System I O Analog Output Channel 1 Alarm History Channel 2 Cal History Warning Mode Fault Mode Spectrum Capture Block Mode Level Field Loop Check Record Result Data AO CH Calibration 8 1 Common Troubleshooting Steps For most conditions the troubleshooting steps are common In general the most common issues with the analyzer revolve around ensuring an adequate amount of the laser light is received at the detector Under any warning conditions it is recommended that the following steps are carried out prior to contacting YOKOGAWA 8 1 1 On Process Gas or Zero Gas or Span Gas Check Status LEDs This will ensure that power is routed properly to the system components Status LEDs are listed below from left to right pe tv Analog tO board power supply ev Main power supply O pty Analog tO board power supply IM 11YO1B02 O1E A 4th Edition September 11 2012 00 8 TROUBLESHOOTING 8 3 Record Results Download data files from the analyzer for e mail to Yokogawa Laser Analysis Division 8 1 2 Trouble Shooting Procedure for Lost and or Low Transmission For a
26. 96 for an application that often runs at less than 7096 transmission New Number of spectra to capture when warning FB Advanced Data Determine whether or not the analyzer should capture spectrum Spectrum Capture When Alarm files under a FAULT condition Note this may be useful to do so however if the Fault alarm conditions are not set correctly then there could be excessive files Current created for less meaningful Fault alarm conditions These files are often useful for Factory based diagnostics New Number of spectra to capture when fault IM 11YO1B02 O1E A 4th Edition September 11 2012 00 lt 9 DATA FILES AND FORMAT 9 8 9 2 Downloading Transferring Exporting the Data All the files can be easily transferred from the analyzer to the supplied USB memory device NOTES Please use the supplied SanDisk USB memory device with when getting data from the analyzer Each analyzer is supplied with one pre tested USB memory devices please retain them and use with each appropriate analyzer If an un recognized USB memory device is used then the MS Windows XPe operating system may attempt to install new hardware This will not affect the normal operation of the analyzer however if you have a full display interface operational a Windows based pop up may ask for a system reboot Do not attempt to plug in any other USB based products keyboards WiFi etc in to the USB ports Windows based hardware conflicts may
27. ACTORY ASSISTANCE CUR CENTER setting of center point for laser current ramp ONLY ADJUST WITH FACTORY ASSISTANCE IM 11YO1B02 O1E A 4th Edition September 11 2012 00 6 BASIC OPERATION 6 12 TI Advanced Calibrate amp Validate HE3 ADVANCED CALIBRATE amp VALIDATE MENU OFFLINE CALIBRATIONS allows zero calibration zero offset span calibration transmission adjustment gt gt Offline Calibrations dark current calibration and peak search OFFLINE VALIDATIONS allows manual or automatic configuration of check gases 1 through 3 ONLINE VALIDATIONS DO NOT USE THIS FEATURE on TDLS220 Online Validations Tl Advanced Calibrate amp Validate DE3 OFFLINE CALIBRATIONS use for all TDLS220 ZERO CALIBRATION manual or automatic calibration of Zero gt gt ZERO OFFSET allows manual adjustment of Zero by Zero Offset applying a concentration offset SPAN CALIBRATION manual or automatic span Calibration calibration of Span TRANSMISSION adjustment of transmission value DARK CURRENT calibration of detector dark PEAK SEARCH initiates a system scan of absorption Peak Search peaks to validate current peak selection is correct F Advanced Calibrate amp Validate E OFFLINE VALIDATIONS ee CHECK GAS 1 to 3 allows manual or automatic configuration up to 3 check gasses See section 5 5 4 gt gt Check Gas 1 Check Gas 2 Check Gas 3 IM 11YO1B02 O1E A 4th Edition Septe
28. AL NO displays analyzer serial number VERSION software version number ies Obes The spectra screen raw detect or absorption allow Basic Spectra Raw Detect capture and view of current spectra The screen auto scales the vertical axis which will result in a visually noisy absorption spectrum when at low gas levels In fact the spectra may not be noisy but simply that the display range is extremely low 10 eU 30 40 02 amp 20 00 Trans fea 95 00 Temp C 20 31 Pres barA 1 014 Press ENTER to capture the spectrum F Basic Data E The BASIC DATA MENU allows the user to select ALARM HISTORY displays the last 50 alarms and faults with brief description date and time gt gt CALIBRATION HISTORY displays the last 50 calibration events with adjustment amount date and time RECORD RESULT DATA The default setting during normal operation is User Data The system should only be switched to Factory Data when advised by Yokogawa Laser Analysis Division Note recording Factory Data is only for specific diagnostic purposes and should not be selected under normal operation IM 11YO1B02 O1E A 4th Edition September 11 2012 00 6 BASIC OPERATION 6 7 F Basic Trends Oks The TREND SCREEN is identical for BASIC or ADVANCED MENUS It allows the user to trend up to the last 750 minutes of current day of data for Trend Graph Max 750 minutes PE Refresh 24 REFRESH
29. C via direct Ethernet link using Ethernet crossover cable Hemote Access using VNC via Ethernet connection Ultra VNC via external computer laptop Remote Access using optional Remote Interface Unit RIU with VAC software Whether directly connected or connected via network operating the analyzer with an external connec tion allows two basic functions i Remote control of the analyzer via TDLS220 software allows full control of the analyzer The user will see the same screen with the same access functions as if controlling using a built in keypad and display Data transfer via UltraVNC software allows upload and download of data files to from the analyzer 6 5 1 Instructions for Connecting an External Computer to the Analyzer If the remote access via Ethernet link is used on a regular basis during normal operation it is the end user responsibility to equip the Control box with appropriate approved connectors Inside the Control box a standard Ethernet connector is to be plugged as shown in the picture below During troubleshooting and diagnostics Ethernet cable can be connected directly to the SBC with the Control box open Windows 98SE or later is required on computer to be connected to the analyzer and crossover Ethernet cable Contact your local Yokogawa agent for a free copy of the necessary Ultra VNC exe file that will enable the VNC connection with the analyzer This Ulta VNC exe file should be loaded on to the connecting
30. COMPONENTS 4 5 Remote Interface Options A number of options are available for remote access to the analyzer Hemote Interface Unit RIU shown below allows remote analyzer control and data transfer from analyzer to RIU data can be transferred from RIU via USB eno stick or Compact Flash card Allows multi unit field communication via central user interface Not required for individual analyzer operation interface and data transfer only Connects with 1 7 analyzers via Ethernet switch Integral Keypad and 6 5 display External Computer via Ethernet A separate computer can be connected to the analyzers locally or through an Ethernet network to allow analyzer control and data transfer Figure 4 Networked Analyzers The optional Remote Interface Unit RIU consists of Back Plane circuit board SBC Display and Keypad Optional Analyzer Feed through circuit board and or Ethernet switch All field electrical terminals are located on the Back Plane A single RIU can be used in conjunction with up to 7 analyzers via Ethernet more with additional custom Ethernet switches The unit acts as a remote interface for the analyzer Should the physical location of the actual analyzer s be inconvenient for easy access then the RIU can be used It can be mounted up to 100m 330ft away from the analyzer s using the standard 10 BaseT twisted pair wiring method It communicates to the analyzer s through a Virtual Network Connection VNC If there i
31. ILES AND FORMAT 9 1 9 Data Files and Format The TDLS220 TDL analyzer is capable of automatically storing many important pieces of information All the files are stored in simple ASCII text format for easy importing to MS Excel spreadsheets or other data manipulation software as appropriate The rate at which data is captured may be configured from within the TDLS220 software There are several files that are stored in the system Example of files contained within the serial number specific data export folder or the Data folder when viewing through a File Transfer function on Ultra VNC connection Daily Results in the form of ASCII data files that can be opened with Microsoft Notepad as simple txt file formats The content can then be copied and pasted into Microsoft Excel spread Each day as a separate file name in the MMDDYY format with the res file extension meaning result Each file starts with the first up dated measurement set of data for that date and then sequential Daily Results ly contains every up dated measurement set of data in the same dated file until the end of that date A new dated file is created each day Files are deleted automatically on a First In First Out FIFO basis if the allowable Data folder has no spare memory Allows for review of daily results and 092407 diagnostic data on a measurement by measurement basis Daily Spectra in the form of ASCII data files that can be opened with Micro
32. IU Optional Ethernet Switch If there is more than one analyzer connected to the RIU then they are routed via an industrial Ethernet switch Up to four analyzers can be routed through one RIU switch The switch is powered by 24VDC from the back plane and includes several status LEDs Ethernet Analyzer 1 Analyzer 2 Switch SBC SBC Analyzer TB6 Analyzer TB6 Feed Feed through Through Board Tx Tx Rc Rc Tx Tx Rc Rc Tx Tx Rc Rc Figure 6 RIU Ethernet Switch IM 11YO1B02 O1E A 4th Edition September 11 2012 00 4 ANALYZER COMPONENTS 4 7 4 4 TruePeak TDLS220 Software The TDLS220 Analyzer Software has three significant design criteria based on the previously field proven TDLS200 software TruePeak Extensive Capabilities amp Features Intuitive Menu Structure amp Commands Easy Operation The software loads itself automatically upon analyzer power up and the initial display is the MAIN MENU From the Main Menu several key parameters are displayed as well as access to the different User Levels Basic or Advanced and Active Alarms NOTE Please use the Shut Down option on the Main Menu to correctly close the program and Windows BEFORE removing power from the analyzer This will prevent potential corruption of the Windows XPe operating system software image 4 5 Data Reporting Storage and Retrieval The TDLS220 analyzer has been designed with extensive data reporting capabilities All data is available in the analyzer as a
33. O1E A 4th Edition September 11 2012 00 6 BASIC OPERATION 6 2 Online Menu Level 1 Menu Level 2 Menu Level 3 Menu Level 4 Menu Level 5 Menu System Valve Control Laser Spectra amp Control ADVANCED Configure System I O Analog Output Channel 1 Password None Protected 4 mA 20 mA Channel 2 Channel 3 similar to Channel 1 Warning Mode Block Mode Track mode Hold Mode Fault Mode similar to Warning Block Mode High 20 mA Low 3 3 mA Field Loop Check CH 1 check mA value CH 2 check mA value CH 3 check mA value AO CH Calibration CH 1 Calibration CH 2 Calibration CH 3 Calibration Processing Conc1 Conc2 Tran Temp Pres Analog Input CH 1 Calibration CH 2 Calibration Digital Output Detector signal low Transmission Low Spectrum noise hig Process pressure out of range Process temperature out of range Concentration out of range Board temperature out of range Validation failure Laser temperature out of range Detector signal high Dectecor signal lost Outlier rejection Peak center out of range Alarm Limit Conc Trans Val Cal High Low and limit Field Loop Check CH 1 Check Ch 2 Check Ch 3 Check Password Old Password New password Confirmation of Change Date amp Time New Date New Time System Temperature Launch Unit C Detect Unit C Serial Communication Choose serial type between CPU amp FPGA Time Sequence Next Valve Selection Valve on
34. T Du cecec User s TDLS220 TITT Manual Tunable Diode Laser Spectroscopy Analyzer r rn IM 11YO1BO02 01E A vigilantplant YOKOGAWA P 1 um E am m umm M amm E E a um unc ume gt NE um gum a E P YOKOG AWA o Yokogawa Corporation of America IM 11YO1B02 01E A 2 Dart Road Newnan Georgia U S A 30265 Ath Edition Yokogawa Corporation of America Tel 1 800 258 2552 Fax 1 770 254 0928 PREFACE This Instruction Manual has been compiled for Owners Operators of the Model TDLS220 Tunable Diode Laser Analyzer A CAUTION SAFETY should be considered first and foremost im portance when working on the equipment described in this manual All persons using this manual in conjunc tion with the equipment must evaluate all aspects of the task for potential risks hazards and dangerous situations that may exist or potentially exist Please take appropriate action to prevent ALL POTENTIAL ACCIDENTS AVOID SHOCK AND IMPACT TO THE ANALYZER N WARNING This analyzer contains a low power laser source Direct eye exposure to the laser radiation must be avioded A CAUTION The Instrument is packed carefully with shock absorb ing materials nevertheless the instrument may be damaged or broken if subjected to strong shock such as if the instrument is dropped Handle with care Notice Media No IM 11Y01B02 01E A 4th Edition Sept 2012 USA All Rights Reserved Copyright 2012 Yokogawa Corporation of America
