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User`s Manual - Northwest Instruments & Controls INC

1. Figure 34 Off Line Calibration Overview LAUNCH UNIT 7 00 7 98 C 203 178 FRONT VIEW IGHI VIEW BACK VIE Figure 35 Launch and Detect unit Dimensions IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 lt 5 INSTALLATION AND WIRING 5 10 INCLUDED BRACKETS MAY BE MOUNTED VERTICALLY HORIZONTALLY 13 31 12 22 338 313
2. 1 3 00 50 76 1 76 FRONT VIEW RIGHT VIE BACK VIE Figure 36 Remote Interface Unit INCLUDED BRACKETS MAY BE MOUNTED VERTICALLY OR HORIZONTALLY FRONT VIEW IGH VIE BACK VIE Figure 37 Universal remote Display URD IM 11Y01B01 01E A 5th Edition Feb 9 2012 00 lt 5 INSTALLATION AND WIRING 5 11 INCLUDED BRACKETS MAY BE MOUNTED VERTICALLY OR HORIZONTALLY 7 00 FRONT VIEW RIGHT VIE BACK VIE Figure 38 Universal Power Supply UPS ALIGNMENT ADJUSTMENT NUTS 4 ANALYZER QUICK CONNE COU
3. BOLT HOLE TYP 4 20 750 19 a _ 0 690 ANSI RF 2 150 18 FLANGE PROCESS LAUNCH DETE CONNECTION MOUNTING HOLES TYP 4 51655 BODY Figure 39 Alignment Bellows Other flange sizes available to meet application needs IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 lt 5 INSTALLATION AND WIRING 5 12 ANALYZER QUICK CONNECT COUPLING ANSI RF 4 1504 PROCESS CONNECTION LAUNCH DETE E C MOUNTING HOLES 5 8 11 18 8 SS STUDS 51655 BODY ALIGNMENT ADJUSTMENT BOLTS 4 Figure 40 Large Apenture Other flange sizes available to meet application needs 5 40D 137 5i lt 8 32 THREAD 5 5 625 292 RF ANSI EH VITIA m Ww ANALYZER SIDE PROCESS SIDE A RNG E M SEPM Gier 1 SY SILICONE RTV WINDOW HOLDING COMPOUND NON PROCESS CONTACT LORY BORE THROUGH gt KALREZ O RING COMPOUND 4079 WAY SAPPHIRE ISOLATION WINDOW 1 4 THICK TAA 5 8 11 18 8 SS STUDS BORE THROUGH AND WELDED TYP 4 NN MM Lm Is 316SS ISOLATION WINDOW RETAINING RING NON PROCESS CONTACT 1 4 FNPT
4. 6 30 IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 10 06 Vale CONO Roe c E 6 30 6 7 Introduction for measurements in Methane 6 32 6 8 Introduction to Gas Temperature Predictions with High Temperature Oxygen Measurements 6 38 6 9 Controlling the Analyzer Remotely or Locally via external PC Laptop esses 6 34 6 9 1 Instructions for Connecting an External Computer to the 2 6 35 6 9 2 Using Ultra VNC SOWA svat aanraak Ena 6 36 6 9 3 Remote Interface Unit RIU 1 llsesseessesseesseeeesee nennen nenne nnne nnne nennen nnn n nnn ranas nn nnns 6 37 6 9 4 Virtual Analyzer Controller VAC Operating Software 6 37 06 9 5 pemote Intonaco EUR aE AREER ERRE RIS EEE TA esten idi en 6 38 6 9 6 Virtual Analyzer Controller VAC Operating Software 6 38 FROUTING Nainen e n 0f 7 1 1 Maintaining Good Transmission 7 1 PME PU aac ese esc Ss conte EET 7 4 Validation Calibration usc e
5. n rnpe Restore old zero calibration result Press 9 ta restore previous zero calibration press to restore factory zero calibration or press ESC to cancel Ensure analyzer is purged with nitrogen When an acceptable zero has been established arrange the purge tubes as shown below and then follow the on screen instructions for Span calibration IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 8 VALIDATION AND CALIBRATION 8 7 1 CAPPED PORTS ZERO GAS NITROGEN gt 99 95 5 SPAM GAS NSTRUMENT AIR 20 98 O2 4 ALL GASES MUST BE DRY 70 F DEWPOINT CLEAN 5 MICRON AND OIL FREE ALL GASES ARE APPLIED AT SLPM TE hanged Calibr aie lk Vat dada Dpr CA orn Enter calibration cell pressure 14 7 Enter calibration cell temperature F Enter calibration cell length n B 6 After entering cell pressure cell temperature and cell length 28 6 or 72 6cm the following option will appear on the basis of two gas measurement option Please toggle to either of the two gases configured within the analyzer or as in the example below there is no second measured gas configured Tl d iib wie Validate Calva Gas Type amp Concentration Gas Type Bo 22 0 Input span gas type and concentration 5 Note after entering the desired span gas value the following display will prompt you to press 9 to actually perfor
6. 720 Pres esis EY Press ENTER to capture the speclrum IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 6 BASIC OPERATION 6 7 The BASIC DATA MENU allows the user to select ALARM HISTORY displays the last 17 alarms and faults with brief description date and time CALIBRATION HISTORY displays the last 17 calibration did events with adjustment amount date and time c 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 REFRESH The trend will NOT update automatically use the refresh button to update the trend CONC analyzer reading of gas concentration shown here as O2 or whatever Gas 1 is configured STDEV1 the standard deviation of 25 consecutive concentration readings for gas concentration 1 Gas2 analyzer reading of gas 2 concentration STDEV2 the standard deviation of 25 consecutive concentration readings for gas concentration 2 Refresh the screen TRANS transmission 96 of laser light through the process gas 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 Trend Graph M
7. IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 Yokogawa Corporation of America Yokogawa has an extensive sales and North America distribution network 2 Dart Road Newnan GA 30265 1094 USA i Phone 800 258 2552 Fax 770 254 0928 Please refer to the website www yokogawa com us to contact your nearest representative 12530 West Airport Blvd Sugar Land TX 77478 Phone 281 340 3800 Fax 281 340 3838 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 Bay 4 11133 40th S SE Cal AB Canada T2C2Z4 cmd regis 303 256 0182 YOKOGAWA IM 11Y01B01 01E A 02 1002 A I Subject to change without notice Printed in The USA Copyright 9 2008 IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00
8. e Aleck Mode Level Field Loop Check Record Result Data m ru m FA Cn Lalibrabaon IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 9 TROUBLE SHOOTING 9 2 9 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 e Check Status LEDs This will ensure that power is routed properly to the system components Status LEDs are listed below Blue LED Voltage VDC from left to right D20 slate power supply ert Isolate power supply ee FB laser driver power supply as FB laser driver power supply 15 Analog I O board power supply kD power supply ____ Main power supply ___ 15 Analog I O board power supply __ DO 8B power supply a SU amp 9 45V ISOR 5 Ls 7 lt EVAZ IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 9 TROUBLE SHOOTING gt 9 3 e Adjust Analyzer Alignment Adjusting the alignment will ensure the analyzer has not physically changed to the point where the laser beam is off center at detect unit While monitoring transmission 96 adjust the alignment in all directions by a small amount until you see the transmission increase Fine tune the adjustment to ensure maximum alignment e Initiate On Line Validation if fitted
9. Ensure the check gas is ready to start purging the integral on line check gas flow cell BUT DO NOT start the flow yet The standard purge gas typically Nitrogen should still be flowing through this cell at this time Connect check gas to launch unit Press ENT then apply check gas Press ENT and then switch to flowing the check gas through the cell IM 11Y01B01 01E A 5th Edition Feb 9 2012 00 8 VALIDATION AND CALIBRATION 8 19 Following the on screen directions enter in the pressure of the i i gas within the on line line check gas flow cell Typically this enter check gas pressure psia cell is vented to atmosphere so an atmospheric pressure value 14 7 psiA or 1 01barA will work Press ENT to proceed Enter in the temperature of the gas within the on line line check uM Tr gas flow cell Typically this cell is the same temperature as am bient Use a thermometer DVM with appropriate thermocouple 14 70 attachment or radio to the control room for an ambient reading Proc C brale Onine Check Enter check gas temperature F Press ENT to proceed Ti Advanced Calibrate E Validate The length of the on line check gas flow cell has been already entered a default value and should be in the order of 3 5 to Enter check gas pressure psi 5 5 or 75 to 1 15mm 14 700 Enter check gas temperature F Press ENT to proceed 78 49 Enter check gas length n H20 Concentratio
10. IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 10 DATA FILES AND FORMAT gt 10 3 calibr pik Calibration Pick List FACTORY PERSONNEL ONLY Factory Use Only dat Chemometric Model File Parent spectra for chemometric model used only for specialized applications that utilize the TruePeak CLS measurement capability spe Span Calibration Spectra This file is essential to the analyzer calibration if Absorption Spectrum this file does not exist or is corrupted modified or coefficients at time of otherwise tampered with then the analyzer calibration calibration is invalid It contains essential information relating to the Span Calibration of the analyzer spe Historical Span spanO1 through spanO9 are previous files with Calibration Spectra span01 being the most recent The most recent Previous Absorption previous spanO1 can be restored in the analyzer Spectrum and as Previous Calibration The factory calibration POA Cien Br which can also be restored in the analyzer is previous calibrations named span10 cfg System Configuration This file is essential to the analyzer if this file All essential analyzer amp does not exist or is corrupted modified or otherwise installation specific tampered with then the analyzer cannot function It parameters required by the analyzer for the given application amp installation contains analyzer specific parameters relating to every detail of the measurement calibrati
11. IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 lt 5 INSTALLATION AND WIRING 5 14 CHECK GAS 4 SCFH 2 SLPM 77 ANALYZER 0 SCFH 5 DETECT UNIT WINDOW 64 SCFH 30 LAUNCH UNIT WINDOW P 64 SCFH 30 S PURGE GAS 50 PSIG 3 4 BARG MIN 100 PSIG 7 BARG MAX V1 54 8 PSIG VALIDATION STANDARD P 20 PSIG 1 4 BARG MAX SV1 VALVE ACTUATION GAS VENT a rg 50 PSIG 3 4 BARG MIN 100 PSIG 7 BARG MAX PURGE preise V NOTES 1 ALL TUBING SHALL BE 316SS 1 4 0 035 WALL UNLESS OTHERWISE INDICATED 2 ALL TUBE FITTINGS SHALL BE SWAGELOK UNLESS OTHERWISE INDICATED 3 ALL BULKHEAD CONNECTIONS ARE 1 4 TUBE UNLESS OTHERWISE INDICATED 4 ALL GAS SUPPLIES MUST BE CLEAN 5 MICRON OIL FREE AND DRY 70 DEGF DEWPOINT Figure 44 Utility Panel Tubing Detail Standard Single Auto validation CHECK GAS CHECK GAS ANALYZER PURGE DETECT UNIT WINDOW P DETECT UNIT WINDOW PURGE LAUNCH UNIT WINDOW P LAUNCH UNIT WINDOW PURGE
12. User s TOLS200 TDLS2 IruePeak Manual 00 Tunable Diode Laser Spectroscopy Analyzer C IM 11YO1BO01 01E A YOKOGAWA 4 2 Dar Foe Newnan Geog USA 3026 11Y01801 01E A Yokogawa Corporation of America Tel 1 800 258 2552 Fax 1 770 254 0928 5th Edition Introduction Thank you for purchase the TDLS200 Tunable Diode Laser Analyzer Please read the following respective documents before installing and using the TDLS200 Notes on Handling User s Manuals 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 for the particular purpose of the user e Every effort has been made to ensure accuracy in the preparation of this manual However when you realize mistaken expressions or omissions please contact the nearest Yokogawa Electric representative or sales office e his manual does not cover the special specifications This manual may be left unchanged on any change of specification construction or parts when the change does not affect the functions or performance of the product e fthe product is not used in a manner specified in this manual the safety of this product may be impaired Yokogawa is not responsible for damage to the instrument poor perfor
13. Utility Requirements Purge Protective Gas Supply 20 psig 1 4 Bar minimum Suggested to compensate for Pressure to Pressure Regulator enclosure leak rate Purge Protective Gas Supply Water and oil free 40 F 40 C dew point particles lt 5p ISA Quality grade hydrocarbon free Power Input Consumption 0 5 Watts maximum Voltage 4VDC model 19VDC to 28VDC 47 to 63 Hz CYCLOPS Z Purge Indica tor Mains Supply Fluctuation Not to Exceed 1096 Environmental Conditions Operating Temperature Range 40 F to 150 F 40 to 65 Used and Mounted For Indoor and Outdoor Use Casing Material Specifications Anodized Aluminum Weight 2 48 lbs 1 13 kg Anodized Aluminum Protection NEMA 4 IP66 IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 6 BASIC OPERATION 6 1 6 BASIC OPERATION 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 mA value New Track Pressure Hold 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 Gas 1 Concentration Min Max STDEV of Gas 1 Concentration Minutes Gas 2 Concentration STDEV of Gas 2 Concentration Transmission Laser Temp Setpoint Laser Temp in degC P
14. 20 CIRL BAS S end as Asayrer Conrollers Session T uiun4M j9ga 10 0 5 47 Job OFELIA EIT wosa Advanced Config Laser Spectra amp Control Note during normal process operation with 90 Raw Detector Signal Absorption Spectrum 10096 methane gas flowing in the cell the laser temperature set point LTSP is configured to control the methane peak position at data point 220 as dd shown red in absorption spectrum right H20 ppm Temp C Control Mode Cur Center The actual measurement of H O ppm absorption 19 13 lg 5022 amp 10000 that H Oppm is not visible to the eye within this 100 13 44 700 22 226 absorption spectrum when 100 ppm as shown Peak Pos blue in absorption spectrum right 22 226 220 3 11 30 2010 09 21 35 peak is made the data point region of 160 note CH4 Pres psiA LTS 6 8 Introduction to Gas Temperature Predictions with High Temperature Oxygen Measurements For some high temperature oxygen measurements operating at the correct conditions the analyzer can predict the gas temperature as well as the oxygen concentration The TruePeak TDL analyzer scans a tunable diode laser over a small wavelength range across measurement gas absorption line profile The measurement gas concentration can be predicted from the absorption peak with combustion parameters of optical path length gas temperature and gas pressure The gas temperature has sig
15. SUPPLY 90 740 MAX 2 50 60Hz LAMB TEMPZ 10 TO 50 Made in USA For Zone 2 CAT 3 ATEX use the following labels will be attached as appropriate j 101 644inch TOLS Analyzer Pressurized Enclosure internal Free Volume E Purge Gas AIR Min imbar T16mbar MM Min Purge Flow 1OL rain Min Purge lime 12 minula Leakoge Rate iz Balley type fitted Lithium CRZD32 0 21AR 3 0 D Ji ba mg p Certificate qum Exot 20C t 500 EPSILUM UG ATEK 24125 THIS PRODUCT COMPLIES Max Supply Line lt 6 3barg WTH 21 CFR PART 1040 10 Min Supply Line U 2borG YOHMOGAMA 210 Gemini Street Houstan Texas 77058 Made in USA WARMING eleclrasbatie chargng hazard cem Do mot open when an plesi god alomosphers may be present Do mot open when merged HOTE Analyze input pressure iB uz Earb Note A amp asyzer pressure iB 0 2 101 644Inch i TDLS Analyzer Pressurized Enclosure Laut Aes WX MAX 1204 BED MB TEMPA ao TO Soc Min Purge Time 18 minutes IOA Leakage Rate te Ballery type fitted Wm Lithium CRZO032 D 21Ah 3 0V L36 Certificate Fear in 4541 EPSILUM OH ATEX 2412x THIS PRODUCT COMPLIES Max Supply Line 5 SbarG WITH 21 CFR PART 1040 10 Min Supply Line
16. e 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 e Mini display which is an Integral display 4X20 smart VFD cycles information No keypad menu access via local or remote external computer Ethernet connected e Keypad with 6 5 display e 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 Remote Interface Options A number of options are available for remote access to the analyzer Remote Interface Unit RIU model YR200 shown below allows remote analyzer control and data transfer from analyzer to RIU data can be transferred from RIU via USB memory stick or Compact Flash card i e Allows multi unit field communication via acil central user interface e Not required for individual analyzer operation interface and data transfer only e Connects with 1 8 analyzers via Ethernet switch e Integral Keypad and 6 5 display wr External Computer via Ethernet A separate computer can be connected to the analyzers locally or through an Ethernet el aM B network to allow analyzer control and data transfer Figure 14 Networked Analyzers The Remote Interface Unit RIU consists of
17. VALIDATION STANDARD 2 PURGE GAS 8 lt aer VALIDATION STANDARD 1 VALVE ACTUATION GAS PURGE Figure 45 Utility Panel Tubing Detail Standard Dual Auto validation IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 lt 5 INSTALLATION AND WIRING 5 15 5 10 Wiring 5 10 1 Wiring of Launch for the US version V 90NvC MJZATVNV AG _ Q343MOd N
18. i follows ambient temperature It is not as accurate as an active input but it is more accurate than a Fixed value ACTIVE PEAKS is used for special high temperature oxygen combustion application when the gas is above 800 C used only when approved by Yokogawa and not functional 800 C CONTROL is not used in TDLS 200 Active Ambient Active Peaks NON PROCESS PARAMETERS EE This software feature allows the user to enter all necessary parameters associated with the Non Process Parameters configuration Refer to detail section of User Guide for more information Opere and follow the on screen directions for programming details Siem Selector input parasseter values for the measured gas in the optical path thal is outside of the process path IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 dean ed Cony gt gt Path Length T Advances System If Ane Output gt gt Channel 1 Channel 2 Channel 3 Warning Mode Fault Mode Field Loop Check AO CH Calibration I E T DHEEESETRES CHi Calibration CH 2 Calibration 6 BASIC OPERATION 6 10 UNITS Path Length select the appropriate units of measure for Path Length in ft cm m Pressure select the appropriate units of measure for Pressure psiA barA kPa torr atm Temperature select the appropriate units of measure for Temperature F C K SYSTEM 1 0 ANALOG OUTPUT CHANNEL 1 to configuring each 4
19. Current New Input air purge measurement gas concentration d Cani Change Ai Purge Alarm Alarm Type Fault Warming Select alarm type and PH threshold for non process gas leak Input 1 to disable the alarm 6 BASIC OPERATION 6 21 NON PROCESS TEMPERATURE This is the temperature of the non process gas with two modes of input FIXED manual input of fixed temperature value ACTIVE AMBIENT ambient gas temperature derived from integral sensor on detector circuit with offset adjustment typically 5 deg C and an adjustable coefficient value 1 0 shown left To derive the optimum coefficient value please contact Yokogawa with installation and application details This will ensure the optimal coefficient value taking into account the temperature gradient from ambient to process gas temperature for the non process purge gases NON PROCESS ALARM SELECTION This allows the selection or disabling of alarm when then non process gas peak height falls below the entered threshold value In this example the analyzer is configured to FAULT Alarm when the peak height is lower than 0 001 au see absorption spectrum This value can be determined with assistance from the Yokogawa factory to suit the specific application This alarm function can be used to help detect the leakage or loss of line locking gas for example 96CO on combustion CO CH4 applications To disable this alarm simply enter 1 as the threshold
20. Offline Calibrations or Offline Validations the Launch unit and Detect unit need to be removed from their respective process interface and connected to an Off Line Calibration Cell If the analyzer is installed on an extractive flow cell enhanced flow cell or low volume flow cell then it is already capable of being validated calibrated in off line mode Figure 59 Before removing the units from the process ensure that the process gas and window purge gas are correctly isolated to prevent excessive pressure process or purge gas from being released or from over pressuring the analyzer AVOID SHOCK AND IMPACT TO THE ANALYZER PERMANENT LASER DAMAGE MAY OCCUR IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 8 VALIDATION AND CALIBRATION 8 3 Moving the analyzer to the off line calibration cell If the process gas is at a positive pressure Isolate the analyzer from the process and shut off the window purge gas flow to prevent excessive pressure building up on the window If the process is at or near negative pressure then be aware that ambient air will be d
21. 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 origi nal 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 billing instructions for return of material plus the name and phone number of a contact person who can be reached for further information Heturned goods that have been in contact with process fluids must be decontaminated disinfected before shipment Goods should carry a
22. e Analog Output Mode specifies Block Track or Hold of all 4 to 20 mA output during online check Tj Advanced Calibeate amp Validate mr X dvanoec Check Gas Concentration Check Gas Fathlenath Check Gas Temperature Check Gas Pressure Valve Selection Check Gas Purge Time Normal Gas Purge Time Validation Reacing J Calibecation amp Validahon Onine Validation Settings Analog Ouput Mode IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 9 TROUBLE SHOOTING gt 9 1 9 TROUBLESHOOTING The TDLS200 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 15 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