35. TDL analyzer to function correctly there must be a suitable amount of the laser light reaching the detector There are several factors or combinations of that can affect the amount of light that is detected on a flow cell of TDLS220 Alignment The mechanical alignment of the laser beam with the detector unit o The beam is not directed at the mirror and not reflected to the detector o he detector not aligned with the incoming laser beam from the mirror e Contamination of Window and or Mirror The process gas or other contaminants have fouled the cell window and or mirror cleaning required and improvements to sample system to prevent repeat incident Particulate The process gas optical clarity O Excessive smoke density opacity and or particulate matter that prevents sufficient light from reaching the detector Improvements to the sample handling conditioning system should be made to remove particulate Weak Laser The output power of the laser module itself o Weak or dead laser diode source not outputting sufficient light 8 2 Analyzer Warnings Detector Signal Low This is based on the amount of signal gener Refer to Low or Lost Transmission procedure ated by the detector Clean window and or mirror Refer to Low or Lost Trans mission procedure Transmission Low This is the most important diagnostic feature of the analyzer Transmission is a measurement of the laser power striking the detector It is an arbitrary number
36. This manual should be passed on to the end user The contents of this manual are subject to change without prior notice The contents of this manual shall not be reproduced or copied in part or in whole without permission This manual explains the functions contained in this product but does not warrant that they are suitable the particular purpose of the user Every effort has been made to ensure accuracy in the preparation of this manual However if you find mistaken expressions or omissions please contact the nearest Yokogawa Electric representative or sales office This manual does not cover special modifications This manual may not reflect change of specifications construction or parts when the change does not affect the functions or performance of the product If the product is not used in a manner specified in this manual the safety and performance of this product may be impaired Yokogawa is not responsible for damage to the instrument poor performance of the instrument or losses resulting from such if the problems are caused by Improper operation by the user Use of the instrument in improper applications Use of the instrument in an improper environment or improper utility program Repair or modification of the related instrument by an engineer not authorized by Yokogawa Safety and Modification Precautions Follow the safety precautions in this manual when using the product to ensure protection and safety o
37. YO1B02 O1E A 4th Edition September 11 2012 00 lt 5 INSTALLATION AND WIRING 5 2 5 2 Sample Inlet and Outlet Considerations The following criteria should be considered when selecting the installation point in respect to the process conditions 1 4 OD Swagelok tube fittings Process Gas Condition The sample should be clean dry non condensing at the inlet to the sample cell The dew point of the sample should be below the sample cell operating temperature If the sample cell is not heated and un insulated then the sample must be non condensing through the entire ambient operating conditions NOTE Oils waxes impure cleaners and other deposits on the sample cell mirror will cause optical noise and subsequent analytical performance degradation Please take all necessary precautions to ensure the incoming sample gas is clean and dry at all times Process Gas Flow Conditions Typically 1 10lts min sample flow A so called normal flow rate would be in the order of 2 3lts min Higher flow rates will improve the sample lag time within the measurement cell Sample flowmeter can be typically installed on the inlet when equipped with needle valve Excessive flow rates may result in gas temperature control issues if the delta T of incoming gas and cell temperature set point exceed 15 deg C Process Gas Temperature It is recommended that the sample gas inlet remains within 15deg C of the sample cell temperature set point If the sample cell
38. al Blocks TB2 Remote Initiate Validate TB3 External Calibration Solenoid Valve s Drivers 12w EA TB4 Alarm Contacts Warning Alarm amp Fault Alarm TB5 Alarm Contacts User Alarm amp optional Purge Alarm TB6 Ethernet 10 100 4 2 Process Interface The TDLS220 is provided with a flow cell through which the process sample gas flows Different cell materials and window seal materials may be used pending application 14 Swagelok tube fit tings are typical connection size for the purge and process gases Typical cell volume 300cc 4 3 Communications Stand Alone Options The analyzer is capable of fully independent operation with no external computer or interface required A number of options are available for a built in user interface mounted on Launch Unit Blind with no display or keypad Access to the analyzer through Ethernet connection local or remote computer Remote Interface Unit RIU Universal Remote Display remote display only no keypad with menu access via external computer Mini display which is an Integral display 4X20 smart VFD cycles information No keypad menu access via local or remote external computer Ethernet connected Keypad with 6 5 display Regardless of the user interface selected the analyzer will continuously record results diagnostics and spectra Data can be transferred from the analyzer via USB or Compact Flash IM 11YO1B02 O1E A 4th Edition September 11 2012 00 4 ANALYZER
39. alvanic corrosion Stainless Steel captive screws and optional keypad Laminated Safety Glass for optional display s Maximum 120 C with ambient temperature 40 C Maximum 100C with ambient temperature lt 50 C Maximum 100 psig Vertical wall 24 x 24 plate 316L Stainless back plate Note Fach application may differ in maximum limitations depending upon the combination of gas temperature gas pressure and concentration of gas being measured IM 11YO1B02 O1E A 4th Edition September 11 2012 00 Performance specification 0 01 O Typically R2 gt 0 999 Precision Linearity Response time 5 or 10 seconds plus transport time to analyzer Drift Span drift 6 12 month calibration lt 0 1 O Zero drift 6 12 month Calibration lt 0 05 O Analog I O Optional Outputs Concentration Transmission 8 4 20mA isolated Sub 4mA for warnings faults Inouts Pressure Temperature Feed for Compensation 2 4 20mA isolated powered or loop power Digital I O Outputs Warning Fault Concentration Limit Relays 3 Form C Relay SPDT rated 1A 24VDC e Valve Control 39 24VDC Max 10W per valve zero span e Inputs Remote Validation 3 voltage free floating contacts for zero span Communications Ethernet IEEE 802 3 10 100 Mbps RJ45 Automatic USB data transfer upload download settings and data Calibration Hecommended Calibration Check Interval 3 6 Months Gas Sampling The extracted sample should be typicall
40. and Spectrum Cap ture These will ensure the analyzer stores important information during operation that may be used to verify operation status diagnostics and other trouble shooting Go to the Trends screen and review plot several of the listed parameters to check analyzer performance over a period of time Non Process If the application is to using purge gas containing the target gas e g Oxygen measurement with Parameters Instrument Air Purge then the Non Process parameters should be configured as detailed later in this manual under the Software Section Normal Operation When the site field configuration is complete and the analyzer has operated for at least two hours with out any functional alarms then perform an export data routine To Export Data simply insert an empty USB memory stick in to a USB port on the launch unit back plane The data transfer may take several minutes DO NOT REMOVE THE MEMORY STICK DURING THIS TIME BENE Close out the VNC software and disconnect the service PC if connected BENE Ensure the doors lids are closed and tightly sealed re The system is now in normal operation mode We RECOMMEND sending all the Exported Data files to Yokogawa Laser Analysis Division along with any notes and comments We will then be able to store these files on a master record for future reference Please carefully read the appropriate Sections of this Instruction Manual The TDLS220 Tunable Diode Laser TDL Analyze
41. and several connectors to accommodate various plug in boards The board is designed such that any field terminations are located along the lower edge of the board via pluggable terminal blocks for customer or field cable interface All components and devices on the board are designed for extended temperature 10 to 80 C and low drift operation The Backplane Circuit Board contains the following integrated circuits DC Power Input DC Power Distribution Watchdog Circuit Display Backlight Power Interrupt Alarm Relays Remote Calibration Initiation Calibration Valve Driver Relays Laser Temperature and Current Control Board temperature DC Power Input There are four pluggable screw terminals located on the lower right hand side of the Back Plane These are used for connecting the 24VDC power input supply These are factory configured to receive power from the adjacent power supply enclosure Therefore the analyzer power input requirement is AC voltage and a 24VDC power supply is integrated to the analyzer There is an adjacent On Off miniature toggle switch and re settable thermal fuse The single 24DVC power supply is distributed to various output power channels Each output power channel has the appropriate DC DC converter regulator s filtering capacitors and status LEDs etc All accessible voltages in the Control module are below 24V A 65V 10 mA power source is protected by a cover with a High voltage warning sign Watch
42. ate for the analyzers intended use System Configuration History in the form of ASCII data files that can be opened with Microsoft Notepad as simple txt file formats The content can then be copied and pasted into System History Microsoft Excel spread Each configuration change is logged system his A historical log of configuration with the date MM DD YYYY and time that it occurred the changes parameter e g opl and the new value Also whenever the analyzer is started up or shut down the TruePeak Open Close parameter will be logged Example 11 20 2006 08 13 10 opl inch 39 96 43 31 11 20 2006 08 13 26 temperature F 509 0 86 0 11 20 2006 08 13 40 pressure psi 14 50 14 50 IM 11YO1B02 O1E A 4th Edition September 11 2012 00 lt 9 DATA FILES AND FORMAT gt 9 4 System Configuration History When the system his file exceeds 100KB size the contents is saved to this bak file and the his file is emptied This bak file is in the form of ASCII data files that can be opened with Microsoft Notepad as simple txt file formats System History Back Up The content can then be copied and pasted into Microsoft Excel A back up of historical log of spread Each configuration change is logged with the date MM configuration changes DD YYYY and time that it occurred the parameter e g opl and the new value Also whenever the analyzer is started up or shut down the TruePeak Open Close parameter will b
43. ation Available systems standard or custom for e Manual or Automatic Validation e Manual or Automatic Calibration e Manual or Automatic Stream Switch e Analyzer purge gas control e Other options Available Display and Software Functions TruePeak software has multiple levels the default or start page is the Main Menu Main Menu Displays Gas Concentration Transmission Status warm up OK Warning Fault etc Temperature Fixed Active Ambient or Active Pressure Fixed or Active Main Menu Basic Menu Configure 3 functions View Spectra 2 functions Data 3 sub menus Trends Advanced Menu Configure 9 sub menus User Password Calibrate amp Validate 3 sub menus Data 4 sub menus Trends Active Alarms List of active alarms Shut Down Analyzer Instructions to close TruePeak local or VAC IM 11YO1B02 O1E A 4th Edition September 11 2012 00 3 GENERL SPECIFICATIONS 3 3 Model and Suffix Codes Model TDLS220 Tunable Diode Laser Gas Analyzer mos seme popenoei OOO TDLS220 mm Tunable Diode Laser General Purpose NEC Class 1 Div 2 BCD CSA Special acceptance certification for general purpose CSA acceptance certification for Class 1 Div 2 pies Basic 02 0 196 up tp 0 2596 oxygen Stainless Steel 316L back plate 316L flow cell sapphire windows and teflon encasulated viton o rings 316L flow cell sapphire windows and Kalrez o rings Monel A400 flow cell sapphire