23. use only when sure the purge paths are correctly Peak Search configured TRANSMISSION adjustment of transmission value DARK CURRENT DISABLED feature Factory use only PEAK SEARCH DISABLED feature that initiates a system scan of absorption peaks to validate current peak selection is correct Factory use only span Calibration inii ERR OFFLINE VALIDATIONS EE CHECK GAS 1 to 2 allows manual or automatic configuration up to 2 check gasses Gas 1 Validation Two Gas Validation allows the user to configure two validation gas checks sequentially Gas 2 Validation An example would be Oxygen analyzers used for Marine Vapor Recovery applications whereby a single validation u Two Gas Validation command shall execute both a zero and span gas check UTE Results for the two gas off line validation are shown for both f f 2 7 n 5 3 D M DATALSS gases along with their corresponding results Offire Validation Two Gas Vascasen Expected Reading 0 00 22 0096 Actual Reading 22 17 22 27 Offline Tw Gas Validation FAIL PASS IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 T Advanced amp Volt gt gt Check Gas 1 Check Gas 2 Alarm History Cal History Spectrum Capture 6 BASIC OPERATION 6 17 ONLINE VALIDATIONS CHECK GAS 1 allows user to select and configure the on line validations for check gas 1 The configuration options include Manual or Aut
24. 796 O2 Example If the introduction of 596 CO causes a 600ppm change in the process reading then this will be the expected step change in reading and Tracked 4 20mA during on line validations Initiating Validation There are several ways in which the Automatic Validation sequence can be initiated e Remote Contact The analyzer has the ability to monitor a pair of voltage free contacts These contacts would typically be located at the DCS or a simple switch located near the analyzer The analyzer continuously monitors the remote contacts or switch for a return voltage 24 VDC generated by the analyzer When the contacts close the return voltage is sensed and the Auto Validation sequence is initiated e Local User Interface The TDLS200 software allows for the user either through a laptop PC running VAC software or via installed 6 5 display amp Keypad to initiate the Auto Validation sequence The operator would be at the analyzer in this case e Preset Timed The TDLS200 software allows for the analyzer to automatically initiate the Auto Validation sequence based on a user configurable timed basis e URD amp Laptop PC with VAC software The TDLS200 software allows for the user through a laptop PC running VAC software to initiate the Auto Validation sequence The operator would be at the URD with the laptop PC plugged in to the Ethernet port on the URD Feed Through board e with VAC software The TDLS200 software allow
25. A 5th Edition Feb 9 2012 00 8 VALIDATION AND CALIBRATION 8 15 A tunable diode laser emits light energy within a very narrow wavelength range which is controlled by the analyzer itself typically no more than 0 1nm across the entire scan region This therefore allows laser scanning across just one absorption peak and baseline zero absorption regions on either side The analyzer scans this region approximately 1 000 times per second while accumulating the spectra in memory The scanning i e wavelength adjustment is controlled by rapid adjustment of the electrical drive current on the diode itself Below is the typical Raw Detector Signal received from the detect unit On the left it is shown with no oxygen present and on the right it is shown with some oxygen present 5 Raw Detect fink Soectria fom Dotoc Con 097 Tres gt 72 Teg Tu 41 Pres DM 0 Er Troms TEE Tero 8 248 Mes bora Press ENTER to capture the spectrum Press ENTER to capture the spectrum Raw Detect Signal No Oxygen present Raw Detect Signal Oxygen Present The TruePeak TDLS200 uses the raw detector signal to produce the actual absorption spectra See below note the vertical scale in Absorbance Units is different between the two spectra which is then used to calculate the peak area It is the peak area that is proportional to the oxygen concentration with given process parameters The given process para
26. Angular tolerance PROCESS FLANGE BOLT ALIGNMENT NOZZLE FLANGE BOLT PATTERN MUST BE AS INDICATED TO ASSURE PROPER MOUNTING OF i ANALYZER LAUNCH AND DETECT UNITS COMBINED ANGULAR OFFSET OF BOTH NOZZLES MUST NOT EXCEED 2 IN ANY DIRECTION BEST INSTALLATION WILL HAVE NO ANGULAR OFFSET Figure 27 Angular Alignment Tolerances for Launch or Detect Unit Flanges IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 lt 5 INSTALLATION AND WIRING 5 5 5 4 Process Flange Clear Aperture The Launch and Detect unit flanges and insertion tubes if used should be installed in such a way that a minimum clear through aperture opening diameter of 1 12 38 mm when the distance between the 2 150 flange faces does not exceed 6ft 2 m Note Larger clear through apertures may be required when operating over longer distances CONSULT FACTORY for further details PROCESS FLANGE CLEAR APERTURE TOLERANCE D T MINIMUM CLEAR APERTURE 1 75 MINIMUM CLEAR APERTURE LATERAL OFFSET OF NOZZELS MUST BE MINIZED AS TO ALLOW FOR MINMUM 1 75 45MM CLEAR APERTURE BEST INSTALLATION WILL HAVE NO LATEAL OFFSET Figure 28 Clear Aperture for Launch or Detect Unit Flanges 5 5 Mounting the Launch and Detect Units to the Process Flange Securely bolt the Launch and Detect Units to the process flanges using the standard bolt holes provided Ensure the correct size bolts nuts and gasket are used in accordance with the flange speci
27. If the current R22 value is greater than the current R23 value change R23 to the next greater value available in the resistor bag ii If the current R22 value is same as the current R23 value change R22 to the next greater value available in the resistor bag iii If the current R22 and R23 are already 24k the greatest value available in the resistor bag please contact Yokogawa for assistance IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 6 BASIC OPERATION 6 30 9 Close the detector enclosure Write down the final values of R21 R22 and R23 below for record R21 R22 R23 10 Keep the resistor bag and this procedure document by customer DO NOT leave them the detector box or throw them away 11 Enter these new resistor values into the analyzer configuration under Advanced Menu Configure System Adjustable Resistors Detect R22 Detect R23 and Detect R 23 NOTE all resistors values are entered in kOhm units 6 5 3 Detector Gain Adjustment Service Tips e How to remove a gain resistor On the detector board find the location of the gain resistor Please note that the resistor is not soldered but resting in sockets Carefully remove the resistor from the socket on the board Since the analyzer is still powered on please take extreme caution to prevent a short circuit on the board i e loose wires or touching adjacent components with pliers or tool used to remove resistor e How to install a new gain
28. TT mmm 5 14 5 11 Hazardous Area 5 19 5 11 1 Purging Analyzer for Hazardous Areas with On Line Validation 5 20 5 11 2 Purging Analyzer for Hazardous Areas without On Line Validation 5 20 5 11 3 Purging Analyzer and Universal Power Supply and or URD for Hazardous Areas with On Line nennen nnne nnnm nnn nnnm nennen nana nnns 5 21 5 11 4 Purging Analyzer and Universal Power Supply and or URD not using On Line Validation 5 21 5 12 Cyclops Division 2 zone 2 Purge Indicator with Switch ccccsececsececeeeeceeeeceeeeeseeeeseeeesaeessaeeess 5 22 B3SICOPETAONS areca TETTE 6 1 m MB aede er 2 o ELIT E TTE 6 1 e a UNS NENNT 6 5 6 3 Non Process PParamieletssssscsivicuvkveus EHE EXE FETU EV DIA DURO Vi De Hid ry ER Vira C PE UR M Ud P 6 18 6 4 Reference Peak Lock with 2nd Absorption gas ccccccceecceececeeeceeceueeaeeecaeesaueceueeseeeseeeeeeeaeeesaeees 6 22 DS Eie Tile quui ide e m E T T m er 6 26 6 5 1 LAO Installation Alignment amp Dector enne 6 27 6 5 2 Adjustment of Dector Gain for LAO seesseesseesssseseeenenn nennen nnne nnne nnns nnne nns 6 28 6 5 3 Dector Gain Adjustment Service Tips
29. WINDOW 3 16 SS BODY PURGE PORT 2 Figure 41 Isolation Flanges model IF200 IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 lt 5 INSTALLATION AND WIRING 5 13 ANALYZER SIDE PROCESS SIDE 0 750 26 000 19 6152 LENGTH PER APPLICATION 2 000 pe BUT us 1 1 4 SCH 80 INSERTION TUBE LENGTH DETERMINED BY APPLICATION 5 8 11 18 8 SS STUDS BORE THRU AND WELDED TYP 4 316SS ANSI RF 2 150 FLANGE Figure 42 Insertion Tube Detail PPED PORTS ZERO GAS NITROGEN gt 99 95 ERO CALIBRATION SPAN GAS INSTRUMENT AIR 20 95 02 GASES MUST BE DRY 70 F DEWPOINT EAN 5 MICRON AND OIL FREE 5 ALL GASES ARE APPLIED AT 2 SLPM 3 PSIG 21 KPAG MAX OPTIC PATH LENGTH OF CAL CELL 28 35 IN 72 CM LEJ SPAN CALIBRATION Figure 43 Off Line Calibration Gas and Purge Detail
30. We would recommend that the data files are downloaded periodically and stored at a local drive for future reference Also if there is any sign of potential trouble with the analyzer and or the process please download files as soon as possible to ensure potentially helpful data is stored saved off line 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 TDLS200 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 092407 res Daily Results Allows for review of daily results and diagnostic data on a measurement by measurement basis Daily Spectra Allows for review of daily results and diagnostic data 092407 spe on a measurement by measurement basis 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 sequentially contains every up dated measurement set of d
31. 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 valspe his Validation Spectra Spectra captured for historical Validations On Line and All spectra captured Off Line are stored in this file during On Line and Off Line Validations valspe bak Validation Spectra Back When the valspe his file exceeds 1MB size the contents is Up saved to this bak file and the his file is emptied This bak Backed up spectra captured file is Spectra captured for historical Validations On Line and during On Line and Off Line Off Line are stored in this file Validations System History Back Up A back up of historical system bak log of configuration changes zeroOO spe Zero Calibration Spectra This file is essential to the analyzer calibration if Absorption Spectrum and this file does not exist or is corrupted modified or coefficients at time of cali otherwise tampered with then the analyzer calibration is bration invalid It contains essential information relating to the Zero Calibration of the analyzer zeroO1 spe Historical Zero 2 01 through zeroO9 are previous files with zeroO1 to Calibration Spectra being the most recent The most recent previous Previous Absorption zero01 can be restored in the analyzer as Previous S
32. analyzer limits Access to appropriate utilities Adjacent space for mounting to Calibration Cell when off line Figure 23 Launch and Detect Unit In Situ Installation Overview Figure 24 Launch and Detect Unit In Situ with Insertion Purge Tube Installation Over IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 lt 5 INSTALLATION AND WIRING 5 3 Figure 25 Launch or Detect Unit Installation Dimensions The standard flange sizes are either 2 or 3 150 R F ANSI as well as DN50 and DN80 Please check the exact flange size specified and provided for the particular installation Other flange sizes and a variety of materials to suit the process are available so please check these details prior to installing the flanges on the process Note The process isolation valves should have at least a 1 38mm diameter clear bore size aperture to ensure there is sufficient tolerance to align the laser beam after installation Ducts and Stacks that have thin and flexible walls should be reinforced to ensure that the laser beam alignment is maintained at all times Rigid mounting for the process flanges is highly recomm
33. as 50 due to the variables and dynamic nature of the application On Line Validation can be considered as Response Checking Please consult Yokogawa for further information and help in determining what an appropriate Pass Fail criteria is for the specific application DO FAULT DELAY this feature allows the end user to minimize potentially non impacting nuisance alarms by adding some delay before the analyzer reports the Fault Alarm Validation failure IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 7 Coalig A Ovancod Contig Systom VO Digiti Output Usor Akira Concentration Transmission Digital Output User Alarm Conligurabion core LIA 0 615 19 2 1 7 22 F Channel 1 6 BASIC OPERATION 6 13 CHANNEL 3 USER ALARMS Enables digital output alarm for concentration value High or Low Transmission High or Low or Validation Calibration the contact changes state during a validation or calibration DIGITAL INPUT STATUS CHECK The user can check the status of remote Digital Inputs IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 6 BASIC OPERATION 6 14 SYSTEM oome 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 TCP IP the analyzers real IP address used for Ethernet communications can be changed via this menu option External ke
34. beam that expands over distance and a large aperture optics detector scheme i e a large target for the laser to hit The general concept of diverging beam and large aperture optics is shown below 3 150 BELLOWS A 4 150 RF ANSI ALIGNMENT LANGE FLANG 777 s y 7 A P A mi Ein RM 7574 20407 7 7 2 LES 7 2 77 Yj ee LAU T ag 9 PPP ARABS AK 7 RRA T ty 7 PP PE 9 6z7 f V P9 b f I I P yy yy P p fo Z 4 1 iB A E T P VI AIAR 4 47 Af M 27 JA Ui p ep LS UE Wi 2 TTE Lae CLARA 7 d T I H Mp 2 tf P 4 P ai 22 MM TIT TIT Figure 52 In a standard TruePeak TDLS200 analyzer the laser beam exiting the launch unit is normally collimated parallel before hitting the opposing detect unit The collimated beam size is typically less than 1 diameter However this optical layout is not appropriate for long path applications the dimension of process is longer than 30 feet During initial installation it is also difficult to align the laser beam so that it can hit the targeted detect unit over a long distance small changes in the launch unit angle are magnified over long distances Also it is almost impossible to keep good alignment with varying ambient and process
35. cell to observe a step change in the H O ppm output value Nitrogen gas with typical 100 120 ppm H O 10 ppm content can be switched through the on line validation cell at 10psig for example equipped with a 10 psig pressure relief valve on validation cell outlet The analyzer readings for H O will be increased by approximately 10 12 ppm based on 110 ppm pathval cell pathflow cell or roughly equivalent to 10 of the cylinder certified H O ppm value This is an observation only of step change to the introduction of H O into the optical path sometimes considered a response check or analyte spiking IM 11Y01B01 01E A 5th Edition Feb 9 2012 00 6 BASIC OPERATION 6 33 Normal Operation TDLS200 TruePeak Software Main oem cham hes 10 0 5 47 Jog Menu 2 2 2 aasa H20 Concentration ppm CH4 Concentration The analyzer is configured to measure not only H O ppm but it will also indicate the CH concentration value as 1 8 8 1 OQ 1 shown on the Main Menu display below Note that the flow cell gas temperature is also shown as Active based on flow system regulator fixed setting cell sensor active input and pressure is input as a Fixed value shown in psiA units based on the external sample p p Working properly Active 50 24 C Shut Down Analyzer i 7 Fixed 44 700 ps A Den be ded Erter to proceed Tag XOXC XX XXX SN 18 1243 09 Ex 17 30 500
36. 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 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 Dont install general purpose type instruments in the hazardous area CAUTION The intrument is packed carefully with shock absorbing materials nevertheless the instrument may be damaged or broken if subjected to strong shock such as if the instrument is dropped Handle with care IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 1 TABLE OF CONTENTS SUE OGUIGTION i PrOCUHONS NRRETED TT OT TE DET EEEa ii MEET cadem 1 2 2 Introduction and General Description 2 1 Al JFURC HOM AHS SCM m 2 1 A T AVN ASCE SVS escar a T mmm 2 2 2 2 ET EAE E E E E E AE E A 2 2 MEME C n clbeeellelbl RETE EE 3 1 cM lt ES TT COUE icra pecan eer UU T UT m mm 3 4 ORE 4 1 MEE Dalai MT 4 2 4 2 Main Electronics 4 3 4 3 Laser Assembly Y 4 6 4 4 Check Gas Flow Cell for 4 7 MS
37. check gas flow cell Use off line calibration cell Use off line calibration cell Use flow cell or bypass piping and introduce cal gases IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 Manual introduction of check gas and follow manual proce dure via user interface at RIU local LCD or PC with VNC Viewer Automatic introduction of check gas requires appropriate hardware valves etc and implements automatic procedure from selected initiation method Manual introduction of zero or span gas and follow manual procedure via user interface Manual introduction of zero or span gas and follow manual calibration procedure via user interface Manual or automatic introduction of Zero and Span gases for validation or calibration when equipped with appropriate hardware valves etc 8 VALIDATION AND CALIBRATION 8 2 T deem od Cala uto Oude E Please note that you can select the block mA value for automatic Sunci Ovipyi Wade Dus Tare Cabra Off Line Zero Calibration Off Line Span Calibration Off Line Validations and On Line Validations LEE output signals wif be held at above when is om Track cutpul signals wil comtinwees G aching the meatu od value Held present cutpet signals wel be held Iuli 8 1 Off Line Manual Automatic Checking and Off Line Calibration ate e Walde Cile utn Y Valtiale X Clear Validation Alarms To perform either
38. consultation APPLY F2 must be selected to save changes L From the VAC Main Menu Ctrl F1 will bring up the Help Screen Ii Jam YOKOGAWA This will give at system text help describing the shortcut keys and their function Virtual Analyzer Controller fot VA asd Pros fut Fam Tat pn Ci ges aad i oi Be L ix Diss To hide Fi Pimi n Lead Eo ee ee deri Emi _ Abl 4 IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 6 BASIC OPERATION 6 40 PT Mere Pee 10 mI aoi WwISssATQTZSGHSE To shut down the RIU press the Esc key and the screen will appear as shown Press 9 to continue with the shut down process and when the YOKOGAWA Q RIU screen turns white the power can be switched off Note there is no watch dog in the RIU so un like the TDLS 200 it will Virtual Analyzer Controller not automatically re start after a period of time if power is not switched off Plaaze Comins System Shuldean ALWAYS END VNC SESSION TO ANALYZER WHEN DONE THIS Presa 9 1o Shuldown WILL PREVENT THE ANALYZER AND OR RIU FROM HANGING DO NOT LEAVE THE RIU PERMANENTLY CONNECTED TO ANALYZER CONNECT ONLY WHEN IN USE Esc lo qa back IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 7 ROUTINE MAINTENANCE gt 7 1 7 ROUTINE MAINTENANCE The T
39. 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 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 YY YY 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 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 can then be copied and pasted into Microsoft Excel spread Each Calibration and or Validation event is logged with the date MM DD YY YY 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
40. if validated correctly would show AND output 20 996 O2 as the validation result Another example would be 596 CO being the validation gas value and the hence the calculated AND output value when Track is selected for 4 20mA would also be 596 In some cases the output range might be scaled below the validation gas value e g 0 1096 O2 while validating with 20 996 O2 In these cases the Validation Only result can be scaled down to fit within the configured 4 20mA output range Example 0 5 000ppm CO is set for 4 20mA output range 596 CO is used for the validation gas To make the Tracked 4 20mA output read 5 000ppm during validation at the DCS the Factor should be 0 1 To make the 596 CO validation gas read 2 500ppm at the DCS the factor should be set to 0 05 Process Validation When this method is selected the analyzer will calculate AND output the result as a response relative to the process conditions The displayed result on screen will be shown as Expected result say 20 996 O2 compared to actual result say 20 7 02 however if Track mode is selected for the 4 20mA then the mA will track the result as if the validation gas was process gas Example If the validation gas is introduced without the analyzer knowing and the process reading changes by 296 O2 then this should be addition amount during each validation So if process reading is 596 O2 then when an on line validation is performed the reading and Tracked 4 2mA will change to