44. centration BarA calculation OPL xx x in cm Optical Path Length over which the analyzer is measuring the target gas Launch unit internal temperature Detect xx C Detect unit internal temperature IM 11YO1B02 O1E A 4th Edition September 11 2012 00 6 BASIC OPERATION 6 5 6 2 Software Guide 3 TruePeak Transmission 95 0 aETTITNB Up Down to select Enter to proceed O2 Concentration 96 Initializing Active 20 31 C Fixed 1 014 barA Tag MDI VENT O2 SN 76 1205 08 ExA 12 10 2008 13 51 33 CTRL BKSP to end Virtual Analyzer Controller Session Jas 3 TruePeak Select Analog Output Mode During Maintenance Block Track Hold Block output signals will be held at 3 8 mA and automatic spectrum capture is disabled until user returns to MAIN MENU Track output signals will continue tracking the measured value Hold present output signals will be held until user returns to MAIN MENU F Basic Menu Configure Set path length process pressure process temperature View Spectra Data Trends MAIN MENU Display of Concentration amp Transmission Status Window notification of initiating working properly warnings or faults Gas Temperature Gas Pressure Selection of Basic or Advanced Menu Active Alarm Display Button Analyzer Shut Down Button Tag number and serial number Analyzer date and time After selection of either Basic or Advanced Menu you will se
45. d SAK 2 5 screw terminals Internal storage on CF card result files spectra capture configuration data etc USB1 and USB2 connection for data transfer using USB memory stick Capture rate is configurable typically 7 10 days of data are stored 5 min for functioning 60 min for full operation within specifications 80w analyzer with headed cell option power consumption varies based on application typical max 380W 100 C cell temperature WxHxD 750mm x 600mm x 200mm 30 x 24 x 10 approx 67lbs or 30 4kg Environmental Specifications Ambient Temperature Humidity Altitude Area Classification Weather resistance Cable entries Gas Connections Enclosures Sample Gas Temperature Sample Gas Pressure Mounting 20 to 50 C O 90 RH non condensing or O 100 with correct purge gas specifications Maximum 3000 m The analyzer is designed for operation in General Purpose area The addition of a Purge System facilitates operation in Hazardous Area for gaseous releases Class 1 Division 2 Group B C and D ATEX CE Pending Optional CSA Special Acceptance certification IP65 which is equivalent to NEMA 4X or indoors 24 FNPT threads unused holes are plugged Analyzer 1 4 welded Swagelok connection Die Cast copper free Aluminum grade AL SI 12 with a powder coat exterior finish The alloy is particularly resistant to salt atmosphere Sulfur gases and g
46. d interval in the event of an analyzer warning or fault including concentration values and manually via the user interface Calibration History is stored during every calibration or validation event Alarm Fault History i Events History which includes any changes made to the system settings All data can be retrieved using a USB flash drive at the analyzer via the RIU or over an Ethernet connection If opening the protective enclosure is not desired for safety reasons end user can install approved hermetic Ethernet and USB throughputs on the box glands See below for USB data download port location inside control unit Insert Yokogawa RI i v Supplied SanDisk 23 Analytical Specia Back Plone Boord USB memory Part No 20 1e4e 87 laa Storage Device TITE Figure 18 USB Port Location IM 11Y01B02 01E A 4th Edition September 11 2012 00 lt 7 ROUTINE MAINTENANCE 7 11 7 4 Validation and Calibration There are several methods that can be used to validate and or calibrate the TDLS220 TDL analyzer Generally we recommend routine validation of the analyzer either on line if appropriately set up or off line Actual calibration should only be performed if certain performance criteria have not been met during the validations and should only be performed by appropriately qualified personnel The options for Validation and Calibration are Validate Off Line or Cal Check Manual introduction of zero or
47. d to verify operation status diagnostics and other trouble shooting Configure Using the correct password Default 1234 enter in to the Advanced Menu then the Configure ADVANCED et fo Select the desired measurement units for path length pressure and temperature IM 11YO1B02 O1E A 4th Edition September 11 2012 00 1 QUICK START 1 3 Co Gas Pressure Select Fixed or Active If Fixed enter in the correct process gas pressure If Active enter in the 4 20mA input signal range proportional to the pressure transmitter output range Co Co Gas Temperature Select Fixed or Active If Fixed enter in the correct process gas temperature If Active enter in the 4 20mA input signal range proportional to the temperature range Configure the system I O by entering in to the System I O sub menu in Configure If the optional Analog I O board is installed then select Analog Output and set the appropriate 4mA and 20mA values for Ch1 Concentration and Ch2 Transmission Select what mode Block Track or Hold the 4 20mA outputs are to be when the analyzer is in Warning Fault Export Data and Calibration Modes Configure Digital I O Warnings and Faults Many of these will be factory pre set so if unsure about any settings then leave as Factory Default Select and set level for Alarm Limit to either the Measured Gas or Transmission Go to the Data screen and set the appropriate parameters for Record Result Data
48. dog Power Interrupts The power output channels for microprocessors have control logic lines TTL activated These allow for watchdog interrupt reset functionality Alarm Relays There are three alarm relay circuits on the board These are capable of actuating Form C Single Pole Double Throw SPDT relays The three connections of each relay Common Normally Open and Normally Closed are routed through the board to field terminals The contacts are rated for a maximum of 1A 24VDC We do not recommend applying AC voltage across these relay contact The pluggable field terminals are mounted on the lower edge of the board just to the left side of the DC power input terminals The appropriate relay s is actuated when there is an analyzer Warning Fault and or Level Alarm The Power off condition is the same as alarm condition i e they are powered in normal or no alarm condition Remote Calibration Initiation A calibration routine can be initiated from a remote location up to 300m away using contact closures The Back Plane has circuitry such that it can monitor for a return voltage The return voltage comes from remote Volt Free Contacts VFCs at the customer DCS or other control system The circuits include suitable protection against inadvertent shorting grounding of the supply 24VDC or the application of excess power to the monitoring circuit There are three sets of remote contact monitoring circuits on the Back Plane IM 11YO1B0
49. duration in minutes Valve 2 Valve 3 Restore Override similar to valve 1 Remote control channel Concentration Concentration 2 or Tranmission Laser Temperature in C Gas temperature Gase Pressure Peak Position Control Mode Current Center Laser Temp Set Spectrum Capture LTSP Limits IM 11YO1B02 O1E A 4th Edition September 11 2012 00 6 BASIC OPERATION 6 3 ADVANCED Calibration Offline Calibration Zero Calibraton Online Menu Level 1 Menu Level 2 Menu Level 3 Menu Level 4 Menu Level 5 Menu Password Protected Trends Offline Calibration Offline Validation Online Validation Alarm Alarm History o Cal History Spectrum Capture Record Data Gas 1 Concentration STDEV of Gas 1 Concentration Gas 2 Concentration STEV of Gas 2 Concentration Transmission Laser Temp Setpoint Laser Temp in DegC Peak Center Position Gas Temperature Gas Pressure Similar to Gas 1 Concentration Local Initate Remote Initiate control channel Time Initate frequency Settings valve purge tiime AO mode Restore Old Calibration Factory Calibration Zero Offset Current Span Calibration Local Initiate Remote Initiate control channel Time Initiate frequency Settings conc opl temp pres SS Calibration ocean Calibration Transmission Current New a with Lower WL m with Higher WL Peak Search All A Peaks
50. e areas of potentially hazardous voltage are labeled with this sign Caution refer to the user manual E Alternating current Direct current Protective ground terminal Function ground terminal do not use this terminal as the protective ground terminal E Warranty and service Yokogawa products and parts are guaranteed free from defects in workmanship and material under normal use and service for a period of typically 12 months from the date of shipment from the manufacturer Individual sales organizations can deviate from the typical warranty period and the conditions of sale relating to the original purchase order should be consulted Damage caused by wear and tear inadequate maintenance corrosion or by the effects of chemical processes are excluded from this warranty coverage In the event of warranty claim the defective goods should be sent freight paid to the service department of the relevant sales organization for repair or replacement at Yokogawa discretion The following information must be included in the letter accompanying the returned goods Part number model code and serial Number Original purchase order and date Length of time in service and a description of the process Description of the fault and the circumstances of failure Process environmental conditions that may be related to the failure of the device A statement whether warranty or nonwarranty service is requested Complete shipping and bi
51. e is not specific The rotational position of the mounting plate onto the end of the flow cell is also not specific Carefully install the mirror and mounting plate onto the cell and rotate such that the holes align with the threads hand tighten the fasteners with lock washers in position Using the 7 64 Allen key wrench carefully hand tighten each screw using a diagonal pattern and gradually increase each screw incrementally do not fully tighten one screw at a time tighten them down evenly and incrementally to a maximum of 18 Ib in torque When the mirror is fully fastened turn on the analyzer and check the transmission level to see if normal levels have been restored and if the measurements now appear normal Be careful not to touch hot surface of the gas cell If so the transmission level is restored replace the insulation end cap and al low 30 minutes for temperature stabilization Check the Zero and Span with appropriate gases If there is no change in transmission and or the results are still noisy unexpected then proceed with removal and cleaning of the window IM 11YO1BO2 O1E A 4th Edition September 11 2012 00 7 ROUTINE MAINTENANCE 7 6 Window Removal for Cleaning or Replacement Follow the precautions outlined in the Thermal hazard and Chemical hazard sections of the SAFETY chapter If the flow cell becomes contaminated then it may be cleaned using the following procedure Discontinue the process gas flow and in
52. e logged Example 11 20 2006 08 13 10 opl inch 39 96 43 31 11 20 2006 08 13 26 temperature F 509 0 86 0 11 20 2006 08 13 40 pressure psi 14 50 14 50 System User This contains all Factory configuration settings as the analyzer System configuration as shipped from was shipped This is used for reference purposes only the factory Validation Spectra Spectra captured for historical Validations On Line and Off Line All spectra captured during On Line and are stored in this file Off Line Validations are stored in this file Zero Calibration Spectra This file is essential to the analyzer calibration if this file does Absorption Spectrum and coefficients at not exist or is corrupted modified or otherwise tampered with time of calibration then the analyzer calibration is invalid It contains essential information relating to the Zero Calibration of the analyzer zeroO1 to zero10 zero01 through zeroO9 are previous files with zero01 being the Historical Zero Calibration most recent The most recent previous zero01 can be restored in the analyzer as Previous Calibration The factory calibration which can also be restored in the analyzer is named zero10 Spectra Previous Absorption Spectrum and coefficients at time of previous calibrations System Configuration System Configuration at the time of current Zero Calibration At the time of current Zero Calibration zero00 spe zeroref memory memory File Size Mana