41. nor 20 or any other target gas for the given application in the entire optical path Process OPL and Analyzer Purge This is the absorption spectra appearance required for an Off Line Zero Calibration of the analyzer Process Calibration OPL 20ppm NH3 Analyzer Purge N2 In this Absorption Spectra view there is practical ly zero H2O absorption peak in the approximate peak center position PCP region There is approximate 20ppm NH3 approx PCP 120 absorption in this spectra based on 72 6cm OPL ambient temperature and ambient pressure Note other target gases such as CO CO2 HCN etc will also require only target gas absorption spectrum at the time of off line calibration This is the typical absorption spectra appear ance required for an Off Line Span Calibration of the analyzer IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 8 VALIDATION AND CALIBRATION 8 14 8 3 On Line Validation The basic concept of on line validation is to add a known gas concentration via an integral check gas flow cell while still measuring the process gas concentration under relatively controlled conditions The controlled or known conditions for the addition of the validation or check gas are Pressure of the check gas being introduced typically atmospheric Temperature of the check gas being introduced typically ambient Length of the cell in which the check gas being introduced typically 3 7 4 0 Concentration of t
42. 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 If using on a high temperature application in excess of 700 C then please check to ensure the analyzer was specified for high temperature service Detector Signal High fault alarm can occur when high temperature infrared radiation saturates a standard low temperature gas configured analyzer Refer to Adjustment of Detector Signal Gain for further assistance 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 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 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 10 DATA FILES AND FORMAT 10 DATA FILES AND FORMAT 10 1 The TDLS200 analyzer is capable of automatically storing many important pieces of information
43. or local remote switch s 21 danced Config Valve Contre Remote Control Vale 2 Chennel 1 Channel 2 Channel 3 i On Please select remote control channel e Contact signal gt valve on please keep remote contacts closed for at least 10seconds to ensure the analyzer reads registers the contacts at measurement up date e Open signal gt valve off please keep remote contacts closed for at least 10seconds to ensure the analyzer reads registers the contacts at measurement up date AUTO CALIBRATION amp VALIDATION see separate section of User Guide for details 1 Remember the current valve status 2 urn on the assigned valve turn off other valves 3 Resume the original valve status before auto calibration or validation IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 6 BASIC OPERATION 6 32 AUTO ONLINE VALIDATION see separate section of User Guide for details 1 Remember the current valve status 2 urn on the assigned valve s turn off other valves Two valves could be open for auto online validation with blocked line lock gas in validation cell 3 If only one valve is used turn off the assigned valve If two valves are used turn off the first valve 4 If two valves are used turn off the second valve 6 7 Introduction for Measurements in Methane Gas The measurement of H Oppm in methane gas LNG NG is specifically outlined in this section Items contained within this section
44. power at the detector which could indicate misalignment or window fouling where the measurement is still being made but further loss of transmission will cause 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 missalignment or laser failure The TDLS200 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 20 mA signal can change to 3 3 mA under a fault or warning condition user changeable The digital output of the analyzer will trigger Channel 1 Warnings Channel 2 Fault Channel 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 HL ppm rur IER Channel Warnings nee Channel 2 Faults E Field Loop Check Este cer ae Oyster MILD Chula gt gt Alarm History Chi
45. seal and external mechanical alignment system typically used when gas containment is important e AO Large Aperature Optics for long path combustion application e Flow Cell may be used when the process gas has been extracted or is used in a by pass flow loop This allows for heat tracing if necessary and easy introduction of both Zero and Span gases e Isolation Flanges are supplied with process windows mounted in the flanges themselves typically for very corrosive and or high pressure applications e By Pass Piping may be used when the process gas line is of small diameter typically lt 10 and when no suitable section of pipe work exists on this which the analyzer can be mounted By pass piping systems may be provided or supplied at site Heat tracing may also be supplied or provided at site e Off Line Calibration Cell is used for off line verification of the system This cell is used to flow Zero and Span gases when the analyzer is not connected to the process PROGESS Figure 13 Process Interface Examples IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 4 ANALYZER COMPONENTS gt 4 10 4 7 Analyzer Connections Launch Detect Interconnect The two units are connected to each other via a four twisted pair cable suitable for tray installation outdoors Pluggable terminals strips are provided at both units to enable field termination of the cable The cable pairs are individually shielded as well as an overal
46. the analyzer may change due to mechanical thermal properties of the installation or perhaps the alignment nuts not being fully tightened originally In these situations the analyzer can simply be realigned Adjust the mechanical alignment using small adjustments of typically one quarter turn per nut at a time and allowing for at least two measurement up dates before making further adjustments Start by adjusting the laser launch unit in the vertical plane i e direct the launch unit up and then down while observing transmission or detector signal voltage If no improvement is achieved then ensure the alignment is set back to the best possible vertical position Then proceed with launch unit horizontal adjustment again using quarter turns per nut and waiting for 2 measurement up dates before making the next adjustment If no improvement is achieved then ensure the alignment is set back to the best possible horizontal position Now adjust the laser detect unit in the vertical plane i e direct the detect unit up and then down while observing transmission or detector signal voltage If no improvement is achieved then ensure the alignment is set back to the best possible vertical position Then proceed with detect unit horizontal adjustment again using quarter turns per nut and waiting for 2 measurement up dates before making the next adjustment If no improvement is achieved then ensure the alignment is set back to the best possib
47. the start of the raw detector ramp Then Carefully make small adjustments in the alignment of detect unit to minimize the slope at the start of the raw detector ramp for good alignment see GOOD alignment example right Ensure transmission level is still good Basic Spectra Raw Defect 8 Apply manual force to the launch unit vertical and horizontal to ensure the transmission remains stable and that the system is mechanically tight If there is any movement or change in transmission then ensure all alignment nuts are secured and check again for mechanical stability 9 Apply manual force to the detect unit vertical and horizontal to ensure the transmission remains stable and that the system is mechanically tight If there is any movement or change in transmission then ensure all alignment nuts are secured and check again for mechanical stability IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 8 VALIDATION AND CALIBRATION 8 5 12 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 13 Follow the detailed on screen instructions when check the analyzer zero and or checking the span idomi O LAM TITAN TE LLL EN T Zero Calibration span Calibration Transmission Dark Current Peak Search 14 We do not recommend calibrating the Zero unless some core spare parts have been re
48. this may be useful to do so however if the Fault alarm conditions are not set correctly then there could be excessive files created for less meaningful Fault alarm conditions These files are often useful for Factory based diagnostics IM 11Y01B01 01E A 5th Edition Feb 9 2012 00 10 DATA FILES AND FORMAT gt 10 7 10 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 occur Insert Yokogawa Supplied USB memory Storage 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 i
49. value with the toggle in either Fault or Warning position NON PROCESS ALARM SELECTION This allows the selection or disabling of alarm when then non process gas peak height falls below the entered threshold value In this example the analyzer is configured to FAULT Alarm when the peak height is lower than 0 001 au see absorption spectrum This value can be determined with assistance from the Yokogawa factory to suit the specific application This alarm function can be used to help detect the leakage or loss of line locking gas for example 96CO on combustion CO CH4 applications To disable this alarm simply enter 1 as the threshold value with the toggle in either Fault or Warning position IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 6 BASIC OPERATION 6 22 6 4 Reference Peak Lock with 2 Absorption Gas In some measurement circumstances instead of using the measurement gas i e NH absorption peak to lock the laser wavelength tuning range the analyzer uses an a H O absorption peak near the NH absorption peak as the reference This is because in the typical application process NH concentration is normally zero or very low such that its absorption peak is not large enough for wavelength lock function Moisture levels however are typically always high about 1096 and therefore provide a large enough absorption peak for the wavelength locking function Other applications using this same approach may include CO CO o
50. will supersede any prior information within the User s Guide particularly items pertaining to calibration methods Please also note the special requirements needed for the flow cell measuring conditions as these can affect the measured H Oppm concentration values Spectroscopic detection of moisture in natural gas presents a specific challenge for traditional TDLS methods because a weak at low ppm moisture content absorption line of water must be detected on a high absorption background of methane and other components C2 C3 of the natural gas This challenge has been successfully overcome with TDLS200 by using a special previously proven approach to spectroscopic data processing However reliability of results relies on stable and well defined conditions in the flow cell of the TDLS200 analyzer Note that typically temperature of the process calibration gases within the flow cells is to be maintained at 50 0 0 5 C and the gas pressure controlled at 30 0 25 psig Maintaining these conditions ensures well defined absorption of methane and reliable ppm moisture concentration readings At the same time this method eliminates the need for routine analyzer calibrations zero or span This is due to the fact that the strength of molecular absorption is an intrinsic property of the chemical species When the gas temperature pressure and its bulk composition are defined absorption spectrum depends only on the absorption path length which is also f
51. xx F C K PRES Act Con Fix xx x PsiA BarA KPa torr atm OPL xx x in ft cm m Launch xx deg C Detect xx deg C Line 4 Information Transmission xx x 96 CHA xx x 96 Second measurement gas and unit Laser light transmission strength 0 10096 range shown during the power up and initialization of the analyzer WARNING Conditions FAULT Conditions Validation Status Data Transfer Status Analyzer Name Analyzer Serial No Configured 4 20mA output for AO1 AO2 amp AO3 Static IP Address Process Gas Temperature used for gas concentration calculation Process Gas Pressure used for gas concentration calculation Optical Path Length over which the analyzer is measuring the target gas Launch unit internal temperature Detect unit internal temperature IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 6 BASIC OPERATION 6 5 6 2 Software Guide A NOTE At any time in the Main Menu press the F5 key only on Screen amp Keypad versions to toggle the LCD backlight on off If there is no keypad or VNC activity for 30 minutes then the LCD backlight will automatically switch off press any key to restore backlight MAIN MENU Home Page Display of Concentration amp Transmission or 2 Concentration Status Window notification of initiating working properly Gas Temperature O72 Concentration 55 Transmission 9 T Gas Pressure 77 Selection of Basic or Advanced Menu Tag No and Serial No SN configured to analyz
52. 012 00 3 GENERAL SPECIFICATIONS gt 3 4 3 1 Model and Suffix Codes Model Suffix Code Option Code Type N General Purpose None CE General Purpose CE Class Div 2 BCD Purged ATEX CAT 3 zone 2 Purged TIIS Hazardous Area Gas Parameter Oxygen O 600 C 0 25 Oxygen O 1500 C 0 25 Oxygen O 1500 C 0 25 Temp Carbon Monoxide CO 9o 500 C Carbon Monoxide ppm CO lt 500 Carbon Monoxide ppm CO 1500 C Carbon Monoxide CO ppm lt 1500 C CH4 0 596 Ammonia NH up to 0 5 000ppm Ammonia NH 0 5 000ppm amp 0 50 20 Hydrogen Sulfide H S up to 0 50 Carbon dioxide CO High Range 0 1 0 5 Carbon dioxide CO Extend Range 0 5 0 50 Water moisture H O min 0 30ppm CI2 background Water moisture H O ppm non hydrocarbon background Water moisture H O ppm Hydrocarbon background High moisture H O level min 0 5 Special Applications Laser Interface None Blind Controller Integral Mini Display Integral Color LCD Backlit Interface No Process Interface Included Large Aperture Optics with 3 1502 alignment bellows Large Aperture Optics with 4 1502 alignment bellows 2 1502 Alignment Bellows 3 1502 Alignment Bellows 4 150 Alignment Bellows DN50 Alignment Bellows DN80 Alignment Bellows Options Ext USB Port IP66 NOT ATEX Pressure Comp Curve Diverging Beam No Large Aperture Optics IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 4 ANALYZER COMPONEN
53. 3Q IVNIAM3I LINA HONO VI 4318vO L193NNOOMA3AINI 193130 HONRVI NHIVAIQOd MO VG vL N3Q138 4 Jes no no o o o SIR IRIS IRIS s 8 9Sv9c 0 0 0 99999990 81 3AO8V 71130 NOLLWNINSAL 33S ja ex r E zm w o ex VES 9Sv9vcl PECL 9Sv9vcl 9GvVECL 819Gvc 0 0 0 0 0 0 0 fal o 0 0 0 0 TIN o VOYVO GSSGGG GSGGG 9999909 b 99990909 999990 999990990 aL val 991 cal vlad 691 891 91 8 1 130 qaavog 0 1 NOILWNINYSL 33S 90 IVNV 8 9S5v926l dW3lQ L IWAMSHL Gy cdWN3ld Inc j j 153 THM g Sg l cd 20 1 xu c E 20 0 de 951 IOAZ L m 2 130 A HOLIMS M3MOd 7 190 A SUME wis Pt 2 TWVISG NOLVNIWNH3L d18vO l1Odl3Q0 HONRVI iL Feb 9 2012 00 IM 11YO1BO1 O1E A oth Edition 5 INSTALLATION AND WIRING 5 16 5 10 2 Launch and Detect Unit Wiring Standard for CE ATEX SPECIAL NOTE Noise sources magnetically coupled to the 4 pair launch to detect cable can cause errors to the measurement if the frequency and applied total voltage meet or exceed the following Frequency range of 0 1 to 7 5 MHz and Total induced voltage of 3Vrms A combination of these parameters will cause measurement error outside of the analyzer performance specification In practice these potential errors can be easi
54. ATE 2 TEMPERATURE PRESSURE SENSOR GASES MUST HE GAY f Ter CHT WEAN 5 MERGN AND OL FREE JPS PURLE WERT FX ELECTROHICS Figure 31 IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 lt 5 INSTALLATION AND WIRING 5 8 Typical Purge Large Aperture Optics LAO combustion O2 CO CH4 Figure 32 5 9 Dimensional Drawings LAUNCH UNIT 42 1 2 LJ 1080 PROC CUSTOM CUSTOM ESS CONN YOKOGAWA SUPPLIE ESS INTERFACE EFER TO BILL OF MATERIAL ER SUPPLI ECT ESS CONN ER SUPPLIE D ED ON ECTIO 8 203 Figure 33 General Installation Clearance Requirements IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 lt 5 INSTALLATION AND WIRING 5 9 FMOVE LAUNCH AND DETECT UNITS FROM ALIGNMENT FLANGES AND INSTALL ON CAL CELL POR CALIBRATION
55. 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 8 analyzers via Ethernet more with additional custom Ethernet switches IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 4 ANALYZER COMPONENTS gt 4 12 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 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 RIU Enclosure is 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 Wall mounting brackets are included with the RIU The environmental protection rating is
56. DLS200 TDL analyzer requires little routine maintenance if it has been installed set up and calibrated correctly This section will outline the routine maintenance procedures 7 1 Maintaining Good Transmission The 96 Transmission of the laser light through the process is the most important variable to consider for routine maintenance and troubleshooting Under normal operating conditions nonfailure transmission will be affected by e Alignment of the Launch and Detect units Covered below e Window fouling For most applications where solids or liquids are expected in the process a window purge is recommended see installation section e Particulate in the process Particulate in the process will block the laser light to some extent To maximize performance in particulate laden processes it is important to maximize alignment and ensure windows are clean 7 1 1 Maintaining Clean Windows If the window purge supplies have been set up correctly on a reliable supply line then under normal operating conditions there should be no window fouling Window fouling may be caused by one or more conditions e oss of window purge gas flow pressure which then allows the dirty process gas to contact the windows and leave deposits e oss of window purge gas flow pressure which then allows the hot process gas to contact the window condense any liquids and leave deposits e Over pressure of the process gas which allows the process gas to overcome the window pu
57. Figure 1 The current is ramped to scan across the wavelength region desired The collimated light passes through the gas to be measured The amount of light absorbed by the peak is proportional to the analyte concentration The light is then focused on a detector Figure 2 This signal is used to quantify the light absorbed by the analyte Figure 3 Upon delivery unpack the instrument carefully and inspect it to ensure that it was not damaged during shipment If damage is found retain the original packing materials including the outer box and then immediately notify the carrier and the relevant Yokogawa sales office TDLS Analyzer MODELZ TDLS200 SUFFIX Zi 24 0 VDC AMB TEMP NO1 O O o THIS PRODUCT COMPLIES WITH 21 CFR PART 1040 10 YOKOGAMA Made USA Make sure the model number on the nameplate of the instrument agrees with your order Note The nameplate will also contain the serial number and any relevant certification marks Be sure to apply correct power to the unit as detailed on the nameplate Note For products used within the European Community or other countries requiring the CE mark and or ATEX classification the following labels are attached as appropriate IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 2 INTRODUCTION AND GENERAL DESCRIPTION 2 3 REMOTE INTERFACE UNIT 2000 2900 A SUPPLYY 24 0 VDC MAX 120W 10 TO 50 C YOKOGAWA Made in USA Note
58. History Trends Allows for the displaying of data in a trend format IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 6 BASIC OPERATION 6 6 3 Bask Contig BASIC CONFIGURE PATH LENGTH allows adjustment of the optical path gt gt distance the laser 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 live signal fed from pressure transducer no changes are allowed Active pressure compensation settings are found in Advanced Menu ressure 14 696 psiA TEMPERATURE allows adjustment of the gas pressure value if using fixed pressure If the analyzer is using active pressure d compensation live signal fed from pressure transducer or active ambient no changes are allowed Active pressure compensation settings are found in Advanced Menu IP ADDRESS displays the analyzer IP address SERIAL NO displays analyzer serial number VERSION software version number Spectra The spectra screen raw detect left or absorption below A allows capture and view of current spectra The screen auto scales the vertical Y axis this will result in a visually noisy spectra when at low gas levels In fact the spectra may not be noisy but simply that the display range is extremely low xc gt coco EEN KEIN SE Base Sentra w Tm 200 trans