53. e loss of measurement Faults These are conditions where the measurement is lost or degraded past the point of reliability An example would be loss of transmission which could indicate complete miss alignment or laser failure The TDLS220 system will diagnose many common warnings and faults taking the following actions The analyzer generates a status flag that is displayed on the main screen if only one warning fault is present the system will display this on the screen The ACTIVE ALARM menu selection will allow the user to view all active Warnings and Faults The system will log the warning fault in a log file along with a description time triggered and time cleared The 4 20mA signal can change to 3 3mA or 20ma under a fault or warning condition user changeable The digital output of the analyzer will trigger Channel 1 Warnings Channel 2 Fault Channel 3 Concentration or Transmission The analyzer will capture spectra for diagnostic assistance The Results file will indicate a Warning 1 or Fault 2 in the continuous Results file Pf TruePeak Jor oe Config ia Ic X Advanced Config System I O Digital Output H20 Concentration ppm Transmission 4 9 95 0 Alarms PT este wena Channel 1 Warnings Channel 2 Faults l Multiple warnings or faults Advanced Menu Active 68 56 F Shut Down Analyzer Fixed 14 700 psiA Up Down to select Enter to proceed Channel
54. e the Output Selection screen This allows control of the analog output while the user is working in the analyzer software Block will hold outputs at 3 8mA until return to Main Screen Track will allow outputs to continue to report concentration and transmission until return to Main Screen Hold will hold outputs at their current value until return to Main Screen BASIC MENU Configure allows setting of Path Length Gas Tem perature Gas Pressure View Spectra user will select display of raw detector signal or absorption spectra Data Alarm History Calibration History Record Hesult Data Trends allows for the displaying of data in a trend format IM 11YO1B02 O1E A 4th Edition September 11 2012 00 6 BASIC OPERATION 6 6 T Basic Config Des BASIC CONFIGURE PATH LENGTH Factory set do not adjust Typical gt gt 40 distance the laser beam is exposed to the process gas PRESSURE allows adjustment of the gas pressure value if using fixed pressure If the analyzer is using active pressure compensation no changes are allowed Active pressure compensation settings are found in IP Adress 10 0 2 05 Advanced Menu TEMPERATURE allows adjustment of the gas pressure value if using fixed pressure If the analyzer is using active temperature compensation no changes are allowed Active temperature compensation settings are found in Advanced Menu IP ADDRESS displays the analyzer IP address SERI
55. ean 4 7 4 5 Data Reporting Storage and Retrieval ccccscccsscccseeceeeeceeeceeeeseeeseueeseeesaueesseeeees 4 7 5 instalation and Wiring siisii qnin eicere seio puces desean eaa a Roa Sdet oov e eee anaia 5 1 Sid MOUNINO TMS i oci ANE UTI PUE 5 1 5 2 Sample Inlet and Outlet considerations leeseeeseeeseeseeeneeenree nnne 5 2 SS dae E 5 3 5 4 Purge Gas Requirements and Hazardous Area Systems ccscccseeeeeseeseseeeeeeseeeeees 5 5 6 Basic ODeraliO p uin n iv Rosi EN IM dRe cR DE EDD DU UM MN C Le E E UNDE cH QM d DILE ON LEE 6 1 6 1 Menu Structure Ma Pire oret t tduta i Pes Fa Fei oM er S eee M LIT 6 1 6 2 SOltWare GUIG Cap P a a a a a a 6 5 6 3 Non Process Parameters cccscccecceecceecsecceecaeeceecaeecuecaeceeesaesagesseceeesaeeceesanseeeees 6 14 6 4 Stream Switching and Valve Control Outputs eese 6 16 6 5 Controlling the Analyzer Remotely or Locally via External PC Laptop 6 19 6 5 1 Instructions from Connecting an External Computer to the Analyzer 6 19 6 5 2 Using Ultra VNOG SOWIE 3 tois MEO a EE men US opio in t uud Rara ua nM asa MU RUE dE 6 20 6 5 3 Remote Interface Unit RIU armirani A 6 21 6 5 4 Virtual Analyzer Controller VAC Operating Software Map 6 21 6 5 6 Virtual Analyzer Controller VAC Operating Software Guide 6 22 T ROUTING MaintenaNt e
56. em Look for excessive heat output from adjacent processes perature is outside of the analyzer design range 10 to 50C and or radiant process and or direct sunlight causing the internal temperatures to exceed the preset limit 8 3 Analyzer Faults For analyzer faults it is recommended that you contact Yokogawa Laser Analysis Division immediately There is typically no user intervention that should be attempted unless specifically diagnosed or directed by Yokogawa Yokogawa Laser Analysis Division personnel will step you through diagnostic and repair steps Laser Temperature Out of Range This is an indication that the system can not control the laser temperature resulting in wavelength instability of the laser Detector Signal High Detector is saturated i e too much detector signal gain or has been damaged Detector Signal Lost The analyzer is not receiving a detector signal please check all electrical connections and follow the procedure for Troubleshooting Low or Lost Transmission Outlier Rejection Future feature yet to be implemented Peak Center Out of Range Indication that the system can not keep the peak centered in the scan range Please review the absorption spectra to check the actual peak position check that some target gas in the optical path capture spectra and send to Yokogawa Laser Analysis Division or local agent for further assistance IM 11YO1B02 O1E A 4th Edition September 11 2012 00 9 DATA F
57. er analyzer warning and subsequent DO CHANNEL 2 FAULTS Setting of levels that will trigger analyzer fault and subsequent DO CHANNEL 3 USER ALARM Setting of either Con centration or Transmission level high or low that will trigger analyzer warning and subsequent DO FIELD LOOP CHECK allows wiring connection check during field installation Field Loop Check F Advanced Config Obs CHANNEL 1 WARNINGS menu allows setting of Advanced Config System I O Digital Output Warnings various analyzer WARNING conditions Warning is an event that will reduce but not eliminate the measurement integrity it is an indication that maintenance is required but the analyzer is still operational DETECTOR SIGNAL LOW level at which low detector signal will trigger a warning ONLY ADJUST WITH FACTORY ASSISTANCE TRANSMISSION LOW level at which low transmission will trigger a warning ONLY ADJUST WITH FACTORY ASSISTANCE SPECTRUM NOISE HIGH level at which excessive spectrum noise will trigger a warning ONLY ADJUST WITH FACTORY ASSISTANCE PROCESS PRESSURE OUT OF RANGE upper and lower levels at which process gas pressure reading will trigger a warning PROCESS TEMPERATURE OUT OF RANGE upper and lower levels at which process gas temperature reading will trigger a warning IM 11YO1B02 O1E A 4th Edition September 11 2012 00 6 BASIC OPERATION 6 10 CONCENTRATION OUT OF RANGE upper and lower levels at which
58. f the human body the product and the system containing the product IM 11Y01B02 01E A 4th Edition September 11 2012 00 Safety Precautions ll Safety Protection and Modification of the Product n order to protect the system controlled by the product and the product itself and ensure safe operation observe the safety precautions described in this user s manual We assume no liability for safety if users fail to observe these instructions when operating the product e If this instrument is used in a manner not specified in this user s manual the protection provided by this instrument may be impaired f any protection or safety circuit is required for the system controlled by the product or for the product itself prepare it separately Besure to use the spare parts approved by Yokogawa Electric Corporation hereafter simply referred to as YOKOGAWA when replacing parts or consumables Modification of the product is strictly prohibited The following safety symbols are used on the product as well as in this manual AN DANGER This symbol indicates that an operator must follow the instructions laid out in this manual in order to avoid the risks for the human body of injury electric shock or fatalities The manual describes what special care the operator must take to avoid such risks A WARNING This symbol indicates that the operator must refer to the instructions in this manual in order to prevent the instrument hardwa
59. g Visually inspect the o ring and replace if necessary L r 2 Ur 1 4 5 P T A oH 5 Cleaning of the mirror should be performed as follows while taking great care not to scratch the surface of the mirror First any loose impediments and dirt should be blown off the surface using a clean compressed gas source Take care not to spray liquid propellants onto the mirror surface IM 11YO1BO2 O1E A 4th Edition September 11 2012 00 7 ROUTINE MAINTENANCE 7 5 Using optical grade glass cleaner or IPA wet the surface of a non abrasive lint free tissue Place the wetted tissue on the surface of the mirror and drag across the mirror face in one direction only Use a second clean dry tissue and wipe in one direction only to dry the surface Inspect for cleanliness and if necessary repeat the process NOTE If suitable cleaning media are not available then contact Yokogawa service group and a cleaning kit can be purchased If the mirror cannot be cleaned such that there are no traces of any films dirt etc then it should be replaced with a new mirror contact Yokogawa for replacement parts Once the mirror is ready for re installation and the o ring has been inspected replaced then the mirror within its mounting plate can be re installed Carefully check the mirror surface again from different angles to ensure it is thoroughly clean before re installation The rotational position of the mirror within the mounting plat
60. gement for Results FACTORY PERSONNEL ONLY used by TruePeak software to manage the res files File Size Management for Spectra FACTORY PERSONNEL ONLY used by TruePeak software to manage the spe files valspe bak Validation Spectra Back Up When the valspe his file exceeds 1MB size the contents is Line and Off Line Validations Spectra captured for historical Validations On Line and Off Line IM 11YO1B02 O1E A 4th Edition September 11 2012 00 lt 9 DATA FILES AND FORMAT 9 5 9 1 Configuring Data Capture fr Advanced Menu zx Lil x Select Data Export data view laser detector Calibrate amp Validate information automatic spectrum capture sittings E Trends f Advanced Data m Select Record Result Data f advanced Data Select either User Data result or Factory Data Data Record The default setting during normal operation is User Data The system should only be switched to Factory Data when advised by Yokogawa Laser Analysis Division Note recording Factory Data is only for specific diagnostic purposes and should not be selected under normal operation Record data mode User data Factory data Please select data file record mode IM 11YO1B02 O1E A 4th Edition September 11 2012 00 lt 9 DATA FILES AND FORMAT 9 6 Ff Advanced Data O64 To select the Spectrum capture stay in Advanced Menu user mode and the Data sub section select Spectrum Capture Ff Advanced Da
61. ght absorbed by the peak is pro Signal at Detector proportional to the target gas concentration The light is then focused on a detector This signal is used to quantify the light absorbed by the target gas Processed Detector Signal Mounting plate Figure 1 Basic Layout IM 11YO1B02 O1E A 4th Edition September 11 2012 00 3 GENERL SPECIFICATIONS gt 3 1 3 General Specifications Measurement range Output signal Output Span Contact outputs Valve control Current Input Digital Communication Data storage Warm up time Power Consumption Size Weight Dependent on application Ranges from 0 196 up to 0 25 for analysis of Oxygen 3x 4 20mA DC with maximum load of 900 Ohm Three isolated outputs for concentration transmission of light and may be used for gas concentration transmission retransmission of data inputs or dual range 3 3 or 20mA user configurable on warnings and faults Programmable within measuring range 3x configurable relays for Status Fault Warning concentration level etc Form C Single Pole Double Throw SPDT contact outputs with maximum 1A 24VDC or 0 5A 125 VAC 3x 24VDC power supply to activate calibration solenoid valves for zero and span gas Maximum load 1A max 10W valve for zero and span gas 2x 4 20 mA inputs for mA transmitters for pressure and temperature Loop or lined powered Ethernet IEEE 802 3 10 100 mbps RJ45 an
62. he optical path that is outside of the process path IM 11Y01B02 01E A 4th Edition September 11 2012 00 6 BASIC OPERATION 6 15 advanced Conf 5 NON PROCESS PATH LENGTH This is the optical path length inside the laser amp detect measurement unit Typical values would be 3 5 to 4 with the Current default value to use at 3 75 Note that this dimension will vary between analyzers Change Air Purge Optical Path length Contact Yokogawa if unsure New Input new air purge optical path length 3 NON PROCESS PRESSURE This is the pressure of the non process gas Typically this will be close to atmospheric pressure of 1 01BarA or Current 14 7PsiA Check the actual operating conditions and enter the appropriate value Contact Yokogawa if unsure New Input new air purge pressure NON PROCESS TEMPERATURE This is the temperature of the non process gas with two modes of input Change Air Purge temperature Mode ACTIVE AMBIENT ambient gas temperature derived from Fixed i i i A integral sensor on detector circuit with offset adjustment typically 18 deg C Note this off set is due to the internal heat of the controller unit where the detect board is located in TDLS220 Modify air purge temp ambient offset C FIXED manual input of fixed temperature value 4 NON PROCESS CONCENTRATION This is the concentration of the non process measurement gas For Instrument Air purge ga