59. Instrument air purge when measuring Oxygen or CO line locking gas for combustion CO applications UNITS selection as defined below independently 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 etc allows setting of date time TCP IP 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 PROCESS PATH LENGTH Enter the distance over which the laser will be exposed to the process gas this excludes any purge paths Consider just the distance of process gas exposure to the laser beam path Consult Yokogawa is any assistance required For by pass applications with window purges typically the center line distance from inlet outlet pipes is used For combustion applications the distance inside the refractory for example NOTE for extractive applications this will match the flow cell condition typically 40 NOTE when using an off line calibration cell the standard optical path will be 28 6 72 6cm IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 6 BASIC OPERATION 6 9 PROCESS PRESSURE FIXED is used when the process gas pressure will not vary under normal operating conditions when the measurem
60. M T E AEE AE 4 8 A0 Process Merna G TO TT TETTE 4 9 4 7 Analyzer 4 10 Mmmm 4 11 vce ce 4 13 5 Nstallation and VV WING sassi gna aa a aiaa aaa 5 1 5 1 Process Measurement Point Considerations 5 1 5 2 Position of Process Flanges for Launch and Detect 5 2 5 3 Process Flange Welding Alignment and LING Up ccccccceecceececeeeceeceeeeceeesaeeceueeeeeeseeeseuseeeeeseeeees 5 4 5 4 Process Flange Clear Aperture ccccccsscccsececeececeececeucecsuseseueeseueeeeeeesseeesausesaueetsgeesaueesseeesseesseeeeses 5 5 5 5 Mounting the Launch and Detect Units to the Process Flange 5 5 5 5 1 Process Window Purge Gas Connection cccccceseeeseeeeceeeeceececauceseecsaueeseueesaueeeseeessaeeesageesaaes 5 6 5 6 Mounting the Process Interface ccccccceeccsececeeeseeeeeeeeceeecaeeceeeeseeecageseueesseeseueseueseueesseesusseeeeseeeses 5 6 5 7 Typical Purge Gas Configuration In Situ sseeseseeessessesesseeee eese nennen nnne nnne nnne nn nnn nnn nnns 5 7 5 8 Typical Purge Gas Configuration Extractive trace ppm H O 5 7 5 9 Dimensional MIAN NRI 5 8 SAUBER
61. NG 5 19 V NOTES ISOLATE PAIR 2 WHITE CONDUCTOR DO NOT TERMINATE DO NOT GROUND ISOLATE INDIVIDUAL SHIELDS DO NOT TERMINATE DO NOT GROUND OVERALL SHIELD TERMINATED AT CHASSIS OVERALL AND INDIVIDUAL SHIELDS TWISTED TOGETHER TERMINATE ONE WIRE AT TB 8 TERMINATE REMAINDER AT CHASSIS 5 ANALYZER POWER SUPPLY MUST BE 24 040 5VDC REQUIRES MAX 4 0 96W 6 ANALYZER SUPPLIED VOLTAGE 24VDC TO VOLTAGE FREE CONTACTS DO NOT GROUND OR APPLY EXTERNAL VOLTAGE DAMAGE TO ANALYZER WILL OCCUR ANALYZER PROVIDES 24VDC 12W MAX FOR SOLENOID OR RELAY OPERATION 8 FORM C CONTACTS SHOWN IN SHELF ALARM STATE 1 24VDC 0 5 125VAC NON INDUCTIVE NO OPEN ON ALARM NC CLOSE ON ALARM 9 4 20mA OUTPUT 9000 MAX 1500Y ISOLATION 10 REFER TO USERS MANUAL FOR OTHER DETAILS 11 REFER TO FIELD WIRING DIAGRAM FOR TERMINATION DETAILS BON 5 11 Hazardous Area Systems The TDLS200 Analyzer requires a continuous nitrogen or I A 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 are clean dry etc If using a purge gas that also contains the measured gas e g purge with instrument air and measuring process combustion oxygen then the Non Process Parameters software feature para
62. O Sbari YOKOGAMA 10 Gemini SireetHeustan Texas 77058 USA Mode in USA WARNING Polenlid chergng harga sen matruchion Do nol open when on explosive gos dtamoephere may be present e noi op when energized Asphydoteom Hazard enclosure purged with Mitrogen For YR 200 Remote Interface Unit RIU Zone 2 CAT 3 ATEX use the following labels will be attached as appropriate 101 64 4inich d Internal Free Volume 34 000cm Pain Purge Flow in Purge Time 12 minutes Lithium GREOI2 O21 An Expr 5 20 ba 526 EPSILON OB ATEX 2412 THIS PRODUCT COMPLIES Max Supply Line lt 6 3barG WITH 21 CFR PART 1040 10 O SbarG i 10 Gemini Street Houston Texas 770589 LIS A Made in WSA 7h WARRING alariiragtate charging hazard Baa instructian e not open when on gave goa dtomosphera may be prasent a n t apen whan energized Pe A lt 101 604 inch i Max Anolzer input pressure ig G2 barG i 101 6C4inich Y Internal Free Volume 24 000cnT Min Purge Flow L min win Furge Time 18 minutes Lihiurm CREOJ2 Q E1AR 3 03 EPSILON 08 ATEX 2412 THIS PRODUCT COMPLIES WITH 21 CFR PART 1040 10 Min Supply Line O SbarG 910 Gemini Skreet Housken Texas 72058 USA in USA Zh WARNING electrostatic charging hazard See ietruciien Do nol open when an axploshes goa
63. OILVSN3dOO N 90NvZ JOYNOS WNM3IX3 49 _ _ Q3N3MOd NOILVSN3dOO p NOLVNINYJL 68 i f 0 9 x4 v in L OGAvZ S xa XVI MZL OQA vZ XLS STVNOIS YAXA GAS S soyez NO 35019 ON WaVIY NO N3dO ON x 0 ANA GION TOS f ALVIS WHV1V J13HS NI NMOHS SIOVINOO 9 fr 9 S1 oowz 1 39VI10A TWNYSLXS L YO QNnONO LON OG SIOVINOO 33M4 39VI10A OL 39VI10 03119915 YIZATYNY G 35155359 s eund NNO E E SISSVHO N3ONIVAN SLVNINYSL L HOS L NG _ f Nanas S 8 8L LV IXM 31VNIWNM3I H3HI3901 Q3ISIML SOTIIHS 1VAQOIAIANI ONY TIVMSAO v NOLIVSN3dWOO 5530049 omz 2 A 5 SISSVHO IV Q31VNIAH3L 073 TVJO FYNAIVYSd WAL T3A31 Z NOLLVOMWA xoaHo S v 3 GNNOND LON OG 31VNIAM3L LON OG SGTAIHS IWAGIAIGN 31V1OSI Z A N CH JIVILINI JLONIY O32 4 o0wz 2 fS QN ONO LON OG 3IVNI S3I LON OO NOIOnONOO 3llHM Ayd 31V1OS L 2 W804 xo3Ho f NYANI SALON f 9 HON UNA 9 1 1 1 SIOVINOO L L L 90 vZ S Linv4 OWNOO 9 vuoz b 1 105 a ONG a SJ mG UJ SINdLNO SOTVNY oy L OGAvzZ 8 ON ve c JA 394d L O0 vZ d yes 2 NYVM OWWOO M3MOd OGAPZ TT L L 0 1 L L ON 0 L L oqwvz 1 NOLLdIMOS
64. On line validation will provide an indication of whether the analyzer is responding to gas changes During this step manually record the amount of analyzer reading change detector e Record Results Download data files from the analyzer for e mail to Yokogawa e SPECIAL NOTE Parts removal if necessary should be done so with great care There are electrostatic sensitive devices such as the Laser Diode Module that can be damaged if not handled correctly DO NOT CUT WIRES TO REMOVE ANY ITEMS PARTS e THE LASER DIODES MODULES AND DETECTOR MODULES ARE ELECTROSTATIC SENSITIVE IMPROPER HANDLING CAN CAUSE PERMANENT DAMAGE AND SUBSEQUENT REPLACEMENT OF PARTS 9 1 1 Trouble Shooting Procedure for Lost and or Low Transmission For a TDLS 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 e Alignment The mechanical alignment of the laser beam with the detector unit O The beam not directed at the detector window detector not aligned with the incoming laser beam o Miss aligned flanges and or nozzles e Plugging The quality of the clear aperture through which the beam travels o Physical obstructions inside the nozzles and or piping o Dirt or residue fouling of the process windows o Mechanical obstructions e Particulate The process gas optical clarity O Excessive smok
65. P Div2 all units ANALOG I O BOARD T 2 DC k 3 24VDC VDC 9 Q2 1 24VDC RETURN 3 24VDC 0 2 CH1 Cn CH2 I 4 RETURN 5 24VDC RETURN 24VDC OVDE x 3 24VDC F 4 OVDE 5 24VDC T24NDC SV 1 SV2 CN 12 T jur C AQ BH e 2 S CONS COWEN COLONOS n ko i TBS TB14 MA LV te oO PURGE KIT d o ANALYZER 24VDC POWER 57 V REMOTE INITIATE VALIDATION 6 SOLENOID VALVE DRIVER SIGNALS ATE ANALOG OUTPUTS ISOLATED 4 20mA 9 TEMPERATURE PROCESS COMPENSATION INPUTS 4 20mA SEE DETAIL AT RIGHT PRESSURE REMOTE DISPLAY CONNECTION OPTION SEE FOLLOWING NOTES 5 18 POWER TO PURGE KIT 1 NC COMMON gt WARN 3 NO E 4 NC COMMON gt FAULT DNO ALARM CONTACTS 1 NC in A2 COMMON gt LEVEL 4 PURGE LOSS TX ays ETHERNET 4 RX TBY TERMINATION DETAIL TEMP PRESS _ e M COMPENSATION POWERED eS 24v00 BY EXTERNAL SOURCE E Os COMPENSATION POWERED BY ANALYZER 6 24VDC Please NOTE that ALL analog output signals from TB 8 are POWERED BY THE ANALYER Outputs from TB 9 can be configured for POWERED inputs or LOOP POWERED external transmitter PLEASE CHECK CAREFULLY BEFORE APPLYING POWER TO THE ANALYZER IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 lt 5 INSTALLATION AND WIRI
66. Safe Areas General Purpose An optional Z Type purge control system can be fitted to the RIU and it includes a local indicator and pressure switch alarm contacts When applied the purge system allows for operation in e NEC CSA A Class 1 Division 2 Groups A D e ATEX Zone 2 CAT 3 dual regulators at the inlet MUST be used The purge gas may be either Instrument Air or Nitrogen 4 9 Purge Systems The TDLS200 Analyzer requires a continuous nitrogen gas purge to prevent ambient oxygen ingress to the opti cal 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 they are 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 The process interface may also require purging to maintain clear windows refer to Process Window Purge details separately IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 4 ANALYZER COMPONENTS gt 4 14 Purging Analyzer for Safe Area The block diagram below shows the sections of the analyzer that require nitrogen purging The purging should be carried in sequence typically as shown below Nitrogen or I A Purge Gas Main Detect Electronic Laser Detect Electronic Housing Module i Module Housing F
67. TS gt 4 1 4 ANALYZER COMPONENTS Launch Unit Launch Unit Detect Unit e Main Electronics Housing e Analyzer detachable from process e Detect Electronics User Interface optional interface for Off Line calibration service Housing e Laser Assembly Flanged O Ring Alignment e Detector Assembly e Check Gas Flow Cell for Flanged Metal Bellows Seal Alignment On Line Validation Flow Cell INNER ee E E r E E Oe Isolation Flanges By Pass Piping Custom designs for specific applications Hazardous Area Purge optional ees NEC CSA Class 1 Div 2 Gr A D i ATEX Zone 2 Cat 3 T 1 pl b ouo um am ER RR GERD UR RR OCcCess lt QC SG 2 A TfOCees WII 2 Figure 4 System Overview The Launch Unit and Detect Unit are connected to each other via a Tray Rated 4 pair shielded twisted pair cable The Launch Unit requires a single 24VDC power supply by customer or via optional Power Supply Unit Nitrogen purge gas is required to prevent ambient oxygen ingress however for other target gases it may be possible to use Instrument Air for purging The Process Interfaces are available in various formats sizes and materials
68. Using a Tunable Diode Laser as a light source for spectroscopy has the following benefits e Sensitivity As low as 10 by volume lower with path length enhancement e 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 e Power Diode lasers have power ranging from 0 5 mW to 20 mW Also being highly coherent this allows measurement in optically thick environments high particulate loading e Monochromatic no dispersive element filter etc required Light source itself is selective e Tunable Wavelength can be swept across the entire absorption feature this allows resonant peak and non resonant baseline measurement during every scan By measuring the baseline and peak power at the detector transmission can fluctuate rapidly by large amounts without affecting the measurement This is useful for high particulate applications IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 2 INTRODUCTION AND GENERAL DESCRIPTION 2 2 2 1 1 Measurement Current ramp to laser Figure 1 Signal at Detector Figure 2 Processed Detector Signal Figure 3 2 2 Instrument Check 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 wavelength adjustment
69. agnostics 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 9 11 Non Process If the application use 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 Non Process Parameters should also be configured if using a linelocking gas in the validation cell e g CO for combustion 10 0 Normal Operation When the site field configuration is complete and the analyzer has operated for at least two hours without any functional alarms then perform an export data routine 10 1 O 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 NEN Close out the VNC software and disconnect the service PC if connected 9565 Ensure the doors lids are closed and tightly sealed 10 2 uo O O KR The system is now in normal operation mode We RECOMMEND sending all the Exported Data files to Yokogawa Laser Analysis Division E along with any notes and comments We will then be able to store these files on a master record for future reference A CAUTION Please carefully read the appropriate Sections of thi
70. aiaa tcu 10 5 10 2 Downloading Transfering Exporting the 10 8 IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 1 QUICK START gt 1 1 1 QUICK START Ses me beim OOOO 1 0 Preparation Carefully un pack and check equipment for any obvious damage This includes flanges Cables Power Supplies manuals and any other supplied options NOTES There are 14 ferrules in the accessory bag for tubing piping The number of ferrule that are required for actual tubing piping are different by application Please see tubing piping figure specific to project for exact detail O l Ensure the process connections match the supplied process interface 1 2 Ensure the appropriate utilities are available and ready for connection These may include electrical power nitrogen purge gas instrument air validation gas etc S Ensure you comply with any local and or site specific safety requirements 1 4 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 If separate process isolation flanges have been provided for corrosive service then install to the process stack flange isolation valves Attach the process interface alignment flanges to the site installed flanges or isolation valves as appropriate If installing Large A
71. ainless steel body with O rings seals attached to the main electronics housing aser Assembly Process Interface Check Gas Flow Cell Main Electronic Housing PS Figure 7 Launch Unit Overview IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 4 ANALYZER COMPONENTS 4 3 4 2 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 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 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 stain less steel fasteners and a weather tight gasket This allows for external viewing
72. alibration amp Validation Online Validation Settings SEM Check Gas Concentration 7 e Check Gas Concentration specifies the concentration ppm of the gas within the online check gas flow e Check Gas Pathlength specifies the length in of the check gas flow cell e Check Gas Temperature can be selected for either Fixed or Active lf Active Temperature then follow on screen instructions If Fixed Temperature then enter in the temperature of the gas within the online check gas flow cell Typically this cell is the same temperature as ambient 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 IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 8 VALIDATION AND CALIBRATION 8 25 e Check Gas Pressure specifies the pressure at which the gas within the online line check gas flow cell Typically this cell is vented to atmosphere so an atmospheric pressure value 14 7 psiA or 1 01barA will work 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 check gas flow cell Normal gas Purge Time specifies how long N will purge the check gas flow cell Validation Reading specifies the type of reporting method for the validation concentration see earlier explanation of these types
73. alyzer IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 6 BASIC OPERATION 6 24 On Line Process Conditions Analyzer Purged with Nitrogen pemegang 10 0 1 5 C E E DOS NH3 Temp iE Conii Mode Cur Genie Tres 9 Pees bara LTS 39 76 1 01 BE 13 453 Peak LTSP Unis oer rasTiibi 01 g CI aa P EUWIDGS E gy ka pei E Rma Deed 5 gr Agee Sorckum 75 T 1 x NH3 perm Mace Cur Cemi Trans 54 Pred Dara LTS deg LT deg Paak Pos Lins ee dii Jor HIG Aceon Duanden Loe Set Kool UE UTEE 5 Wem 1 Fre Detector Signal Atporpton Soscirum Ripe Tena Conto Mode Tana Frea bara LTS degC 13430 LT degC Peak Pos Process OPL NH and H O Analyzer Purge N In this Absorption Spectra view the Process H O absorption peak can be seen at approximate peak center position PCP 167 This absorption peak is Process H O as there is no reference gas H O in the N analyzer purge gas There is also approximate 20 ppm NH approx PCP 120 absorption in this spectra based on 72 6 cm OPL ambient temperature and ambient pressure Process OPL Zero NH 2 H O Air Analyzer Purge N In this Absorption Spectra view the large process H O absorption peak can be seen at approxima
74. ambient temperatures These small changes are quantified during factory testing to ensure they are within allowed instrument specification and they do not change with time Calculating Oxygen Concentration Given that the optical path length gas temperature and gas pressure are known and fundamental optical drift has been predetermined the only aspect of measurement that can now affect the true peak area is the quantity of oxygen molecules in the optical path The true peak area measurement is ensured because the laser scans wavelength from a non absorbing region see data points 50 90 through the oxygen absorption region see data points 91 159 and on to another non absorbing region see data points 160 200 The two regions of non absorbing spectra allow for a base line to be drawn below the absorption curve and subsequent true peak area calculation On Line Validation By knowing the above measurement principles it is possible to understand that the TDL S200 is Oxygen capable of performing on line validations to verify analyzer EE piion Region Region Region measurement performance When the analyzer is initially calibrated off line using protocol certified gas standards the area of the absorption peak is assigned a calibration coefficient This coefficient is then used in a series of equations to correct for optical pathlength gas temperature and gas pressure Obviously when factory calibrating the analyzer the me
75. and keypad a mini display or a laptop PC connected through VNC Ethernet Go into Laser Spectra amp Control observe the Trans You will need to set up the alignment by first getting both the launch and detect sides as perpendicular to the optical plane as possible This will allow for the initial signal to be found more easily Note the oxygen analyzers tend to be easier to align than CO CH4 analyzers due to the optical detection internal configurations Once this has been done adjust the launch unit till a change in transmission can be seen Do this by loosening the nuts from the launch unit and manually point the launch unit till some transmission is observed Note the change in transmission might be very small depending on the incident angle on the detect optic It is easy to pass over the correct launch alignment without knowing it If a change cannot be found repeat with smaller adjustments in both the X axis and Y axis If no transmission can be established by movement of the launch unit check the general alignment of the detect unit to ensure its axis is generally aligned with the launch unit axis Once some transmission is observed align the detect side so that the transmission is at a maximum To do this back off all four of the setscrews With two people one to do the adjustments and one to watch the transmission slowly adjust the detect alignment by loosening one direction and tightening the opposite till the maximum t
76. ar to Channel 1 Block Mode mA value Track mode Warning Mode Hold Mode mA value Fault Mode similar to Warning High 20 mA Low 3 3 mA Block Mode CH 1 check mA value CH 2 check mA value Field Loop Check CH 3 check mA value CH 1 Calibration CH 2 Calibration AO CH Calibration CH 3 Calibration 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 DO Waming delay Laser temperature out of range Detector signal high Dectecor signal lost Measurement peak no response Peak center out of range 2nd gas threshold Walidation failure base concen trations DO fault delay Conc Trans Val Cal High Low and limit DO use alarm delay System I O Digital Output System Serial Number Laser Serial Number Password Old Password New password Software Version Date amp Time New Date New Time System Temperature Launch Unit Detect Unit C TCP IP Set new IP address sub net mask and default gateway Adjustable Resistors Confirmation of Change Laser Detect R21 Detect R22 Detect R23 Valve Control Valve 1 On Off Next Valve Selection Valve on duration in minutes Time Sequence Valve 2 Valve 3 similar to valve 1 Restore Control Remote control channel Processing Gas 1 Concentration Laser Spectra amp Control Gas 2 Concentration Gas tempe
77. ard Accessories Display and Software Functions Calibration Cell Used for off line calibrations and TruePeak Software has multiple levels the default or start page is validations the Main Menu Stainless steel 316 with free standing frame Main Menu Displays Concentration amp Units 96 or ppm Connects Launch and Detect with Transmission 96 72 6cm 28 6 OPL Status warm up OK Warning Fault etc Flow Cells Used for extracted sample streams at Temperature Fixed Active Ambient or any location Active 31655 low volume fixed alignment Pressure Fixed or Active 50 C 5 5 bar 80psig max Enhanced for 200 C 20 Bar 290psig Main Menu Sapphire window Kalrez o rings and can Basic Menu Configure 3 functions be constructed from 316SS Monel A400 View Spectra 2 functions Hastelloy C 276 Carpenter 20 and other Data 3 sub menus materials on request to suit the process Trends Advanced Menu Configure 9 sub menus Isolation Flanges Used for additional protection for in situ User Password Calibrate amp Validate 3 sub menus or by pass installations Data 4 sub menus 2 or 3 150 or 300 ANSI RF 4 150 Trends DN80 PN16 welded 5 8 or M16 bolt Active Alarms List of active alarms studs included sapphire 20 Bar 290 Shut Down Analyzer Instructions to close TruePeak local or psig VAC or BK 7 5 5bar 80 psig isolation window Calibration Functions Kalrez window seal o ring rate