63. hen the analyzer is configured with a flow cell in an offline application gt I co F Advanced Config x VALVE CONTROL MEM AS N The valve control includes manual and automatic control MANUAL allows for manual ON OFF control of the valve driver output signals TIME SEQUENCE allows automatic valve switching based on time sequence It is normally used for measurement that needs stream switching REMOTE OVERRIDE allows remote valve control by digital contact F Advanced Config Oks LASER SPECTRA amp CONTROL Displays Raw Detector Signal and Absorption Raw Detector Signal sese DSE E Spectrum as well as Gas Concentration Gas ani Temperature Gas Pressure Transmission Laser Temperature and Peak Center Position CAPTURE allows a manual spectra capture user will be prompted to enter a unique file name for captured Control Mode Cur Center spectra gt gt Trans Pres barA LTS C For Display Only CONTROL MODE allows selection of Automatic LT C Peak Pos ey ECT NNNM laser temperature is controlled to keep peak centered using peak center position as set point or Manual laser temperature is controlled using integral laser temperature sensor ONLY ADJUST WITH FACTORY ASSISTANCE LASER TEMP In manual mode allows adjustment of laser temperature ONLY ADJUST WITH FACTORY ASSISTANCE LTSP LIMITS setting of guard limits for laser temperature set point ONLY ADJUST WITH F
64. ile can have up to 8 numerals in its name which are entered at the time the Capture is performed Example 110307 cap 100008 cap Alarm History in the form of ASCII data files that can be opened with Microsoft Notepad as simple txt file formats The content can then be copied and pasted into Microsoft Excel spread Each Alarm incident is logged with the date MM DD YYY Y and time that it oc curred the Mode Warning or Fault or User Alarm the specific condition within the Mode e g Detector Signal Lost and the state ON or OFF Example 10 10 2007 13 21 36 Fault peak center out of range OFF 10 10 2007 19 00 25 Warning detector signal low ON Alarm History Back up When the alarms his file ex ceeds 100KB size the contents is saved to this bak file and the his file is emptied This bak file is in the form of ASCII data files that can be opened with Microsoft Notepad as simple txt file formats The content can then be copied and pasted into Microsoft Excel spread Each Alarm incident is logged with the date MM DD YYY Y and time that it occurred the Mode Warning or Fault or User Alarm the specific condition within the Mode e g Detector Signal Lost and the state ON or OFF Example 10 10 2007 13 21 36 Fault peak center out of range OFF 10 10 2007 19 00 25 Warning detector signal low ON Calibration History in the form of ASCII data files that can be opened with Microsoft Notepad as simple txt
65. in 3 meters of the equipment and not obstructed or placed out of reach in some way It must be clearly labeled as the disconnect device for the TDLS220 equipment The disconnect device must be easily accessed and operated by the authorized personel Water tight conduit cable connections must be used for the customer connections The customer connections should terminate in a normal environment i e indoors Screw Terminal Block SAK2 5 Details also see following diagram for internal wiring TB Field or e mem Notes Comments No Factory 24 VDC DC power from the 24 power supply in adjacent enclosure 0 VDC 24 VDC 24VDC power take off to integral purge indicator 0 VDC switch unit when fitted L j 1remote Cal Val initiate signal loop SV 1 to Remote voltage free contacts switch Do not apply external power SV 2 remote Cal Val initiate signal loop SV 2 to Remote voltage free contacts switch Do not apply external power SV 3 remote Cal Val initiate signal loop SV 2 to Remote voltage free contacts switch Do not apply external power 24VDC power output signal to actuate external solenoid 2 sve valve 1 Max 12 Watts requires ferrite coil on wires l3 svea 24VDC power output signal to actuate external solenoid a sva valve 2 Max 12 Watts requires ferrite coil on wires 5 Sv34 24VDC power output signal to actuate external solenoid valve 3 Max 12 Watts requires ferrite coil
66. isai ni a A a a e eE aAA aaa aa aera 7 1 7A Maintaining Good TRANSMISSION sasssa E E EE 7 1 7 1 1 Maintaining Window and MIPrrOr ccceccseeceeeceeeceeceeceecceceeeceeeeseeseeeseesseeeaaes 7 1 1 2 Analog signal Field Loop Checo aao eau tad hona oa Dd remand ead Orte M LO OUR aU URN 7 10 7 3 Data Reporting Storage and Retrieval ccccccccsssceceeeceeeesseeceueeseeseeeesseeeseeeeaees 7 10 A Validator and Call DF Atl OM menina a doa tu rau Lee ebd ces Na E eS 7 11 7 4 1 Off Line Manuall Automatic Checking Validation ssse 7 11 7 4 2 Off Line Manual Automatic Calibration ccccceecceeeceeeeeeeeeeeeseeeeeeeeeeseeeeeeeaaes 7 14 IM 11YO1B02 O1E A 4th Edition September 11 2012 00 TOC 2 8 IFOUDISSNOOUING eee 8 1 9 1 Common Troubleshooting Step xudcosccdeco educ etta dvd E gavet Mie busco Dd Evo a ue Put eoe bdo uus 8 2 8 1 1 On Process Gas or Zero Gas or Span Gas esseessesseeeeee ener nnns 8 2 8 1 2 Trouble Shooting procedure for lost and or Low Transmission 8 3 G 2 ANY Zen VVarnibigS nosse ta ors idet oen E pado a Mie POP PAULI a TO PIRA LOO hae 8 3 9S 9JADalyzer FAURS lurrari aa a aa aae 8 4 9 Data Fies and Formal t E E 9 1 9 1 Configuring Data CapltUle inscrisa T E 9 5 9 2 GOWNIOAGING the DI i em mc ct 9 8 Revision Record IM 11YO1B02 O1E A 4th Edition September 11 2012 00 1 QUICK START 1 1 1 Quick
67. itiate nitrogen or instrument air purge of the analyzer e Shut down the analyzer disconnect from AC power and wait for 30 minutes to let the gas Open the measurement unit cover by loosening the four Philips head screws use a 2 Phillips head type screw driver IM 11YO1BO2 O1E A 4th Edition September 11 2012 00 lt 7 ROUTINE MAINTENANCE 7 7 s Using 7 64 Allen key carefully insert through the access holes and remove the four window retaining screws and lock washers use long needle nose pliers to carefully hold each screw as it comes lose TAKE CARE not to touch the detector or laser collimation lens e Carefully extract the process window handle with care IM 11YO1BO2 O1E A 4th Edition September 11 2012 00 7 ROUTINE MAINTENANCE 7 8 ff CAUTION THE WINDOW COULD BE HOT FROM THE HEATED CELL This process wetted window is constructed of sapphire and is therefore more durable than the mirror surface Use a clean dry instrument air or nitrogen pressure or canned air supply to first blow off any particulate matter Using warm water and mild soap detergent gently clean the window surface with a soft non abrasive cloth If the deposits do not come off then use a small amount of IPA and a soft non abrasive cloth Use the same clean dry instrument air or nitrogen pressure supply to blow dry the surface Carefully check the entire surface of the window from different angles to ensure it is thoroughly cleaned
68. le ANALYTICAL Virtual Analyzer Controller 1 0 Options Data Dump Options Source Directory Idala Target Directory CASI TDL Export Dala Files File Masks cfg spe res his VNC Viewer Location C asiniwncviewer exe Apply F2 Quit Ese a ANALYTICAL ESE 83232 ak ANALYTICAL Ji specialties Virtual Analyzer Controller v1 0 Help Virtual Analyzer Controller V1 0 VAC VAC is used to automate the use of Win VNC Ultra VNC for viewing and controlling analyzers produced by Analytical Specialties inc Its features inchude the maintenance of connectivity inlormation for each analyzer on E and the in iation of winVNC to view and control the desktop of each analyzer therein The program presenis a consistent and easy to use iMerface which allows for the use of a limiled keyboard mouse or trackball Each feature can be executed by a simple Exit Esc About F4 6 BASIC OPERATION 6 23 After selecting Configuration FA you will be allowed to select the analyzer with description and IP address you wish to configure You will be given the following menu choices Create Connection F2 This will allow programming of Tag Name and IP Address for future connections Delete Connection F3 This is to delete an existing connection Options F4 see next section F5 Backlight Toggle On Off Password Ctl Ins Allows changes to the access password VAC Options Configuration Me
69. lization CAUTION Do not pinch wires between cover and enclosure CAUTION Do not cross thread the Phillips head screws into the cover Check the Zero and Span with appropriate gases If there is no change in transmission and or the results are still noisy unexpected then contact Yokogawa for further assistance IM 11YO1B02 O1E A 4th Edition September 11 2012 00 lt 7 ROUTINE MAINTENANCE 7 10 7 2 Analog Signal Field Loop Check 1 To perform a field loop check of the analog output signals follow the software map below Ensure properly calibrated multi meter and read instructions fully before starting this operation The Multi meter on analog mode should be connected to the appropriate terminals and with correct polarity to prevent damage 2 Software Map a Advanced Menu I Password ii Block Track Hold lil Configure V System IO V Analog Output Vi Field Loop Check Vii CH 1 2 or 3 Check viii mA Value input new value and observe reading Once finished with the loop check go back to the main menu using the ESC key 7 3 Data Reporting Storage and Retrieval The TDLS220 analyzer has been designed with extensive data reporting capabilities All data is available in the analyzer as a text file for import into a spreadsheet for analysis Data stored in the analyzer e Results Every measurement the gas concentration transmission diagnostic data are stored Spectra The analyzer records spectra at a time
70. lling instructions for return of material plus the name and phone number of a contact person who can be reached for further information Returned goods that have been in contact with process fluids must be decontaminated disinfected before shipment Goods should carry a certificate to this effect for the health and safety of our employees Material safety data sheets should also be included for all components of the processes to which the equipment has been exposed IM 11YO1B02 O1E A 4th Edition September 11 2012 00 ilr me n i Safety Precaulons sinnini a a aa Aaa aaa ji MEME Star aranan cseca ease nln eh ates ew ae scene teeta eeeeee ea 1 1 2 Introduction and General De SCIiptiOn c sccssceeccnscensenseeseensenseenseesensenseonsensenssenees 2 1 21 FUNCHONAI Beige T I MI LIT 2 1 2 151 Measurement erise savdu rere oaa Uu OE E Dao uo oa Raus c iet va eV Tue Na RUD OP UA d Dino DINE 2 2 3 General SDECHIGATIONS 2 dioeociava Es cades quao Eu teas cR quuE cua En E dun cuu E do USE UN TUA UE aR uud r E diu PUR UEE 3 1 4 Analyzer COMDONENES 25 5 eve veue E bae au ai aaa as vies dva lu RAE 4 1 4T Mam Electrons AOUS UELUT 4 1 4 2 Process THEO aCe mirida bos wes ci Wee al D ed ewe bd ev edd 4 4 Ad COMMUNIC ON S i sssisedetenni a vugndulo fvvus Pose udis EU Mods aider S Mo redi a E C 4 4 AA SOtWe emitte ide uod n i QR Tx quisa ots ont eno Un S rius i used accede a que Crisis nns
71. low the on screen options Function keys have been pre assigned to certain tasks allowing a RIU keypad to perform all necessary tasks The primary functions of the software are Create a virtual network computing connection to an analyzer thus allowing for control of the analyzer typically for start up service calibration etc Allow for file transfer from an analyzer to a local USB port for memory device Create connections by name and or IP address OFFLINE CALIBRATIONS use for all TDL S220 ZERO CALIBRATION manual or automatic calibration of Zero ZERO OFFSET allows manual adjustment of Zero by applying a concentration offset SPAN CALIBRATION manual or automatic calibration of Span TRANSMISSION adjustment of transmission value DARK CURRENT calibration of detector dark current PEAK SEARCH initiates a system scan of absorption peaks to validate current peak selection is correct After selecting Copy Data F3 you will be allowed to select the analyzer with description and IP address you wish receive data from This will initiate a data transfer for all results and configuration files stored on the analyzer IM 11YO1B02 O1E A 4th Edition September 11 2012 00 a ANALYTICAL ake ANALYTICAL aM s pecrialties Virtual Analyzer Controller 10 Configuration Creabe Commection F2 Delete Connection F3 Options F4 Password Cil ling Erf Esc Configuration Options a