78. aser Spectra amp Control screen to check the raw detector signal Write down the raw detector signal MAX and MIN values for later use LZ 9 emp C Control Mode Genier rene 9 Fad LTS te 7245 14700 21 053 LT MH Deak Pus Change R22 and R23 accordingly based on the current raw detector signal Perform one item of the following selections a b or c If Detector Signal High fault is active change both R22 and R23 to the next smaller value available in the resistor bag and then go back to STEP 6 For example if the current R22 and R23 values are 11k the new R22 and R23 values should be 7 5k9 NOTE please access Active Alarm in the main user interface panel to check if Detector Signal High fault is active If the raw detector signal is within requirement remove R22 and R23 and R21 if it was changed to 1002 in STEP 3 and cut their leads properly to fit the sockets tight and low and then go to STEP 9 NOTE 1 for a low process temperature analyzer with no capacitor on R3 the raw detector signal is within requirement if MAX is between 0 0 and 4 0 2 for a high process temperature analyzer with a capacitor on R3 the raw detector signal is within requirement if MIN is between 4 0 and 8 5 If the raw detector signal is too low other than a and b change either R22 or R23 to the next greater value available in the resistor bag and then go back to STEP 7 How to decide which resistor to change i
79. asurement conditions are different to that of the process Typically the analyzers are calibrated with a 28 6 long optical path and ambient temperature and pressure 75deg F and 14 7psiA The relationships of pathlength temperature and pressure are well known and proven and therefore can be used to correct for other conditions such as a furnace with 60 optical path operating at 600 deg F and 14 6psiA When an on line validation is performed the analyzer is adding a known area to the absorption peak The oxygen concentration of the validation gas is known typically 20 996 O2 the optical path length is known the validation cell has a 4 OPL the gas temperature is known ambient is measured by the analyzer and the gas pressure is also known the validation cell vents to atmosphere Therefore the analyzer knows what additional peak area should be measured during a validation cycle IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 8 VALIDATION AND CALIBRATION 8 17 A validation cycle consists of first capturing a process gas only spectra 1 then adding the validation gas to the validation cell and capturing a spectra 2 and then removing the validation gas and finally capturing a second process gas only spectra 3 Spectra 1 and 3 are then averaged spectra as they represent the process gas only before and after validation Spectra 2 is the combination of process and validation gas so when the averaged 1 3 spectra is subtracted
80. ata 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 Daily Spectra 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 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 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 These files are the individually named spectra that are Captured by the user at any given date or time during operation Each file can have up to 8 numerals in its name which are entered at the time the Capture is performed Example 110307 cap 100008 cap Capture cap Individually named spectra capturedmanually IM 11YO1BO1 O1E A 5th Edit
81. ate Validate uj af ed caliibeation amp Va iat r ze Calbrat a ering Valve Selection Zero Gas Purge Time Process Gas Purge Time Analog Ouput Mode IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 8 VALIDATION AND CALIBRATION 8 10 MANUAL OFFLINE VALIDATIONS Enter into the Advanced Menu Calibrate amp Validate section Off Line Validations Choose Check gas 1 2 or two gas validation and select Manual Validation Ensure analyzer is purged with nitrogen T Advanced Calibrate amp Validate Ves Following the on screen directions enter Gas Type amp Conmcentragon in the pressure temperature cell length amp concentration of the gas within the off line line check gas flow cell Press Enter to proceed Gas Type O2 poo Input Val gas type and concentration Advanced B Validate Chile Validatian Enter check gas pressure psiA 14 00 Enter check gas temperature F Enter check gas length in IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 8 VALIDATION AND CALIBRATION 8 11 Offline Validation Check Gas 1 MANUAL OFFLINE VALIDATIONS E Enter into the Advanced Menu Calibrate amp When reading stabilized Validate section Off Line Validations press 9 to calibrate or Choose Check gas 1 2 or 3 and select Manual press ESC to cancel Validation H20 Concentration ppm F Advanced Calibrate amp Vali
82. ax 750 minutes rof iB mI IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 T iama Coe MEX gt gt Process Path Length 22 60 m Process Pressure Fixed 14 596 pei Temperature Non Process Parameters Valve Contral Processing Laser amp Control TD Advanced Cof Advanced Config Process Optical Path Length Current value in New value in nput new optical path length lt 6 BASIC OPERATION gt 6 8 ADVANCED CONFIGURE MENU PROCESS PATH LENGTH allows user to enter in a new optical path length distance laser is exposed to process gas PRESSURE allows selection of ACTIVE analyzer fed pressure value from external transducer or FIXED value entered into software process gas pressure In Active mode a Back Up value can be entered in case of active input failure CONTROLLED is not applicable for TDLS 200 TEMPERATURE allows selection of ACTIVE analyzer fed temperature value from external transducer ACTIVE AMBIENT ambient gas temperature derived from internal sensor or FIXED value entered into software process gas temperature In Active mode a Back Up value can be entered in case of active input failure ACTIVE PEAKS is used for special Oxygen applications only please consult with Yokogawa directly CONTROLLED is not applicable for TDLS 200 NON PROCESS PARAMETERS allows mathematical subtraction of purge gases that contain the target gas Example would be
83. centration Gas Temperature Gas Pressure Transmission Laser Temperature Peak Center Position and other parameters CAPTURE allows a manual spectra capture user will be prompted to enter a unique file name for captured spectra on pan Control Mode CONTROL MODE allows selection of Automatic laser RELIE T 5000 temperature is controlled to keep peak centered using peak a center position as set point or Manual laser temperature is controlled using integral laser temperature sensor Important MEE auto tune peak height threshold values should not be adjusted Lese NIE without factory guidance ONLY ADJUST WITH FACTORY ASSISTANCE Manual adjustment of the laser temperature set point LTS may be done with care and factory guidance used only to re adjust the absorption peak position if the peak has moved outside of the normal operating range advanced troubleshooting LASER TEMP SETPOINT LTS In manual mode allows adjustment of laser temperature ONLY ADJUST WITH FACTORY ASSISTANCE NOTE the analyzer will return to automatic mode if un touched for 30 minute LTSP LIMITS setting of guard limits for laser temperature set point ONLY ADJUST WITH FACTORY ASSISTANCE MAX CURRENT setting of center point for laser current ramp ONLY ADJUST WITH FACTORY ASSISTANCE FAST UP DATE this function can be Enabled faster update times or Disabled normal operation as necessary W
84. ck on calibration flow cell Set analyzer so that Launch and Detect Unit flanges are butted together IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 9 TROUBLE SHOOTING gt 9 10 Process Pressure out of range The gas pressure range for the application is programmed into the analyzer Process Temperature out of range The gas temperature range for the application is programmed into the analyzer Concentration out of range The process pressure range for the application is programmed into the analyzer L or D unit temp out of range The Launch Unit and Detect Unit have built in temperature sensors This diagnostic is triggered if they sense the ambient temperature is outside of the analyzer design range 5 to 55C 9 4 Analyzer Faults Check pressure transducer feed to analyzer Check to ensure software setting Advanced Menu Configure is correct Check pressure transducer feed to analyzer Check to ensure software setting Advanced Menu Configure is correct Check to ensure software setting Advanced Menu Configure is correct Check purge system flows and excessive heat output from SBC and or other electronic components Look for excessive heat output from adjacent processes and or radiant process and or direct sunlight 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
85. conditions especially during cold starts and shut downs the most extreme thermal changes on the mechanical structures To resolve the above issues Yokogawa Laser Analysis Division has developed a diverging beam and large aperture optics strategy At the launch side the output laser beam has a small diverging angle For example the beam size is about 20 50 cm diameter at 60 18 m optical distance The optical aperture at the receive unit is enlarged from the original 134 diameter With these two changes it is much easier to do initial alignment and keep good transmission during a wide range of operating conditions Please note that when an analyzer is mounted on the standard 0 726m 28 6 OPL off line calibration cell there is a large amount of laser light on the detector Once moved onto a long path installation the diverging beam power is spread out over a larger area and hence weaker this means that once installed on the long path the detector gain may require some manual adjustment increase typically please use the following procedure IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 6 BASIC OPERATION 6 27 6 5 1 Large Aperture Optics Installation Alignment amp Detector Gain The alignment of the Large Aperture Optics or LAO is quite similar to the alignment method of a standard TDLS200 To prepare for the alignment you will need some form of screen at the analyzer this can be a launch unit with a screen
86. connection Please refer to Section 10 for complete details of the available data IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 8 VALIDATION AND CALIBRATION 8 1 8 Validation and Calibration There are several methods that can be used to validate and or calibrate the TDLS200 analyzer Generally we recommend routine validation of the analyzer either on line if appropriately set up or off line when the process gas can be isolated from the optical path such as extractive enhanced flow cell 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 On Line Analyzer remains attached to Manual process and also considered as a gas response check method Validate On Line Analyzer remains attached to Automatic process and also considered as Initiated by a gas response check method Remote Contact Local User Interface Pre Set Timer URD Laptop VAC RIU User Interface Validate Off Line Analyzer removed or Cal Check from the process Manual Zero Span alignment flanges Calibrate Off Line Analyzer removed Manual Zero Span from the process alignment flanges Analyzers with Analyzer can remain extractive flow cells in its off line position and by pass piping Use integral on line check gas flow cell Use integral on line
87. connections od Tube fittings Figure 47 Purge Flow Diagram when using on line validation 5 11 2 Purging Analyzer for Hazardous Areas without On Line Validation e NEC CSA Class 1 Division 2 Groups A D e ATEX Zone 2 CAT 3 Dual regulators must be used on the inlet The block diagram below shows the sections of the analyzer that require nitrogen purging Z Type purge control system is fitted the Launch Unit and it includes a local indicator Bright Green rugged light and pres sure switch alarm contacts open on loss of purge pressure ess nterface Figure 48 Purge Flow Diagram when not using on line validation IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 lt 5 INSTALLATION AND WIRING 5 21 5 11 3 Purging Analyzer and Universal Power Supply and or URD for Hazardous Areas with On Line Validation e Class 1 Division 2 Groups A D e ATEX Zone 2 CAT 3 Dual regulators must be used on the inlet The block diagram below shows the sections of the analyzer that require nitrogen purging when using in conjunction with either or the Universal Power Supply and Universal Remote Display AZ Type purge control system is fitted the Launch Unit and it includes a local indicator Bright Green rugged light and pressure switch alarm contacts open on loss of purge pressure Nitrogen or I A Purge Gas Check Gas 1 Flow Cell Pro ess Interface Figure 49 Purge Flow Diagram when
88. considered IP65 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 RIU is supplied with standard integral display and keypad RIU Interconnect to Launch 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 SBC Analyzer TB6 Figure 15 Connecting RUI to Analyzer s IM 11Y01B01 01E A 5th Edition Feb 9 2012 00 4 ANALYZER COMPONENTS gt 4 13 RIU Optional Ethernet Switch If there is more than one analyzer connected to the HIU 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 Figure 16 RIU Ethernet Switch RIU Optional Feed through Board To facilitate the connection of more than one analyzer to the RIU an optional Feed through board can be used The board has pluggable screw terminals that allow for the landing of field cables from the analyzers at the RIU RIU Hazardous Area Purging The standard HIU is designed for operation in
89. ct that YOKOGAWA cannot predict in advance IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 E TDLS200 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 AVOID SHOCK AND IMPACT TO THE ANALYZER THE LASERS CAN BE PERMANENTLY DAMAGED Laser Safety amp Classification according to FDA Regulations The TDLS200 is Registered with the United States FDA as a Laser Product WARNING THIS ANALYZER CONTAINS A LASER PRODUCT THAT IS GENERALLY IN ACCORDANCE WITH THE REGULA TIONS FOR THE ADMINISTRATION AND ENFORCEMENT OF THE RADIATION CONTROL FOR HEALTH AND SAFETY ACT OF 1968 TITLE 21 CODE OF FEDERAL REGULATIONS SUBCHAPTER J REFER SECTION 1002 10 OF THE REGULATIONS REFERENCED ABOVE CAUTION INVISIBLE LASER RADIATION AVOID DIRECT EXPOSURE MAXIMUM OUTPUT POWER 1 MW Oxygen MAXIMUM OUTPUT POWER 20 mW other Gases DURING NORMAL OPERATION THIS ANALYZER IS CLASS I LASER PRODUCT according to IEC 60825 1 CAUTION The Instrument is packed carefully with shock absorbing materials nevertheless the instrument may be damaged or broken if subjected to strong shock such as if the instrument is dropped Handle with care
90. ctra amp Control screen captures that depict the different scenarios depending on what process gas es are present in the OPL and what gas is purged through the analyzer Note that the actual magnitude of the absorption units au as indicated on the Absorption Spectrum Y Scale vertical will vary depending upon the actual gas concentrations optical path lengths gas temperatures and gas pressures Off Line Calibration Conditions Pp A Process Calibration OPL N2 ime aw euer Dpecika amp Cornel Analyzer Purge N2 This is how the absorption spectra will appear when there is neither NH nor HO in the entire optical path Process OPL and Analyzer Purge l emn fC Conn Mode 541 At gall Trans Pres bara LTS 1 ECEN meom This is the spectra appearance required for an Off Line Zero Calibration of the analyzer Gumi i nts Process Calibration OPL 20ppm NH 478 qnum IPM Analyzer Purge N In this Absorption Spectra view there is practi cally zero H O absorption peak in the approxi mate peak center position PCP 167 region a There is approximate 20 ppm NH 9 approx PCP 120 absorption in this spectra based INED 2 6cm OPL ambient temperature and ambient inu MIL KENN pressure This is the spectra appearance required for an Off Line Span Calibration of the an
91. d for the initializing period 5 minutes this means that even manual control of the laser temperature is disabled during this period N N o N Initially observe the Transmission value through the appropriate user interface The objective is to adjust alignment until the maximum transmission value is obtained Perfect alignment in a clear process gas will yield close to 10096 transmission If the analyzer displays a Warning Validation Required this indicates there is no target gas ab sorption peak found at start up Introduce some measured gas into the optical path and re start or perform a validation with target gas 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 If you have 100 certainty that the analyzer is already measuring the process gas and validation is not currently possible then this alarm can be cleared via the Advanced Calibrate amp Validate menu N O Alignment check Initially observe the Transmission value through the appropriate user interface The objective is to adjust alignment until the maximum transmission value is obtained Perfect alignment a clear process gas will yield close to 10096 transmission Start by adjusting the Launch unit alignment flange nuts up down and left right Look for increase
92. d max Off line Calibrations Zero calibration 200 C Zero off set 316SS Monel A400 Hastelloy C 276 Span calibration Carpenter 20 other on request Transmission Dark current Note Must use in conjunction with alignment flanges peak search Off line Validations Check gas 1 Utility Panel Used for convenient field installation of Check gas 2 utilities configurations for Check gas 3 Single dual or four analyzers On Line Validations Manual Manual or automatic on line validation Automatic controlled by analyzer Setup Functions Configuration Safe area GP Div 2 purged or non Process Path Length purged ATEX CAT 2G components Pressure Purge flowmeters with integral needle Temperature valve glass tube variable area Units Swagelok double ferrule stainless steel System 1 tube fittings and tubing standard System Panel mounted or fiberglass NEMA 4X Valve Control IP65 with viewing window Laser Spectra amp Control 5A 24VDC power supply output to analyzer requires VAC input power Diagnostics Warnings include Detector signal low Note Custom configuration available to suit customer requirements Transmission low Spectrum noise high Integration Used for convenient analyzer amp extractive Process pressure out of range system flow cell integration Process temperature out of range Free standing frame galvanized steel Concentration out of range with 304SS roof B
93. d there shall be a minimum of two pressure regulators in the air nitrogen supply line Materials of Construction The analyzer incorporates a variety of materials in its construction and they should therefore be used in an appropriate manner Any chemicals liquid or gas that may have a detrimental effect on the product s structural integrity should not be allowed come in contact The electronic enclosures are constructed from Aluminum Alloy AL Si 12 ASTM A413 and have a protective epoxy powder coated surface finish The welded bodies are constructed of stainless steel grade 316 The fasteners are constructed of stainless steel grade 18 8 The windows when fitted are constructed of laminated safety glass IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 2 INTRODUCTION AND GENERAL DESCRIPTION 2 5 Maintenance Work by Qualified Personnel Unqualified work on the product may result in severe personal injury and or extensive damage to property If the Warnings contained herein are not adhered to the result may also be severe personal injury and or extensive damage to property This product is designed such that maintenance work must be carried out by trained personnel Trained personnel are considered as below Engineers familiar with the safety approaches of process analytical instrumentation and or general automation technology and who have read and understood the content of this User Guide Trained start up commissioning analyz
94. dary window purges for lethal service gases Start other utilities accordingly IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 1 QUICK START 1 2 Leak check all connections and ensure pressure ratings not exceeded 5 0 Power Up Apply power to the analyzer and using a multi meter check for 24VDC power at TB1 on the launch unit back plane 51 UsetheintenalOn Off switch to power up the analyzer Use the internal On Off switch to power up the analyzer 5 2 Observe the various LED clusters on the backplane and FPGA boards blue LEDs located on the lower right side of the back plane should be on 5 Observe the Green power indicator on the SBC sa o Observe the LEDs on the analog I O board Checking If there is an installed optional 6 5 Display and Keypad Observe the Main Menu messages and status information EIL If there is an installed optional Mini Display 4x20 VFD Observe the status line message If there is no installed User Interface then connect a laptop PC via Ethernet to the SBC mounted on the backplane Initiate the supplied VNC 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 one or more alarm message due to low transmission out of range parameters or other final system configuration is still required Please also note that the analyzer laser temperature control is disable
95. date 26 AUTOMATIC OFFLINE VALIDATIONS The Validations may be for Gas 1 Gas 2 or Two Gas Validation such as Zero amp Span Check or 2096 amp 8096 FS checks as required by some regulatory applications The Offline Validations can also be automatically configured Refer to later section for details Local Initiate will start the automatic online validation sequence when selected It will use Two Gas Validation the existing Settings see below for details on Settings Remote Initiate will enable disable monitoring of the selected Remote Initiate contacts on ii Arend m SS TB 2 within the Launch Unit When enabled the analyzer will detect the chosen contact closure and automatically start the online validation Local Initiate 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 Remote Initiate Time Initiate gt gt settings IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 8 VALIDATION AND CALIBRATION 8 12 There are several critical parameters that must be preconfigured in the TDLS200 software when using the automatic validation sequence These parameters MUST be correctly set otherwise the analyzer will report false incorrect validation results Check Gas Concentration specifies the concentration ppm or 96 of the gas within the offline flow cell Check Gas Pathlength specifies
96. ded otherwise damage and files corruption may occur Please also ensure before copying any of the following factory supplied up load files the USB stick is empty Available field up loadable files include TruePeak exu in USB memory to upgrade TruePeak exe TruePeak uiu in USB memory to upgrade TruePeak uir system upl in USB memory to replace system cfg system lau in USB memory to replace system las zeroO0 upl in USB memory to replace 2 00 spanOO upl in USB memory to replace 00 lt e c 9 3 Analyzer Warnings Warning Action Stops o Detector Signal Low This is based on the amount of Refer to Low or Lost Transmission signal generated by the detector procedure Transmission Low This is the most Adjust analyzer alignment important diagnostic feature of the Clean windows analyzer Transmission is a measurement of the laser Check on calibration flow cell power striking the detector It is an arbitrary number Set analyzer so that Launch and Detect Unit 96 that can be calibrated The analyzer mounted on flanges are butted together a calibration cell in the factory is calibrated at 100 Refer to Low or Lost Transmission transmission when leaving the factory procedure Spectrum Noise High This is based on a Adjust analyzer alignment measurement of the noise standard deviation Clean windows of the absorption peak baseline regions Che
97. ding Continuous operation 10 C to 50 C start up temperature 0 C to 50 C Extended temperature installation options are available please contact Yokogawa O 90 96 RH non condensing or O 100 with correct purge gas specifications CE Marked for zone 2 ATEX group II Cat 3G with purge system EEx pz II T5 Class 1 Div 2 Group BCD with integral purge kit IP65 94 FNPT threads unused holes are plugged Analyzer 74 welded Swagelok connection Flow Cells and FNPT other connections upon request 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 galvanic corrosion Stainless Steel captive screws and optional keypad Laminated Safety Glass for optional display s Maximum 1500 C Application Dependant Maximum 20 bar Application Dependant 2 150 ANSI HF or 3 150 ANSI RF or adaptors for 4 150 ANSI RF Flange alignment tolerance within 2 degrees Launch Unit 16kg x 35lbs Detect Unit 5 5kg 12165 2 150 Alignment flange 4 5kg 10lbs 3 150 Alignment flange 9 5kg 15lbs Maximum 9596 transmission loss Note Fach application may differ in maximum limitations depending upon the combination of gas temperature gas pressure optical path length and concentration of gas being measured IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 3 GENERAL SPECIFICATIONS gt 3 2 Stand
98. e density opacity and or particulate matter that prevents sufficient light from reaching the detector e Weak Laser The output power of the laser module itself o Weak or dead laser diode source not outputting sufficient light This procedure will help new and existing installations with respect to troubleshooting situations that incur lost and or low or even none transmission Transmission is a relative value for light power received at the detector Typically a functional analyzer with clean windows mounted on an off line calibration cell the transmission will be anywhere from 90 to 100 sometimes a little over 100 Additional isolation windows can further reduce transmission typically by an additional 30 for Sapphire isolation windows and by up 20 for BK 7 windows BK 7 not typically recommended by isolation flanges pending process conditions IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 9 TROUBLE SHOOTING gt 9 4 Resolving Low Transmission LAUNCH UNIT 7 DETECT UNII m Hae Above Good Launch and Detect Alignment LAUNCH UNI S DETECT UNIT Above Poor Launch Unit Alignment LAUNCH UNIT ui lt gt DETECT UNIT f D gt a T hj EE Above Poor Detect Unit Aligament Figure 65 IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 9 TROUBLE SHOOTING gt 9 5 1 Alignment Adjustment a oometimes the original mechanical alignment of
99. e or vessel Typically has nitrogen or other purge gas protecting process windows e Span Validation via serial flow cell see Operation Specifications Full calibration requires removal from process May require pressure and temperature inputs Application Dependant Multiple methods to increase Optical Path Length OPL if needed 5 meter interconnection cable standard Close Coupled Extractive Bypass Configuration PROCESS Measures across a section of pipe where process flow is directed The measurement section can be isolated from process flow for full calibration validation zero and span Process pressure and temperature can be controlled or the analyzer may require pressure and temperature inputs Application Dependant Length of measurement section dependant on accuracy requirements and process conditions Extractive Configuration process sample Zero check gas Span check gas at grade at grade e Sample is fully extracted from process and may be conditioned before measurement Flow cells are available with ability to purge in front of windows balanced flow cell if required Process pressure and temperature can be controlled or the analyzer may require pressure and temperature inputs Application Dependant Length of flow cell dependant on accuracy requirements and process conditions Contact Yokogawa for further details IM 11YO1BO1 O1E A 5th Edition Feb 9 2
100. eak 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 i 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 similar to Path Length Temperature Fixed or Active value or offset Concentration Gas 1 Current Gas 1 New Gas 2 Current Gas 2 New Alarm Selection Warning Fault alarm PH threshold Path Length Select from in ft cm m Select from psiA barA kPa torr atm Tempterature Select from F C K IM 11Y01B01 01E A 5th Edition Feb 9 2012 00 6 BASIC OPERATION 6 2 Online Menu Level 1 Menu Level 2 Menu Level 3 Menu Level 4 Menu Level 5 Menu Advanced Configure System I O Analog Output Channel 1 Conc1 Conc2 Tran Temp Pres Password Protected None 4 mA 20 mA Channel 2 Always uses track mode Channel 3 simil
101. ended to ensure a ligament is maintained In situations where the process flanges are mounted to these thin and flexible duct stack walls a larger reinforcing plate should be welded around the mounting flange area to increase the attaching region The figure below depicts a typical suggestion however it is the installer s responsibility to ensure appropriately rigid installation is provided for the analyzer S S SSS SSS SSS Py 3 TIT P s RR RRR 3 S A SSS d 8 lt nen 2 vu SSNS SS S RANA A LEG ye SS oe SSS 24 KKK RX SS A NS SS N 22 xR cA 7 qum KK x SS SRK CE 5555 RS SS CROCO A AAA PSS RA A ue mR ARTS AAA Figure 26 Suggested Reinforcing Plate for Launch or Detect Unit Flanges reduce flexing with mechnical reinforcement to duck stack walls IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 lt 5 INSTALLATION AND WIRING 5 4 5 3 Process Flange Welding Alignment and Line Up The Launch and Detect units are provided with alignment mechanisms that allow for some manual adjustment of the laser beam direction in both planes It is however recommended that the following angular tolerances be adhered to as closely as possible PROCESS FLANGE ANGULAR TOLERANCE
102. ent is required If there is any process pressure variation then the results are typically affected proportionally according to gas law Fixed is most suited to atmospheric conditions such as vent lines and combustion ACTIVE is used when the highest degree of accuracy is required under variable process pressure conditions or when Fixed manualy input fixed pressure value specified for the given application The range must match the Active derive pressure from analog input 4 20mA Control PID contro pressure with feedback 4 20mA input range and a back up value may be entered in case the input signal fails CONTROL is not used in TDLS 200 Advanced Contig Pressure 2 Advanced Contig PROCESS TEMPERATURE FIXED is used when the process gas temperature will not vary under normal operating conditions when the measurement is i required If there is any process temperature variation then Active Input EX the results are typically affected according to the specific application ACTIVE INPUT is used when the highest degree of accuracy is required under variable process temperature conditions or Control when specified for the given application The range must match the 4 20mA input range and a back up value may be entered in Fixed manually input fixed temperature value case the input signal fails ACTIVE AMBIENT is used when the process gas generally Active Ambient derive ambient temperature from inte
103. er Active Alarm Display Button Analyzer Shut Down Button Up Down to select Enter lo AEM 520 0258 SME TU TRUST 11 85 XT oo end Veni Sas yrer Ganingiker fags After selection of either Basic or Advanced Menu you will see the Output Selection screen PLEASE note the RIGHT ARROW key access to the MENU older version of software require no other key or Press 9 to access MENU This allows control of the analog output while the user is working in the analyzer software Enter mA value form 0 20 e Block will hold outputs at user selectable mA example shows 3 8mA until return to Main Screen but Block output signals will be held at above mA and automatic NOTE CHANNEL 2 ALWAYS TRACKS tru is disabled until tw t i Track will allow outputs to continue to report Track output signals will continue tracking the measured value Moid prosent ouiput signals wil be held until usec concentration and transmission until return to Main Screen Hold will hold outputs at their current value until return to Main Screen NOTE CHANNEL 2 ALWAYS TRACKS BASIC MENU Configure allows setting of Path Length Gas gt gt Configure Temperature Gas Pressure E Ww t Set path length Y mn View Spectra user will select display of raw detector ocess temper E F View Spectra Spectra signal or absorption spectra Data Alarm History Calibration
104. er a number of readings to delay before the alarm becomes active IM 11Y01B01 01E A 5th Edition Feb 9 2012 00 6 BASIC OPERATION 6 12 ee SL CHANNEL 2 FAULTS Menu allows setting of various analyzer FAULT conditions FAULT is an event that will eliminate the measurement integrity it is an indication that maintenance is require and the Detector signal high analyzer is not operational ONLY ADJUST WITH FACTORY ASSISTANCE FAULT CONDITIONS ARE CRITICAL SETTINGS THAT CAN RESULT IN DAMAGE TO THE ANALYZER IF IMPROPERLY Peak center out of range 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 MEASUREMENT PEAK NO RESPONSE Used when Line Locking gas and or Non Process Parameters are enabled to detect the loss of absorption peak i e the measured absorption peak falls below the set threshold value consult factory for further details if attempting to implement Line Locking gas and or non process parameters To disable this Fault only under guidance from factory authorized personnel please enter a value of 1 PEAK CENTER OUT OF RANGE loss of peak center control VALIDATION FAILURE Allows the user to refine the most appropriate for validation PASS FAIL criteria Some process and conditions of application will require a large PASS FAIL criteria as much
105. er technicians who have read and understood the content of this Instruction Manual N WARNING Battery replace Heplacement Battery Installation Type CR2032 located on CPU The battery MUST be factory installed and cannot be installed by others at site soldered connections required Contact factory for further assistance IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 3 GENERAL SPECIFICATIONS gt 3 1 3 GENERAL SPECIFICATIONS A Measurement range Dependent on application and Optical Path B Output signal C Output Span D Contact outputs E Valve control F Current Input G Digital Communication H Data storage 1 Warm up time J Power Consumption K Accessories length Typical O 100 for analysis of Oxygen or Carbon Monoxide Measuring in ppm range is possible for Carbon Monoxide or Moisture 3x 4 20 mA DC with maximum load of 900 Ohm Three isolated outputs may be used for gas concentration transmission re transmission of data inputs dual range or second gas measurement where applicable 3 9 mA user configurable on warnings and faults according to NAMUR NE43 Freely programmable within measuring range configurable relays for Status Fault Warning In Validation concentration level etc Form C Single Pole Double Throw SPDT contact outputs with maximum 1A 24VDC or 0 5A 125 VAC 3x Form C SPDT contact outputs with C connected to 24VDC power
106. ess ENT to configure IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 Advorsced Oats Advanced Data Spectrum Capture Selection Relate Absolute Input number of updates between captures Spectrum Capture When Alarm Current New Number of spectra to capture when warning gt pectrum Capture Whee Alarm Number spectra to capture when fault 10 DATA FILES AND FORMAT gt 10 6 analyzer to capture 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 requirements Typical updates between capture value would be 300 The more frequently spectrum are stored then the larger the MMDDY Y spe files will become NOTE Capturing every spectrum for one day can create a single day file in excess of 30MB Choose the parameters carefully to prevent memory overload Determine whether or not the analyzer should capture spectrum 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 created for less meaningful Warning alarm conditions An example is a low transmission warning alarm set at 70 for an application that often runs at less than 70 transmission Determine whether or not the analyzer should capture spectrum files under a FAULT condition Note
107. extractive installation The valve control logic is outlined below Manual Switch 71 Lisa nca di Cani a ck Moral valve Cantal valve 2 Valve Control ij ON OFF Manually switch solenoid valve 2 e Turn the valve on If time sequence is on record valve start 0 current minute No need to turn off other valves Multiple valves can be on at the same time e Turn the valve off IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 6 BASIC OPERATION 6 31 TIME SEQUENCE e t can happen only when there is no active auto calibration or validation e When time counting is up o Turn off the current valve E Advanced Casar vare Coni H Time Sequence Vale 2 _ Wahe 2 Valve 3 On 1 0 Input the in minutes aad select he nex aream valve Turn on the next valve Start the new time counting Multiple valve time sequences are allowed When configure the parameters please pay attention Time sequence is not recommended to use with remote control at the same time to avoid valve chaos REMOTE CONTROL e The remote initiate contacts are found at TB 2 and the external contact MUST BE VOLTAGE FREE The TDLS200 circuits are low level current monitoring so any externally applied voltage current may cause damage to the analyzer hence use voltage free contact only e t can happen only when no auto calibration or validation is on going e Direct control from DCS and
108. fications and in accordance with the process specifications when applicable NOTE If the process isolation valve flange is excessively hot due to the process temperature or radiant N heat then a thermal insolating flange gasket should be used in order to minimize the heat transfer to the analyzer flange face It is generally beneficial to make the flange of the Launch and Detect Units and the flange of the process concentric with each other Due to the large clearance provided by standard flanges and bolts it is possible to mount the two flanges in an un concentric manner this should be avoided to aid laser beam alignment IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 lt 5 INSTALLATION AND WIRING 5 6 5 5 1 Process Window Purge Gas Connection In order to keep the process windows clean prevent fouling by process gas it is necessary to purge the windows with a clean dry gas of sufficiently low dew point When measuring Oxygen Nitrogen should be used for purging the windows The purge gas or nitrogen should be clean 0 5 particulate dry 40 C dew point oil free The process flanges are provided with two diagonally opposed inlet ports typically 14 OD tube Use Swagelok or equal double ferrule tube fittings and connect both ports with OD stainless steel tubing to the purge gas supply The exact purge gas flow rate will be dependant upon the process conditions that exist at the flange connection and therefore
109. fied for installation and use in ATEX and IECEx for Type Z Purge 11 3 G Ex nA nL pz IIC T6 For Zone 2 gas hazardous areas Certified for installation and use in ATEX and IECEx for Type Z Purge 11 3 G Ex nA nL pz IIC T6 For Zone 2 gas hazardous areas IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 lt 5 INSTALLATION AND WIRING 5 23 Normal Operating Conditions Certified for installation and use in ATEX and IECEx for Type Z Purge 11 3 G Ex nA nL pz IIC T6 For Zone 2 gas hazardous areas Manual Dilution Cycle Time To Typically dilution cycle time is to ensure that at least five 5 Energizing Electrical Equipment times the volume of free space in the enclosure of protective gas supply is exchanged before power is applied to the electrical equipment Ten 10 times volumes for motors generators and other rotating electrical machinery CYCLOPS Z Purge Indicator Green indicator light remains on to show purge pressure being Minimum Pressure maintained above 0 20 inches 20 0 50 mbar in electronics enclosure being monitored N WARNING The number of exchanged volumes may be higher in some situations Refer to TDLS 200 ATEX Purge Warning Labels for Details NOTE Instrument Air and Nitrogen purge gases have different purge time requirement It is important to use clean dry purge gases to ensure the pressure switch contacts do not foul and cause subsequent operating issues i e non functionality of the Cyclops
110. ges and Flow Cells 316 SS Sapphire Kalrez Also available in Monel A400 Hastelloy C 276 Carpenter 20 Titanium Grade 2 and others on request Utilities Instrument Air may be used as a purge gas in principle for all of the below applications but this will depend on the application type and the required precision of the measurement Oxygen Analyzer N CO Analyzer CO Analyzer H O ppm Analyzer 2 N or Instrument Air N or other non CO containing inert gas N with 20ppm levels H O for feed to optional Dryer Package H O Analyzer N 2 Flow Rate e 5 30 L min for window purge 2 L min for validation calibration and optical purge SIL Assessment The TDLS200 has a FMEDA assessment by exida and is classified as a Type B1 device in compliance with the following standards IEC 61508 or EN 954 1 Functional Safety of Electrical electronic programmable electronic related systems SIL 1 capability for single device The TDLS200 is not SIL certified as standard to be certified the unit must be specified and designed from the beginning to meet all SIL specifications Basic System Configuration The TruePeak can be installed in a number of ways depending on process requirements The most typical installation types are shown below however other installation methods are possible please contact Yokogawa with your application details Cross Stack Pipe Configuration Measures directly across process pip