72. lyzer fed temperature value from external transducer ACTIVE AMBIENT ambient gas temperature derived from internal sensor ACTIVE PEAKS value calculated from the measurement spectrum or CONTROL cell temperature controlled at a desired value with a heater and relay In Active Input mode a Back Up value can be entered in case of active input failure NON PROCESS PARAMETER if the analyzer is not purged with a gas that is free of the component being measured i e oxygen this allows user to enter the Path Length Pressure Temperature and Concentration of the purge gas that is present in the non measurement optical path internal analyzer optical path For details see section 4 4 Use this feature if the TDLS220 is being purged with Instrument Air I A IM 11YO1B02 O1E A 4th Edition September 11 2012 00 6 BASIC OPERATION 6 8 UNITS selection of units for path length in ft cm m pressure psiA barA kPa torr atm and temperature F C K SYSTEM I O allows set up and assigning of analyzer Analog and Digital I O SYSTEM displays analyzer information serial number Fat date password software version launch detect unit temperatures allows setting of date time gas type VALVE CONTROL allows for manual and or automatic control of the valve driver output signals SIGNAL PROCESSING Factory set parameters only LASER SPECTRA amp CONTROL displays spectra and allows manual control of laser
73. mber 11 2012 00 6 BASIC OPERATION 6 13 Tl Advanced Calibrate amp Validate Oks ONLINE VALIDATIONS DO NOT USE FOR Advanced Calibration amp Validation Online Validation Z Advanced Data L ADVANCED DATA MENU ALARM HISTORY shows chronological list of analyzer s most recent alarms Alarm History CAL HISTORY shows chronological list of analyzer s recent calibrations SPECTRUM CAPTURE selection of AUTOMATIC user will be prompted to select capture interval number of UPDATES to trigger capture RELATIVE Spectrum Capture concentration level trigger which is a 96 of reading change or ABSOLUTE concentration level to trigger capture in addition the software will prompt for number of spectra to capture when a Warning or Fault occurs MANAUL selection will result in spectra capture only when requested by user RECORD RESULT DATA The default setting during normal operation is User Data The system should only be switched to Factory Data when advised by Yokogawa Laser Analysis Division Note recording Factory Data is only for specific diagnostic purposes and should not be selected under normal operation IM 11YO1B02 O1E A 4th Edition September 11 2012 00 6 BASIC OPERATION 6 14 6 3 Non Process Parameters required when Instrument Air Purging Non Process Parameters is the Yokogawa Laser Analysis Division term used to define regions of the op tical path that may be purged with a gas contai
74. n N TM minutes min max ion minutes E min max rans mission minutes Laser Temp min max Setpo int minutes Laser Temp min max in degC minutes Peak Center min max Position minutes Gas min max Temperature minutes Figure 7 Software Overview IM 11YO1B02 O1E A 4th Edition September 11 2012 00 lt 5 INSTALLATION AND WIRING 5 1 5 Installation and Wiring 5 1 Mounting of the Analyzer Hefer to the SAFETY section Safe handling and relocation for instructions on holding and moving the analyzer The TDLS220 is suitable for wall mounting by means of the four corner located mounting holes as shown below The holed are 2 sized for typically 3 8 or V4 bolts and should be used with appropriate sized flat and locking washers Ensure the analyzer is securing fastened and that there is suitable access for maintenance etc The analyzer is designed for operation outside buildings at normal environmental conditions see Environmental specifications page 11 However it must be protected from direct rain and snow fall Mounting in a vibration free environment will ensure prolonged service life Mounting in vibration prone areas may introduce operational issues Please consider mounting location with care The actual measurement is NOT affected by vibration it is an instrument life time reliability consideration QOOOO OQOOOO0 OOQOQQO Q OOQOQQO Q OOQOQQO QO OOQQOQO Figure 8 Mounting Dimensions IM 11
75. nder normal operating conditions non failure transmission will be affected by Window Mirror fouling For most applications TDLS220 extractive the sample gas should be pre conditioned and clean thus avoiding any window fouling issues o Itis VERY IMPORTANT to keep the process gas clean and non condensing Deposits oily films and other residues depositing on the window mirror may cause performance degradation cyclical drift Alignment of the Laser Beam not necessary for TDLS220 as it is pre fixed at factory Particulate in the process For most applications TDLS220 extractive the sample gas should be pre filtered and clean thus avoiding any window fouling issues 7 1 1 Maintaining Window and Mirror The incoming process gas should be pre conditioned to remove any entrained liquids The sample gas should always be maintained above the dew point to prevent condensation within the flow cell It is recommended that a coalescing membrane type filter be installed up stream of the flow cell inlet Should transmission become lower and or the results become noisy un expected then it is possible the process wetted optical surfaces need cleaning or replacement Use the following procedures to check the Mirror and Window Locations are as shown below IM 11YO1B02 O1E A 4th Edition September 11 2012 00 7 ROUTINE MAINTENANCE 7 2 Mirror Location Window Location Figure 17 Mirror and Window Locations Mirror Removal for Cleaning or Replacemen
76. ning the actual target measured gas The most common application of this is to use Instrument Air 20 996 O2 as the purge gas for analyzers measuring Oxy gen in the process The Laser amp Detect measurement unit will contain some oxygen molecules which must be mathematically cancelled out using the Non Process process parameters In order for the analyzer to measure correctly under these purge conditions the analyzer must know the correct parameters such that the measured output value has been compensated i e the oxygen in the purge gas has been taken into account when determining the process oxygen concentration Calibration The analyzer MUST be calibrated Zero and Span as per the normal methods outlined in the standard User s Guide When performing a Zero Calibration ensure that the entire optical path is purged with Nitrogen When performing a Span Calibration ensure the correct procedures are followed Gil Advanced Config O ADVANCED CONFIGURE MENU UPDATED gt gt The Advanced Configure Menu has been updated with a sub section titled Non Process Parameters CE Advanced Config NON PROCESS PARAMETERS These non process parameters are for the measured gas in the optical path but outside of the process path length These parameters MUST be entered for an accurate measurement if the purge is not nitrogen when measuring Oxygen gt gt Concentration 20 90 input parameter values for the measured gas in t
77. nnect device must be supplied Refer to the Installation section of this manual for details Check termination details before proceeding to prevent damage to electronics Connect any analog I O signals to the optional analog I O Board Outputs land on TB8 and any pressure inputs land on TB9Y Heated flow cells have the gas temperature signal already terminated at TB9 A table of wiring terminations is included in this Instruction Manual Connect any other equipment such as Ethernet solenoid valves digital I O etc Note Solenoids require directional diode or ferrite coil on field wires at terminal block to prevent noise spikes Check terminations and ensure all cable shields are landed per supplied wiring details Utilities and NOTE All purge Validation Gas and other gas utility lines should be thoroughly cleaned dried Sample and purged prior to connecting to the analyzer Failure to do so can result in serious damage to the TDLS220 or contamination to the internal optical elements resulting in poor performance Connect the appropriate analyzer purge gas nitrogen for oxygen analyzers and make site connections per the supplied purge gas sequence details including any Hazardous area purge system Start the purge gas flow accordingly Some Oxygen analyzers may be capable of operating with Instrument Air purge alone or in conjunction with Nitrogen purge of the measurement enclosure I D o gt O c w m Connect pr
78. nt spectra for chemometric model used only for specialized applications that utilize the TruePeak CLS measurement capability This file is essential to the analyzer calibration if this file does Span Calibration Spectra not exist or is corrupted modified or otherwise tampered with Absorption Spectrum and coefficients then the analyzer calibration is invalid It contains essential at time of calibration information relating to the Span Calibration of the analyzer Historical Span Calibration spanO1 through spanO9 are previous files with spanO1 being the Spectra most recent The most recent previous spanO1 can be restored in the analyzer as Previous Calibration The factory calibration Previous Absorption Spectrum l l i a which can also be restored in the analyzer is named span10 and coefficients at time of previous calibrations This file is essential to the analyzer if this file does not exist System Configuration or is corrupted modified or otherwise tampered with then All essential analyzer amp installation the analyzer cannot function It contains analyzer specific system Cfg__ specific parameters required by the parameters relating to every detail of the measurement analyzer for the given application amp calibrations compensation factors I O configurations Valve installation control configurations signal processing etc This file is used by FACTORY PERSONNEL ONLY to evaluate if the configuration is appropri
79. nu Data Dump Options This sets the directories to receive data from analyzer and send data to on system running VAC software Source Directory This is the analyzer data file folder it should not be changed without factory consultation Target Directory This is the remote computer or RIU directory to receive data files File Masks These are the extensions of the files to be transferred it should not be changed without factory consultation VNC Viewer Location specifies the location of the software to remotely control an analyzer it should not be changed without factory consultation APPLY F2 must be selected to save changes From the VAC Main Menu Ctrl F1 will bring up the Help Screen This will give at system text help describing the shortcut keys and their function IM 11YO1B02 O1E A 4th Edition September 11 2012 00 7 ROUTINE MAINTENANCE 7 1 7 Routine Maintenance The TDLS220 TDL analyzer requires little routine maintenance if it has been correctly installed set up and calibrated This section will outline the routine maintenance procedures Maintenance procedures require opening enclosures of certain modules Make sure that there is no ingress of water or other liquids into the analyzer modules during these procedures 1 Maintaining Good Transmission The Transmission of the laser light through the process gas flow cell is the most important variable to consider for routine maintenance and troubleshooting U
80. ocess gas sample to the inlet port and the process sample return vent to the flow cell outlet port Ensure all inlet lines are clean and dry before connecting to prevent contamination of the flow cell and flow cell window mirror IM 11YO1B02 O1E A 4th Edition September 11 2012 00 1 QUICK START 1 2 42 fo Leak check all connections and ensure pressure ratings are not exceeded 5 0 Power Up Make sure the power module door is closed Do not open this door when the analyzer is powered Apply the AC power to the analyzer Open the Control module door Inside this module use the internal On Off switch to power up the ana lyzer located lower right hand side Observe the various LED clusters on the backplane and FPGA boards All blue LEDs located lower right side on the back plane should be on DM Observe the Green power indicator on the SBC sa o Observe the LEDs on the optional analog I O board E Checking If ia is an installed optional 6 5 Display and Keypad Observe the Main Menu messages and status information If there is no installed User Interface then connect a laptop PC via Ethernet to the SBC mounted on the backplane Initiate the supplied UltraVNC software from the laptop to initiate a VNC session with the blind analyzer and observe the analyzer Main Menu via the laptop AT this time there may be alarm or warning messages due to low transmission out of range parameters or other final system config
81. other settings on this menu f Connection X MB VNC Server 10 0 200 2 az host display or host port Quick Options i AUTO Auto select best settings cornea C ULTRA gt 2Mbit s Experimental Cancel LAN gt 1Mbit s Max Colors Canes C MEDIUM gt 128Kbit s Max Colors C MODEM 19 128Kbit s 256 Colors C SLOW 13kKbit s 256 Colors Fuzzy View Only Auto Scaling Options Use DSMPlugin No Plugin detected Config Proxy Repeater If the analyzer connection cannot be established see error message below then check the external computer IP settings connection wires Cat5 cable and IP address Make sure any other LAN devices and WiFi are disabled to prevent conflicts Connection YNE Server 10 0 200 2 Port 5900 Ultr VNC Info Status Connecting Encoder Faded to c t to er Speed 123 kbit s Traffic Bytes Sent Be Bites Received o L ak 0 0 IM 11YO1B02 O1E A 4th Edition September 11 2012 00 6 BASIC OPERATION 6 21 6 5 3 OPTIONAL Remote Interface Unit RIU The OPTIONAL HIU runs the Virtual Analyzer Controller VAC software described below 6 5 4 Virtual Analyzer Controller VAC Operating Software Map Return Main Start VAC Menu Connect select amp Session to Connect Connect Select amp Start Copy Return to Main Menu Create Config Connection Enter Fields Password
82. process gas concentration read ing will trigger a warning BOARD TEMPERATURE OUT OF RANGE warning that analyzer internal temperature is excessive VALIDATION FAILURE a validation failure will trigger a warning there are no settings associated with this T Advanced Config Hj CHANNEL 2 FAULTS menu allows setting of various cc eem c anu E Tier analyzer FAULT conditions FAULT is an event that will eliminate the measurement integrity it is an indication gt gt that maintenance is required and the analyzer is not operational ONLY ADJUST WITH FACTORY ASSISTANCE FAULT CONDITIONS ARE CRITICAL SETTINGS THAT CAN RESULT IN DAMAGE TO THE ANALYZ ER IF IMPROPERLY PROGRAMMED LASER TEMPERATURE OUT OF RANGE upper and lower fault conditions for laser temperature DETECTOR SIGNAL HIGH upper raw detector signal limit DETECTOR SIGNAL LOST lower raw detector signal limit OUTLIER REJECTION threshold of spectrum noise that will result in rejection of measurement PEAK CENTER OUT OF RANGE loss of peak center control f Advanced Config SYSTEM Some settings are not adjustable by user user adjustment is possible for PASSWORD changes password for ADVANCED menu access DATE amp TIME changes analyzer date and time Date amp Time System Temperature IM 11YO1B02 O1E A 4th Edition September 11 2012 00 6 BASIC OPERATION 6 11 Tl Advanced Config mX VALVE CONTROL Typically used w
83. r and translate the detector signal into a signal representing the gas concentration Gas molecules absorb light at specific colors called absorption lines This absorption follows Beer s Law Using a ee Diode Laser as a light source for spectroscopy has the following benefits Sensitivity As low as 10 by volume lower with pathlength enhancement Selectivity The narrow line width of the laser is able to resolve single absorption lines This provides more choices of a particular peak to use for measurement usually allowing one isolated peak to be used Power Diode lasers have power ranging from 0 5mW to 20mW Monochromatic no dispersive element filter etc required Light source itself is selective Tunable Wavelength can be swept across the entire absorption feature which allows resonant peak and non resonant baseline measurement during every scan IM 11YO1B02 O1E A 4th Edition September 11 2012 00 2 INTRODUCTION AND GENERAL DESCRIPTION 2 2 2 1 1 Measurement ph Hh S S Pa d Pd S Pd P Pp pl L S A mu During measurement the laser is held at a fixed temperature This is the coarse wavelength adjustment A current ramp is fed to the laser This is the fine wave l length adjustment di zt a The current is ramped to scan across the wavelength LH Le region desired The collimated light passes through the gas to be measured The amount of li
84. r is a technologically advanced instrument that requires the appropriate care when handling installing and operating Failure to do so may result in damage and can void any warranty If there is any doubt about any aspect of the Instrument installation or use please contact Yokogawa Laser Analysis Division and or your authorized Representative Distributor IM 11YO1B02 O1E A 4th Edition September 11 2012 00 2 INTRODUCTION AND GENERAL DESCRIPTION 2 1 2 introduction and General Description The TDLS220 TDL analyzer is designed to measure concentrations of selected target chemical species most often Oxygen or Moisture in gas phase samples that have been extracted from the process Typically there is a continuous flow of analyzed gas through the TDLS220 optical gas cell The gas should be pre conditioned to meet the sample inlet requirements including but not limited to particulate removal dew point control heated flow and pressure control etc Chemical composition of the sampled gas mixture is determined by the end user It is the end user responsibility to ensure safe delivery of the sampled gas to the analyzer and the subsequent return of the gas to the process or its utilization after analysis The analyzer measures chemical concentrations on a path averaged basis Unless the extractive sampling system up stream removes water or other condensables then the measurements are considered to be on a Wet Basis Measurements
85. re or software from being damaged or a system failure from occurring A CAUTION This symbol gives information essential for understanding the operations and functions A Note This symbol indicates information that complements the present topic D This symbol indicates Protective Ground Terminal This symbol indicates Function Ground Terminal Do not use this terminal as the protective ground terminal E Warning and Disclaimer The product is provided on an as is basis YOKOGAWA shall have neither liability nor responsibility to any person or entity with respect to any direct or indirect loss or damage arising from using the product or any defect of the product that YOKOGAWA cannot predict in advance IM 11YO1B02 O1E A 4th Edition September 11 2012 00 A CAUTION SAFETY should be considered first and foremost importance when working on the equipment described in this manual All persons using this manual in conjunction with the equipment must evaluate all aspects of the task for potential risks hazards and dangerous situations that may exist or potentially exist Please take appropriate action to prevent ALL POTENTIAL ACCIDENTS 1 Safe lifting and carrying If it is necessary to relocate the analyzer it should be lifted by at least two people wearing protective gloves and steel toe boots Mounting holes that can be used for hooks Do not grip area E 1 T t 1 t Aw i T a II w
86. rect validation results Check Gas Concentration specifies the concentration ppm or 96 of the gas within the offline flow cell Check Gas Pathlength specifies the optical path length of the offline flow cell This is typically preset to 40 or metric equivalent Check Gas Temperature can be selected for either Fixed or Active o If Active Temperature then follow on screen instructions o If Fixed Temperature then enter in the temperature of the gas within the offline flow cell Remember that this value will be used whenever the auto validate is used so try to select a value that is representative of when the auto validate might take place day night etc Press ENT to proceed Check Gas Pressure specifies the pressure at which the gas within the offline line flow cell Valve Selection specifies which analyzer s solenoid valve driver is used for the check gas Check Gas Purge Time specifies how long the check gas will purge the flow cell N2 Purge Time specifies how long N2 will purge the flow cell e Analog Output Mode specifies Block Track or Hold of all 4 to 20 mA output during offline check IM 11Y01B02 01E A 4th Edition September 11 2012 00 7 ROUTINE MAINTENANCE 7 14 7 4 2 Off Line Manual Automatic Calibration To perform off line calibration the TDLS220 flow cell is already capable of being validated calibrated in off line mode Using external switching valves or reconfigured tubing connections to
87. s more than one analyzer connected to the RIU then they are routed via an industrial Ethernet switch Up to four analyzers can be routed through one HIU switch The RIU Enclosure is die cast copper free aluminum grade AL Si 12 alloy A413 0 with a powder coat ex terior finish The copper free aluminum alloy is particularly resistant to salt atmospheres sulfur gases and galvanic corrosion An externally hinged door opening to the left incorporates a weather tight gasket seal and four captive fastening screws stainless steel The external dimensions are approx 16 W x 12 H x 7 D 400mm x 300mm x 180mm Wall mounting brackets are included with the RIU The environmental protection rating is considered IP66 EN 60529 or NEMA 4X Cable entries are located on the bottom face of the enclosure They are typically 34 Myers hubs that have 34 NPT female threads Each has a ground lug to facilitate the grounding of cable shields to the chassis The HIU is supplied with standard integral display and keypad IM 11YO1B02 O1E A 4th Edition September 11 2012 00 4 ANALYZER COMPONENTS 4 6 RIU Interconnect to TDLS220 Control Unit s When connecting just one analyzer to the RIU there are two twisted pair wires to consider there are only four wires to be terminated to make the 10 100 Ethernet connection Analyzer RIU Integral SBC Integral SBC TB6 RIU Switch or Txt Tx Ret Rc Field Terminals Figure 5 Connecting RIU to Analyzer s R
88. s the typical value would be Current 20 996 O2 If measuring CO in the process gas and the purge gas is Instrument Air then these parameters are not applicable New i because the CO concentrations typically found in Instrument Air are below practical detection limits Input new air purge pressure IM 11YO1B02 O1E A 4th Edition September 11 2012 00 6 BASIC OPERATION 6 16 6 4 Stream Switching amp Valve Control Outputs The TDLS220 has three valve drivers 24VDC each Q 12W max each terminated at TB 3 These can be used for either calibration Validation and or stream switching functions If using these valve drivers for any type of Calibration Validation function then please refer to the appropriate section of Instruction Manual As shown in the fol lowing drawing 3 process streams are connected to 3 gas valves then to the inlet of the TDLS220 flow cell The gas valves are controlled by three 24V relay output signals from the launch unit of the analyzer During normal operation only one valve can be open at a time The connected solenoid wires at TB 3 may require the installation of a ferrite coil to eliminate noise spikes this is totally dependant on the site specific elec trical grounding conditions If the analyzer appears to be re booting when one or more of the solenoids is activated then this means some noise protection is required Either add a ferrite coil to the connecting wires contact Yokogawa for further as
89. sistance if necessary or add a 3A 50V directional diode across the terminals at TB 3 Stream 1 24V relay control signals from Control Unit Valve 2 Stream 2 TDLS220 Sample Flow Cell Stream 3 Outlet Figure 15 Valve Control BY PASS m RETURN FU AAR lt B m in STREAM 1 Figure 15 Typical Stream Switching Scheme IM 11YO1B02 O1E A 4th Edition September 11 2012 00 6 BASIC OPERATION 6 17 There are 3 ways to control the valves manual control in software automatic valve change in time sequence and remote override though digital contact The following software description defines how to configure the sequencing and timing of the valves when used in a stream switching configuration ADVANCED CONFIGURE MENU Process Path Length Process Path Length glos so ix gt gt anced Config The software setup for the stream switching is configured in Advanced Configure gt Valve Control STATUS OF VALVES This panel shows the current status of all three valves User gt gt ON can enter any valve to modify the settings Note only one valve can be open at a time during normal operation VALVE CONTROL MODE There are three ways to change the valve status Manual automatic Time Sequence and Remote Override Remote Override Manual Valve Control Valve 1 JOE MANUAL VALVE CONTROL By toggling the switch in this panel user can manually turn on off the val
90. soft Notepad as simple txt file formats The content can then be copied and pasted into Microsoft Excel spread Each day as a separate file name in the MMDDYY format with the spe file extension meaning spectra Each file contains spectra captured automatically during that day depending on what rate of spectra capture has been set up Typically the analyzer will Daily Spectra capture one spectrum every 300 measurement up dates if the capture rate is set 300 up dates Additionally if the analyzer goes into Warning of Fault mode during that day there will be spectra captured during these times typically configured for 5 captures in each mode A new dated file is created each day Files are deleted automatically on a First In First Out FIFO basis if the allowable Data folder has no spare memory Allows for review of daily results and 092407 SPE diagnostic data on a measurement by measurement basis IM 11YO1B02 O1E A 4th Edition September 11 2012 00 alarms alarms calibr Capture Individually named spectra captured manually Alarms History A historical log of analyzer alarm events Alarms History Back Up A back up of the historical log of ana lyzer alarm events Calibration History A historical log of analyzer calibrations 9 DATA FILES AND FORMAT 9 2 These files are the individually named spectra that are Captured by the user at any given date or time during operation Each f