111. h validation ppm Online Validation ASS IM 11Y01B01 01E A 5th Edition Feb 9 2012 00 8 VALIDATION AND CALIBRATION 8 21 s If the validation fails repeat the validation after checking the parameters are correct and ensuring there is sufficient purge gas time If the failure Offline Calibrations is due to a known non related event such as incorrect validation gas value or non functioning valve then the Offline Validations validation alarm can be cleared as shown Online Validations gt gt Clear Validation Alarms 8 6 Performing Automated On Line Validation This will require the appropriate automatic valves solenoid valves and or pneumatically actuated valves tubes and tubes fittings such that the integral on line check gas flow cell can be purged with either normal purge gas typically Nitrogen or the check gas instrument air is acceptable for Oxygen analyzers The analyzer can drive one 24 VDC solenoid operated valve external optional valve or customer supply with a max 10W rating Typical Automatic On Line validation will use one of the following approaches e A 3 way solenoid actuated valve that directly switches between the purge gas typically nitrogen and the check gas e A 3 way solenoid valve that is used to pilot a pneumatically actuated 3 way ball valve e A3 way solenoid valve that is used to pilot a pneumatically actuated manifold style valve such as the Swagelok T series or Par
112. he check gas being introduced application specific The fundamental procedure performed is Introduce the known check gas Enter the know validation parameters via software After purging the check gas flow cell for a period take measurement Re Introduce the original purge gas typically Nitrogen or I A After purging the gas flow cell for a period take a third reading Second measurement The analyzer then calculates what the expected addition should be from the known parameters and compares the Expected Value to the Actual Value and determines a PASS or FAIL situation NOTE It is better to perform on line validations when the process is relatively stable Some processes are very dynamic so it at all possible try to perform the validation during a more stable process operating period This will help ensure the validation is meaningful 8 4 ON LINE VALIDATION OVERVIEW Figure 60 A tunable diode laser emits light energy within a very narrow wavelength range which is controlled by the analyzer itself typically no more than 0 1nm across the entire scan region This therefore allows laser scanning across just one absorption peak and baseline zero absorption regions on either side The analyzer scans this region approximately 1 000 times per second while accumulating the spectra in memory The scanning i e wavelength adjustment is controlled by rapid adjustment of the electrical drive current on the diode itself IM 11YO1BO1 O1E
113. he process flow through the measurement section of the process pipe stack then proceed to shut it off accordingly to facilitate full safe unrestricted access If the process gas cannot be isolated as is typically the case then Process Inspection Port must be used see below next page These essentially replace the analyzer units launch and or detect while maintaining the process window purge integrity to allow for visual inspection of the active process conditions Note The rating is the same as for the standard analyzer max 5 5 Barg 80psig and for gas temperatures above 50 C 120 F window purge gas must be flowing To inspect the launch unit nozzle first the process isolation valve has to be closed carefully while coordinating the shut off of window purge gas flow If the process is operating at negative pressure and the ingress of ambient oxygen is not desirable then the nitrogen purge gas must be maintained as the process valve is closed off Once closed the nitrogen purge gas can be shut off and then carefully relieved from the section between valve and window typically loosen a tube fitting Once the process valve is closed and window purge gas shut off and pressure relieved then the launch unit can be removed from the alignment flange Remove the Allen screw from the lower right position and loosen the remaining three rotate counter clockwise then remove and place carefully on solid location typically the floor dec
114. hen enabled the analyzer up date is approximate twice as fast as normal to allow for faster easier alignment during commissioning or troubleshooting Normal up date time is restored automatically after 30 minutes when the screen saver backlight feature also enables Raw Detector Signal Absorption Spectrum d UL a a ADVANCED CALIBRATE amp VALIDATE MENU OFFLINE CALIBRATIONS allows zero calibration zero offset span calibration transmission adjustment OFFLINE VALIDATIONS allows manual or automatic configuration of check gases 1 or 2 or a separate two gas Offline Validations check ONLINE VALIDATIONS allows manual or automatic ADI CLEAR VALIDATION ALARMS allows the user to clear the validation alarm if the user knows that the analyzer is gt gt Clear Validation Alarms functioning and tuned to correct absorption peak IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 6 BASIC OPERATION 6 16 K OFFLINE CALIBRATIONS ZERO CALIBRATION manual or automatic calibration of Zero Calibration Zero ensure there is no absorption peak feature before performing a zero calibration failure to do so can result is false low readings later when the un desired target gas has been removed ZERO OFFSET allows manual adjustment of Zero by applying Transmission a concentration offset use only with factory guidance TED SPAN CALIBRATION manual or automatic calibration of Span
115. hields to the analyzer chassis Detector Circuit Board Detector Circuit Board main function is to convert detector photocurrent into voltage and send it to be digitized LEDs are incorporated to provide simple diagnostic of available power The board has a temperature sensing chip circuit that monitors the ambient temperature inside the detect electronics enclosure The sensor is located on the top edge of the detect board to ensure the maximum temperature reading is monitored The board is medium size approx 4 H x 6 W printed circuit board that mounts inside the enclosure The field terminations are located along the lower edge of the board via pluggable terminal block All components and devices on the board are designed for extended temperature and low drift operation IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 4 ANALYZER COMPONENTS gt 4 9 4 6 Process Interface An appropriate Process Interface is selected to suit the process stack installation The analyzer is detachable from the process interface to facilitate Off Line calibration and service Process Interface Options There are several systems available as well as custom designs for specific applications e Flanged O Ring Alignment comprises typical 2 or 3 process flange with a large diameter O Ring seal typically used for stack or inert applications that are non corrosive e Flanged Metal Bellows Seal comprises typical 2 or 3 process flange with a metal bellows
116. hten all four screws ensuring the lock washers are in place using a T handle wrench Keep tightening all the fasteners in turn by turns thus ensuring an even torque loading e Hand tighten the screws until they are very firmly tightened a T handle wrench as shown below will torque its own shaft by about turn when the screws are fastened securely IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 7 2 7 ROUTINE MAINTENANCE gt 7 4 Alignment Alignment Studs x4 Analyzer Mounting Flange Alignment Nuts x8 h m Process Flange Window Purge Port x2 Analyzer Quick Connect Alignment Bellows Figure 58 Alignment Mechanism 7 3 Data Reporting Storage and Retrieval The TDLS200 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 Hesults 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
117. ific information about the dust loadings within the process such that a proper evaluation can be made If it is then determined that a reduction in optical path length will have a significant improvement on the transmission level or at least improve it to the point whereby analyzer performance is acceptable then Analytical Specialties will advise further detail on the project specific insertion tube requirements Often the insertion tubes have to be constructed of materials that are compatible with the process media e g acidic corrosive gases may require insertion tubes of Hastelloy C 276 or Monel A 400 4 Weak or No Laser Output a If it has been determined that the process aperture is clear the gas is clean and the system has been fully aligned in all directions and yet there is still little or no transmission then the laser output power may be weak or even dead b There is only one certain method to determine if a laser has lost output power and that is to directly place the detect unit in front of the launch unit as per diagram below Before doing so ensure that both process windows are clean CAUTION The laser diode light source will be exposed when the launch unit is accessible in this way so ensure precautions are taken to avoid direct eye exposure to the laser light Figure 69 IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 9 TROUBLE SHOOTING gt 9 9 If there is any sign of a transmission signal then try adjusting
118. igure 17 Purging for Safe Areas Purging Analyzer for Hazardous Areas e NEC CSA A Class 1 Division 2 Groups A D e ATEX Zone 2 CAT 3 The block diagram below shows the sections of the analyzer that require nitrogen purging A Z Type purge control system is fitted the Main Electronics Housing and it includes a local indicator and pressure switch alarm contacts The purging should be carried in sequence typically as shown below Nitrogen or I A Purge Gas Laser a Detect Module E Module Figure 18 Purging for Hazardous Areas IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 lt 5 INSTALLATION AND WIRING 5 1 5 INSTALLATION AND WIRING PAN Note Detailed Installation Wiring Utility Drawings are included on a Project Basis Please contact Yokogawa for any project specific documentation to ensure correct installation Drawings provided herein are considered for standard installation use only 5 1 Process Measurement Point Considerations The following criteria should be considered when selecting the installation point in respect to the process conditions e Process Gas Flow Conditions Laminar homogenous gas concentration distribution conditions across the measurement point are recommended For circular ducts stacks this condition is generally at least three unimpaired diameters D before and after a process bend For rectangular cross sections the hydraulic ductdiameter D is derived from D 4 x duct cro
119. ine Validation Check Gas 1 Clear Validation Alarms Automatic Check Gas 2 similar to Gas 1 Alarm History Cal History Updated Relative Absolute Warning Fault IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 6 BASIC OPERATION 6 4 Online Menu Level 1 Menu Level 2 Menu Level 3 Menu Level 4 Menu Level 5 Menu Gas 1 Concentration Min Max STDEV of Gas 1 Concentra Minutes tion 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 Display Tex Line 1 Measurement O2 xx x 96 Measured gas and unit of measurement For Gas 1 and or Gas 2 as configured moisture xxx ppm _ Line 2 Transmission or Second Gas Measurement Initializing System OK Normal Operation condition with no active alarms WARNING Det Sig Low WARNING Trans Low WARNING Spectr Noise WARNING Gas Pres WARNING Gas Temp WARNING Gas Level WARNING Board Temp FAULT Laser Temp FAULT Det Sig High FAULT Det Sig Lost FAULT Peak Response FAULT Peak Center Line 3 Status Zero Calibrating Span Calibrating Offline Validating Online Validating Data Transferring Transfer Success Transfer Failure Yokogawa TDLS SN 76 1xxx 05 xx AO1 CONC xx xx96 ppm ppb mg m3 or mg Nm3 AO2 TRANS xx xx96 TEMP xx xxF C K 10 0 0 35 TEMP Act Con Fox
120. ion and IP address you wish to configure Virtual Analyzer Controller Conliguration Password het Verwood pr E T EET ax nil uius VISSZSOUS You will be given the following menu choices Sr YOKOGAWA gt Create Connection F2 This will allow programming of Tag Name xs and IP Address for future connections Virtual Analwror Carntraller Conliguratian rz eiye E38 Delete Connection F3 This is to delete an existing connection Options F4 see next section Diera CN dens Password Ctl Ins Allows changes to the access password Em Luc VAC Options Configuration Menu eee Data Dump Options This sets the directories to receive data from YOKOGAWA amp analyzer and send data to on system running VAC software e Source Directory This is the analyzer data file folder it should not be Virtual Analyrer Controller Co changed without factory consultation Ota Carp Options Target Directory This is the remote computer or RIU directory to rece Director E receive data files Target i File Masks These are the extensions of the files to be transferred it pia p should not be changed without factory consultation VG Viewer Locaben VNC Viewer Location specifies the location of the software to Appr remotely control analyzer it should not be changed without factory
121. ion Feb 9 2012 00 alarms alarms calibr calibr his bak his bak Alarms History A historical log of analyzer alarm events Alarms History Back Up A back up of the historical log of analyzer alarm events Calibration History A historical log of analyzer calibrations Calibration History Back Up A back up of historical log of analyzer calibrations 10 DATA FILES AND FORMAT gt 10 2 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 DDYY YY 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 larm History Back up When the alarms 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 can then be copied and pasted into Microsoft Excel spread Each Alarm inci dent 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
122. its 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 Oxygen present in the Instrument Air purge may exist in several section of the optical path including Inside the Launch unit body laser module section Inside the Launch unit body online validation cell Inside the Launch unit alignment flange Inside the launch side process nozzle and valve Inside the Detect unit body Inside the Detect unit alignment flange Inside the Detect side process nozzle and valve It is important that these dimensions are known as they will need to be programmed in if in doubt please contact Yokogawa Laser Analysis Division 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 IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 6 BASIC OPERATION 6 20 ADVANCED CONFIGURE MENU UPDATED The Advanced Configure Menu has been updated with a sub section titled Non Process Parameters NON PROCESS PARAMETERS m These non process parameters are for the measured ga
123. ixed in the supplied analyzers These analyzers are factory calibrated and Therefore the H Oppm in Natural Gas analyzers DO NOT require actual field calibration by end users they can however be Validated Calibration procedure described in the standard TDLS200 User Guide is intended for the different measurements techniques of data processing and must not be used in these units If applied to these H O NGas analyzers it will disrupt the file system with unpredictable erroneous results requiring factory assistance to restore proper functionality At all times the analyzer internal optics must be purged with dry nitrogen lt 0 25 ppm H O content Any moisture present within the analyzer internal optics purge gas or on validation cell purge gas will be added to the actual process gas measurement of H Oppm DO NOT ZERO or SPAN CALIBRATE THE ANALYZER without prior written approval from the Yokogawa Laser Analysis Division Factory Validation response check of the analyzer can be performed in two possible ways 1 Off Line Method interrupting process flow through the cell A pure dry 5 ppm H O methane 100 CH validation gas can be supplied to the flow cell at same flow conditions 50 C and 30 psig analyzer readings for CH must be 100 2 Note at this time the analyzer will also indicate any value of residual moisture in the pure dry methane validation gas standard 2 On Line Method no interruption of process flow through the
124. ker R Max or even NESSI platforms IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 8 VALIDATION AND CALIBRATION 8 22 Analyzer Purge 7 NC Online Check Gas N Gas Inlet Flow Cell Inlet TYP 2LTS min Max 3 psig TYP 2LTS min Figure 63 Automated On Line Validation electric solenoid valve Analyzer Purge NO SK NC Online Check Gas N Gas Inlet Flow Gell Inlet TYP 2LTS min Max 3 psig TYP 2LTS min NO NC Je A or N vent SOV Figure 64 Automated On Line Validation pneumatic solenoid valve Before proceeding with an automatic validation sequence ensure all settings are correct IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 8 VALIDATION AND CALIBRATION 8 23 Types of Validation Reading There are two different ways in which the validation reading can be s T kivanom alib alog E Falc Va biyan Analyzer Heading Der Bass Celine Walden Analyrer Reading During validanon Validation Reading Validation Reading Validation Only Validation Only Process Validation Process Validation Sel cll analyzer reading melthad dur ng cele validation amp modify conc output factor select analyzer reading method during online validation amp modify conc output factor Validation Only When this method is selected the analyzer will calculate AND output the result as the actual gas value e g instrument air
125. king CAUTION the process isolation valve may leak so observe any local safety procedures associated with the particular process unit area Mount the Process Inspection Port install the lower right Allen screw and securely fasten all four screws Connect the purge gas tubing and start the purge gas flow while opening the process isolation valve Using a flash light the process nozzle can now be viewed through the window Use the reverse procedure to remove and re install launch unit IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 9 TROUBLE SHOOTING gt 9 7 h Use the same procedure for the detect side however use CAUTION because the launch unit laser diode source will now be visible if the analyzer is still powered on through the detect side window laser source is inside launch unit body i Remove any obstructions in the nozzles in accordance with any local standards procedures If the obstructions are a re occurring event then please contact your local agent or Yokogawa for advice on how to prevent reduce the events j Some typical remedies for nozzle obstructions include i Increasing the window purge gas flow pressure ii Using smaller bore nozzles inserts ii Using insertion tubes also with smaller bore iv Insulating the nozzles to reduce cold spots v Any combination of or all of the above vi Worst case relocate the analyzer to a cleaner location e g downstream after an ESP after a knock out drum after a fi
126. l shield The cable specifications are as below Number fo Pairs Total Number of Conductors wa Conductors Inner Shield Aluminum Foil Polyester tape 10096 coverage with 20 AWG tinned copper wire drain Insulation F R PVC Flame Retarding Polyvinyl Chloride Outer Shield Aluminum Foil Polyester tape 100 coverage with 18 AWG tinned copper wire drain Outer Jacket F R PVC Flame Retarding Polyvinyl Chloride Wall thickness 0 053 1 35 mm Typical 0 47 12 mm outside diameter Operating temperature 22 to 221 F 30 to 105 C Min Bend Radius 5 127 mm Applicable Standards NEC UL PLTC ITC CMG Flame Test UL1581 FT4 IEEE 1202 amp ICEA T 29 520 Power Limited Tray Rated Cable Nom Conductor DC resistance 20 C Nom Outer Shield DC resistance 20 C Max Operating Voltage UL Conductor Identification Typical Manufacturer amp Part No The maximum cable length should not exceed 150 ft 46 m Please ensure that the Launch to Detect cable is properly terminated and that all grounding and shielding details are correct per installation drawings Espically important for CE A TEX installations IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 4 ANALYZER COMPONENTS gt 4 11 4 8 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