91. t Follow the precautions outlined in the Thermal hazard and Chemical hazard sections of the SAFETY chapter If the flow cell becomes contaminated then it may be cleaned using the following procedure e discontinue the process gas flow and initiate nitrogen or instrument air purge of the analyzer shut down the analyzer and disconnect from AC power supply Wait 30 minutes to let the gas cell cool down to safe temperature If installed remove the flow cell insulation end cap as shown below A CAUTION Potentially HOT SURFACES on heated or insulated flow cells Using 7 64 Allen key wrench remove the four fastening screws and lock washers IM 11YO1BO2 O1E A 4th Edition September 11 2012 00 7 ROUTINE MAINTENANCE 7 3 e Carefully remove all four fasteners and lock washers and the mirror mounting plate A CAUTION The mirror is not fastened or adhered to the mounting plate so during removal keep the mounting plate tilted up wards to prevent the mirror from falling out of the mounting plate ff CAUTION e Visually inspect the mirror surface for any signs of contamination dirt deposits films oils etc If in any doubt about the quality of the mirror surface then cleaning is recommended If obvious severe damage to the actual mirror surface can been seen then a replacement mirror should be installed IM 11Y01B02 01E A 4th Edition September 11 2012 00 7 ROUTINE MAINTENANCE 7 4 Mirror Mountin
92. t in this box is 24V and is not hazardous A higher voltage 65V 10 mA is shielded with an isolating plate and labeled 3 Thermal hazard The gas cell can be heated up to 120 C and cause thermal injury to unprotected skin at direct contact In normal configuration the cell is wrapped in a thermal isolation jacket that prevents such incidents DO NOT REMOVE THERMAL JACKET WHEN THE ANALYZER IS POWERED Prior to performing service operations that require removal of the thermal jacket power the analyzer down and wait 30 minutes to let the temperature drop to a safe level IM 11YO1B02 O1E A 4th Edition September 11 2012 00 Areas of a potentially hazardous temperature are labeled with the following symbol 4 Chemical hazard Analyzer can measure a wide variety of chemical species in various gas mixtures CHEMICAL COMPOSITION OF SAMPLE SUPPLIED TO THE ANALYZER AND ITS VARIATION LIMITS MUST BE APPROVED BY YOKOGAWA to ensure safe operation of the device Gas stream supplied to the analyzer gas cell for analysis can be potentially harmful for people and environment DO NOT DISCONNECT THE ANALYZER GAS TUBES INLET OR OUTLET DURING ITS OPERATION CHECK FOR LEAKS AFTER INSTALLATION BEFORE SUPPLYING THE GAS SAMPLE FLUSH ANALYZER WITH NITROGEN OR INSTRUMENT AIR FOR 15 MINUTES BEFORE DISCONNECTING FROM THE GAS LINES The inlets and outlets of the sampled gas are labeled with the warning sign A 5 Other labels used on this analyzer Th
93. ta O64 To store spectrum automatically select Auto If you do not wish Advanced Data Spec to store any spectrum file during normal analyzer operation then select Manual mode Capture Mode Automatic Manual Press ENT to configure PE advanced Data O64 Determine the rate at which you would like the analyzer to capture Advanced Data Spectrum Capture Selection spectrum files and under what condition The default condition is related to the number of measurement however the user can select Relative or Absolute changes pending the site specific conditions Updates fff requirements The more frequently spectrum are stored then the larger the MMDDY Y spe files will become Relative Absolute NOTE Capturing every spectrum for one day can create a single day file in excess of 30MB This will reduce the number of daily results that are stored in the analyzer Choose the parameters carefully Input number of updates between captures IM 11YO1B02 O1E A 4th Edition September 11 2012 00 lt 9 DATA FILES AND FORMAT 9 7 Pj advanced Data Determine whether or not the analyzer should capture spectrum Spectrum Capture When Alarm files under a WARNING condition Note this may be useful to do so however if the Warning alarm conditions are not set correctly then there could be excessive files Current created for less meaningful Warning alarm conditions An example is a low transmission warning alarm set at 70
94. text file for import into a spreadsheet for analysis Data stored in the analyzer e Results Every measurement the gas concentration transmission diagnostic data are stored Spectra The analyzer records spectra at a timed interval in the event of an analyzer warning or fault including concentration values and manually via the user interface Calibration History is stored during every calibration or validation event Alarm Fault History Events History which includes any changes made to the system settings All data can be retrieved using a USB flash drive at the analyzer via the RIU or over an Ethernet connection IM 11Y01B02 01E A 4th Edition September 11 2012 00 4 ANALYZER COMPONENTS 4 8 Select Pro cess H20 Concentration ppm Transmission 96 Menu AJO Mode 7 Path Length New Block f Hold iic New EITTTITE Active Alarm Temperature New 27 3C Shut Down Analyzer Up Down to select Enter to proceed a IP Address 04 26 2006 10 04 37 TF ates EM Configure fe rs io n Set path length process pressure View Spectra process temperature Haw Detect Spectrum Absorption spectrum View data 0 n Screen Concentration ppm Max 750 minutes Data Alarm History View data Cal Historv e on screen User data Dat Record Data Factory data Refresh current trend screen E Concentration with reference 4 26 2006 n min max Gas Pressure minutes Concentratio
95. uration is still required If the analyzer displays a Warning Validation Required then this indicates that there is no target gas absorption peak found at start up Either shut down the analyzer introduce some measured gas into the flow cell and re start or perform a validation This will ensure that the analyzer is correctly tuned to the measurement gas absorption peak If this Warning cannot be cleared by either method please contact Yokogawa Laser Analysis Division or your local agent for further assistance Configure By way of the appropriate user interface the correct process parameters and other parameters can now BASIC be entered EUM Enter the Basic Menu and go to Configure Gas Pressure Enter in the correct process gas pressure if Active see Advanced Configure Gas Temperature Enter in the correct process gas temperature if Active see Advanced Configure LR any other parameters are required to be set such as analog I O ranges alarms levels Auto Validation EE then the Advanced Menu needs to be accessed Advanced Menu access is Password protected default 1234 can be changed by user if neces sary and should only be used by skilled and trained persons Contact Yokogawa Laser Analysis Division or Local Agent if any doubts Go to the Data section under Basic and configure the appropriate Record Result Data settings This will ensure the analyzer stores important information during operation that may be use
96. ve Valve Control fon Note when user toggles the switch to on while there is another E valve was on previously the valve control will turn the other valve off Only one valve can be open at a time Manually switch solenoid valve 1 IM 11YO1B02 O1E A 4th Edition September 11 2012 00 6 BASIC OPERATION 6 18 MEN NN Note all three valves can be off at same time 73 Advanced Config DPA TIME SEQUENCE Valve Control Time Sequence Valve 1 Off Input the valve on duration in minutes and select the next stream valve 73 Advanced Config a X Valve Control Remote Override Valve 1 Channel 1 Channel 2 Channel 3 Off Please select remote control channel The valves can be controlled automatically based on the time sequence As an example of the left setting Valve 1 stays on for 60 minutes before switching to Valve 2 By setting the Time Sequence of all 3 valves the stream switching can be implemented continuously and periodically REMOTE OVERRIDE Each valve can also be manually turned on by remote digital contact from control room or DCS This panel specifies digital input channel for valve control IM 11YO1B02 O1E A 4th Edition September 11 2012 00 6 BASIC OPERATION 6 19 6 5 Controlling the Analyzer Remotely or Locally via external PC Laptop A number of methods is available to remotely control the TDLS220 analyzer Local Access using VNC and an external computer Laptop Ultra VN
97. windows and Kalrez o rings 316L flow cell sapphire windows and Kalrez 6375 o rings Monel A400 flow cell sapphire windows and Kalrez 6375 o rings No Heat Temp sensor insulation jacket Active T comp General Purpose Safe Area cell heating max 120 C Insulated Jacket General Purpose Safe Area cell heating max 100 C Insulated Jacket Div 2 cell heating 120 C Insulated Jacket Blind Controller Integral Mini Display Integral Color LCD Backlit Options Ext USB Port IP66 w cap can be used with general purpose safe area only NOTE Select an item from each section Example TDLS220 G1 X1 S6 SST GP 1 U IM 11YO1B02 O1E A 4th Edition September 11 2012 00 4 ANALYZER COMPONENTS 4 1 4 Analyzer Components Laser amp Detect Housing Electronics Housing Power Supply amp Heater Figure 2 System Overview Controller Housing 4 1 Main Electronics Housing Enclosure Die cast copper free aluminum grade AL Si 12 alloy A413 0 with a powder coat exterior finish The copper free aluminum alloy is particularly resistant to salt atmospheres sulfur gases and galvanic corrosion An externally hinged door opening to the left incorporates a weather tight gasket seal and four captive fastening screws stainless steel The external dimensions are approx 16 W x 12 H x 7 D 400mm x 300mm x 180mm The environmental protection rating is considered IP65 EN 60529 or NEMA 4X Cable entries are located on the bottom
98. y Conditions filtered clean and dry non condensing Cell volume 260 cc Flow rate of 1 20L min typically 6 L min Pressure of 3 psig to 100 psig Temperature of 20 C 4 F to 50 C 122 F un heated or 120 C 248F heated Gas Measured O 0 01 detection limit Min Range 0 196 Max range 25 Performance Specifications are application dependant Consult Yokogawa for ranges All performance specifications are for 25 C at 1 bar Installation Specifications By Design The analyzer is designed for operation in General Purpose area The addition of a Purge System enables operation in Hazardous Area for gaseous releases Class 1 Division 2 Group B C and D ATEX CE Pending Optional CSA opecial Acceptance certification 3 GENERL SPECIFICATIONS gt 3 2 Flow Cell Wetted Parts Standard 316L Sapphire windows Teflon encapsulated Viton O rings and protected gold mirror Optional Monel Alloy 400 Kalrez 4079 O rings Mains voltage CE 230V model 210 to 240V AC 50 60 Hz single phase 110V model 100 to 130V AC 50 60 Hz single phase Surge and temporary overvoltage immunity in compliance with EN 61326 1 Integration Configuration e Sample is fully extracted from process and should be conditioned before measurement e Process pressure and temperature can be controlled or the analyzer may require pressure and temperature inputs application dependant e Length of flow cell is fixed Purge Gas amp Valid
99. yzer results and reads input process gas compensation values pressure and temperature The board has power status LEDs as well as voltage test points for the input and output channels e Output channels three are ranged 4 20mA They can be assigned to measured values Oxgen Transmission or compensation signal re transmission Input Channels two are used by the analyzer to read active values for process gas temperture and or process gas pressure These are application dependant and may or may not be required inputs There are two channels one for temperature and one for pressure Each may be used to read 4 20mA signals that are isolated or to read and loop power with integral 24VDC signals Optional Mini Display 4x20 VFD mounts on the analyzer enclosure door The display itself is an indus trial grade 4 line 20 character vacuum fluorescence display VFD that is self illuminating i e no back light required IM 11YO1B02 O1E A 4th Edition September 11 2012 00 4 ANALYZER COMPONENTS 4 4 Optional 6 5 Display is an industrial grade 6 5 VGA color TFT LCD Module that has a built in CCFL backlight Both the display and interface board are mounted to a cover plate that attaches to the inside of the enclosure door Keypad is an industrial rated 30 key unit that has a PS 2 6 pos miniDIN interface direct to the SBC It has an Ingress Protection Rating of IP65 equivalent to NEMA 4X and is of low profile design TDLS220 Field Termin

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