127. le horizontal position Repeat steps b through d again to ensure maximum transmission level If transmission is still limited then the issue could be with associated with the actual mechanical installation It may be that the nozzles and or flanges attached to the process are in fact out of tolerance 2 Quality of Clear Aperture through Process Sometimes the original clear aperture through the process can become impaired fouled plugged see image to left by material deposited from the process gas inside the nozzles The deposits are usually solid formations crystalline formations from cooled vapors created when the cool purge gas mixes with the hot process gas and or very sticky viscous tar like substances that may have to be mechanically removed a After having optimized alignment per above the launch and detect units should be removed to facilitate an inspection of the process nozzles b If the installation incorporates Process Isolation Flanges see image and diagram below then the analyzer and alignment flanges can be removed and the nozzle insides can be inspected without compromising the process seal IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 9 TROUBLE SHOOTING gt 9 6 Sa mss pE Tug EAT alga I H ae 8 5 4 BESTE md Figure 66 Insertion tubes with insulation materials dimensions etc are specified to suit each different application If possible to isolate t
128. lter scrubber etc Figure 67 Insertion tubes with insulation materials dimensions etc are specified to suit each different application 3 High Particulate Loading oome process streams contain high quantities of dirt dust particulate matter that will reduce the level of laser light that can reach the detector Typically this information is known in advance of analyzer installation and should generally be accounted for during the design engineering and specification phase of the project The Application Questionnaire asks for this process information Sometimes it may not be known what the levels are and the analyzer may be tried on the application anyway Some processes such as waste incineration thermal oxidation etc will have varying levels of dirt dust particulate The only proven method for improving transmission through these particulate laden processes is to reduce the path length and ensure a good purge is functional Insertion tubes up to 8ft long each have successfully been used in coal fired power plants for several years typically on ammonia slip measurements after the SCR but before the ESP IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 9 TROUBLE SHOOTING gt 9 8 31504 ANSI FLANGE 316155 BORE THROUGH FLANGE AND WELD um SCH 40 HASTELLDY C 2 76X12 3 B 11 X L 5 STUDS WELDED ON 6 0 BOLT H LE CIRCLE STRADOLE CENTER LINE 3161 55 TYP 8 Figure 68 Please consult Yokogawa with spec
129. ly avoided by routing the 4 pair launch to detect cable away from electromagnetic interference sources that could exhibit these parameters Such sources might include power transformers electric motors electric welding machinery high voltage power lines etc Analyzer grounding wires and any other I O lines such as 8 pair launch to utility panel cable or A I O cables to from the DCS should also be installed with similar basic practices to also ensure there is no additional adverse influence on any of the I O signals Launch Unit to Detect Terminations TB 7 ensure 360 cable shield ground T ari y 0 Detect Unit to Launch Terminations TB 7 ensure 360 cable shield ground IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 lt 5 INSTALLATION AND WIRING 5 17 Launch and Detect Unit Wiring Standard GP Div2 CE ATEX Launch Unit to Detect Terminations at TB 7 SEE TERMINATION DETAIL ABOVE I I pj l I I CO I x NOTES DN ISOLATE PAIR 4 WHITE CONDUCTOR DO NOT TERMINATE DO NOT GROUND ISOLATE INDIVIDUAL SHIELDS DO NOT TERMINATE DO NOT GROUND OVERALL SHIELD TERMINATED AT CHASSIS OVERALL AND INDIVIDUAL SHIELDS TWISTED TOGETHER TERMINATE ONE WIRE AT 7 8 TERMINATE REMAINDER AT CHASSIS IM 11Y01B01 01E A 5th Edition Feb 9 2012 00 lt 5 INSTALLATION AND WIRING 5 10 3 Launch Unit Terminations CE ATEX G
130. lyzer 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 After selecting Connect F2 you will be allowed to select the analyzer with description and IP address you wish to control remotely This will allow full analyzer control as if you were at the analyzer itself Please remember that when you have finished working on the analyzer via this RIU VAC software you must END SESSION to the analyzer by pressing the Control Backspace keys simultaneously DO NOT SHUT DOWN analyzer 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 NOTE Please ensure there is a clean or empty SanDisk USB memory stick inserted into either of the two USB ports of the RIU When copying data from an analyzer via the RIU a dedicated folder with the serial number is NOT created the data files are dumped to the root directory of the USB stick IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 6 BASIC OPERATION 6 39 ee T m wi After selecting Configuration F4 you will be asked to Enter Password the default password is 1234 then press F2 to proceed YOKOGAWA B and then you will be allowed to select the analyzer with descript
131. m client system to Analyzer e Onthe computer go to Control Panel Network Connections Local Area Connection Internet Protocol TCP IP Properties 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 i t SBC Ethernet Por er t ae I 4 i E a e b M 8 l i J y 4 LE l1 4 Aor ee 4 rte 4 Ceeoat a 4 lt 2 E severe i 45 mbou H bad Figure 55 Connecting External Computer to the analyzer IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 6 BASIC OPERATION 6 36 6 9 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 2 14 for an ana lyzer Serial number XX 1214 XX etc For analyzers with Serial Tracking number XX 2xxx xx use IP address 10 0 20xx for example 76H 2018 12 Ex would have an IP address 10 0 20 18 F
132. m the calibration or escape to cancel Note the concentration that is being displayed and up dated in the lower box is the currently measured value before the calibration is performed After calibration please check the results and consult with Yokogawa if any questions or concerns IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 8 VALIDATION AND CALIBRATION 8 8 7E hdwaseed Calibrate amp Validate Span Calibration Ensure reading is stable before calibration Analyzer will be span calibrated to 22 0096 O2 Press 9 to proceed or press ESC to cancel O2 Concentration 9 If there is reason to restore either a Span calibration then please follow the on screen instructions 75 Adhsanced Calibrate amp Validate Am EJ danced Calibrghon B Wakdaton toan 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 For Automatic Off Line Calibrations used only on extractive applications please follow the on screen instructions IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 8 VALIDATION AND CALIBRATION 8 9 7H Advanced Calibrate amp Validate Manual Ensure analyzer is purged with nitrogen Gi Advanced E Validate Aaa m n E v ace Airm T Advanced Calibr
133. mance of the instrument or losses Iresulting from such if the problems are caused by e Improper operation by the user e Use of the instrument in improper applications e Use of the instrument in an improper environment or improper utility program e Repair or modification of the related instrument by an engineer not authorized by Yokogawa Drawing Conventions Some drawings may be partially emphasized simplified or omitted for the convenience of description Some screen images depicted in the user s manual may have different display positions or character types e g the upper lower case Also note that some of the images contained in this user s manual are display examples Media No IM 11Y01B02 01E A 5th Edition Feb 2012 YCA IM 11Y01B01 01E A 5th Edition Feb 9 2012 00 All Rights Reserved Copyright 2012 Yokogawa Corporation of America Safety Precautions Safety Protection and Modification of the Product e norder 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 If this instrument is used in a manner not specified in this user s manual the protection provided by this instrument may be impaired e f any protection or safety circuit is required for the system controlled by the product or for
134. meters used in the oxygen concentration calculation are the optical path length gas temperature and gas pressure These known parameters are pre determined and programmed into the analyzer If the process gas temperature and or pressure are varying under normal operation then these values can be actively input via process transmitters In this case the analyzer uses active values for the gas temperature and or pressure and a pre pro grammed value for the optical path length wg T IDgcesaugs Specta amp gt 1 wm Crome Cou Tt aem EN 27 f yen Che m E Press ENTER to capture the spectrum o LS NET Press ENTER to capture the spectrum Absorption Spectra No Oxygen present Absorption Spectra Oxygen Present IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 8 VALIDATION AND CALIBRATION 8 16 Instrument Span Drift The analyzer does not contain measurement components that can wear decay and generally drift in one direction These are items that are used in conventional analyzers that determine the requirement for routine span gas calibrations With TDLS analyzers the measurement drift is limited to essentially optical elements only and these effects are fixed values The amount of drift does not change over time as the actual optical elements do not change The changes within the optical elements that cause the drift relate to dimensional changes under varying
135. meters will have to be implemented 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 The process interface may also require purging to maintain clear windows refer to Process Window Purge details separately AN NOTE Please also refer to any separate Purge System Original Manufacturers Operating Instructions and Manuals in conjunction with this User Guide The Purge Systems are not manufactured by Yokogawa Laser Analysis Division Please also refer to separate detailed manufacturer s instructions and start up information for any Zone 1 or Division 1 automatic purge controller unit operational details Failure to follow the manufacturer s guideline can result in damages and or non functionality of the purging system IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 lt 5 INSTALLATION AND WIRING 5 20 5 11 1 Purging Analyzer for Hazardous Areas with On Line Validation e NEC CSA Class 1 Division 2 Groups A D e ATEX Zone 2 CAT 3 Dual regulators must be used on the inlet The block diagram below shows the sections of the analyzer that require nitrogen purging Z Type purge control system is fitted the Launch Unit and it includes a local indicator Bright Green rugged light and pressure switch alarm contacts open on loss of purge pressure The purging should be carried in sequence typically as shown below All purge gas
136. n Feb 9 2012 00 4 ANALYZER COMPONENTS gt 4 6 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 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 Optional 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 Backplane Field Terminal Blocks TB1 24VDC Power input 80 w and optional purge power TB2 Remote Initiate Validate calibrate and or streamswitch TB3 Solenoid Valve s Drivers max 11 w each 924 VDC TB4 Alarm Contacts Warning amp Fault Form C TB5 Alarm Contacts user amp optional Purge Form C Purge is closed on pressure TB6 Ethernet TCP IP 10 100 TB7 Launch Control to Detect Interconnect TB14 Remote Mini Display Analog I O Board e 8 Analog Outputs three 4 20mA isolated e B9 Analog Inputs two 4 20mA powered or loop powered Optional Feed through Board URD only e B10 Ethernet to remote Analyzer via Interconnect Cable e B11 to remote Analyzer via Interconnect Cable e B12 Local Connection
137. n ppm 1 0 Enter in the concentration of the Check Gas 20 996 for instrument air Oxygen analyzers only If using a cylinder Enter check gas pressure psia of cal gas then check the cylinder certification label and its 14 70 expiration date to be sure Enter check gas temperature 78 49 Enter check gas length inch Check gas H20 concentration ppm Press ENT to proceed IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 8 VALIDATION AND CALIBRATION 8 20 Wait for the reading to stabilize Calbratoe Online Check Many processes are dynamic but judge for yourself when you believe the check gas has fully purged the integral check AMI ULL I 12 flow cell typically at least one minute depending on the sns EXT An CE location of the switching valve Press ENT to proceed H20 Concentration ppm a ye Mem Re apply the original purge gas typically Nitrogen and again wait for the reading to stabilize as the check gas is being purged from the check gas flow cell Remove check gas and input N2 again Press ENT to proceed After the reading is stable for at least one minute press ENT to see the validation result H20 Concentration ppm 6 EN CNN l LEM Observe the on screen results If there is some doubt about the result the Validation may be performed again as many times as Average Processing Gas ppm required Expected Reading with validation ppm Actual Reading wit
138. ndard analyzer is designed for operation in a Safe Area General Purpose The addition of a Purge System facilitates operation in Hazardous Areas in accordance with the relevant UL CSA and ATEX standards for gaseous releases The basic TDLS200 analyzer comprises two units the Launch Control Unit and Detect Unit Various Process Interface configurations are available for connecting the analyzer to the measurement point Several options may be added to the standard analyzer such as Mini Display 6 5 screen and keypad Display sun shield Optional Universal Power Supply with or without a Mini Display e Remote Interface Unit not required for normal operation e Hazardous Area purge systems e Other options may also be added 2 1 Functional Description Tunable Diode Laser Spectroscopy or TDLS measurements are based on absorption spectroscopy The TDLS200 Analyzer is a TDLS 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 TDLS analyzer consists of a laser that produces infrared light optical lenses to focus the laser light through the gas to be measured and then on toa detector the detector and electronics that control the laser 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
139. ndicating LED to stop blinking flashing for at least 5 minutes to ensure the transfer is complete IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 Revision Record Manual Title Model TDLS200 Tunable Diode Laser Spectroscopy Analyzer Manual Number IM 11Y01B01 01E A Edition Date Remark s T April 2008 Newly Published April 2009 Revisions Formatting was corrected 3 April 2010 Revisions General specifications page 3 were added to the document and dimensional drawings were added August 2011 Revisions Dimensional drawings in section 5 9 were corrected and updated Caption titles and figure numbers were added to all figures within the document Page 4 and page 5 specifications were added 5th Feburary 2012 Revisions Quick start section 1 was modified Section 2 added note about area classification Section 2 1 corrected the power range statement Data plate information in section 2 2 was updated Section 4 3 corrected Figure 7 valve relay diagram updated Field terminal block indications Section 4 6 Added process Interface option 7 Reformated Section 5 amp updated area classification information Added Seciton 5 12 Updated software basic structure information 9 Deleted section 7 3 Analog Signal field Loop check and made section 7 5 Validation and Calibration its own Section now becoming Section 8 10 Removed section 8 3 1 amp 8 4 11 Removed Sections 4 10 4 13
140. nificant effect on the absorption line intensity typically weaker absorption at higher temperature for oxygen However there are several oxygen lines whose absorption intensity has different temperature response By simultaneously comparing two oxygen lines with different temperature effect on absorption intensity we can calculate the gas temperature IM 11Y01B01 01E A 5th Edition Feb 9 2012 00 6 BASIC OPERATION 6 34 The following graph illustrates an example At 800 degC there are two oxygen absorption peaks and their ratio is 8 6 At 1500 degC the left oxygen absorption peak increases while the right peak drops significantly The peak ration is 2 2 So by calculating the peak ratio of these two oxygen peaks the gas temperature can be predicted Figure 54 The requirements for accurately predicting process gas temperature with high temperature oxygen analyzers e Gas temperature should be higher than 750 C so it s ideal for combustion zone gas applications typical measured range 750 1 500 C 1380 2 730 F e t needs sufficient oxygen absorption so longer path length and or higher oxygen levels are preferred contact Yokogawa Laser Analysis Division with application details 6 9 Controlling the Analyzer Remotely or Locally via external PC Laptop A number of methods are available to connect to the TDLS200 analyzer Direct Access with optional Keypad and Display Direct Access using VNC and an external computer Etherne
141. nput 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 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 IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 4 ANALYZER COMPONENTS gt 4 4 Watchdog 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 1 Q 24VDC 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 Remote Validation Remote Calibration Initiation A validation 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 moni
142. nter in the correct optical path length 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 range Control mode is not applicable to TDL S200 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 Active ambient and Active Peaks may also be used refer to project specific and application specific details 9 3 9 Control mode is not applicable to TDL S200 co Configure the system I O by entering in to the System I O sub menu in Configure If the 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 and Calibration Modes co N N Configure Digital outputs Warnings and Faults Many of these will be factory preset so if unsure about any settings then leave as Factory Default Select and set level for Alarm Limit to either the Measured Gas orTransmission Go to the Data screen and set the appropriate parameters for and Spectrum Capture These will ensure the analyzer stores important information during operation that may be used to verify operation status di
143. nually applied to the electrical equipment The number of exchanged volumes may be higher in some situations After the manual dilution time cycle has elapsed and the monitored electronics enclosure pressure is being maintained above 0 20 inches H O 0 50 mbar power may be manually applied to the electrical equipment within the purged electronics enclosure The CYCLOPS Z Purge Indicator is designed to indicate the presence of purge pressure from one pressure reference point Several electronics enclosures can be installed in series with purge gas being introduced into the first electronics enclosure and the CYCLOPS Z Purge Indicator monitoring the last electronics enclosure in the series multiple electronics enclosures can now be monitored using only one CYCLOPS Z Purge Indicator The pressure inside the monitored electronics enclosures must maintain at least 0 20 inches H O 0 50 mbar higher than the atmospheric pressure surrounding the electronics enclosure This ensures that hazardous materials are not going to ingress into the pressurized and now protected electronics enclosures If any of the electronics enclosures installed in the series door is opened pressure will show to be below the required 0 20 inches H O 0 50 mbar in all electronics enclosures The exhaust vent which comes as part of the CYCLOPS Z Purge Indicator casing can exhaust purge gas from enclosures with volumes up to 15 cubic feet 425 liters Cyclops Features Certi
144. oard Outputs land on TB8 and Inputs land on Connect any other equipment such as URD Ethernet solenoid valves digital I O etc Check terminations and ensure all cable shields landed per supplied wiring details NOTE All purge Validation Gas and other gas utility lines should be thoroughly cleaned dried and purged prior to connecting to the analyzer Failure to do so can result in serious damage to the TDLS200 or contamination to the internal optical elements 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 ATEX purge requires dual regulators at the inlet purge gas supply to prevent overpressure damage in the event of a single regulator failure Connect the appropriate process window purge gas nitrogen for oxygen analyzers and make site connections per the supplied purge gas sequence details Start the window purge gas flow accordingly ensuring that any isolation valves are open Connect the appropriate analyzer on line check gas flow cell gas nitrogen for oxygen analyzers and make site connections per the supplied purge gas sequence details Start the purge gas flow accordingly Connect and check any other required utility connections such as steam trace for heated isolation flanges or flow cells or secon
145. oard temperature out of range Fiberglass enclosure with powder Validation failure coated steel frame Faults include Laser temperature out of range Heat tracing and insulation for flow cells Detector signal high and sample handling Detector signal lost 316SS and or Monel A400 wetted parts Peak center out of range other on request Output Settings Sample handling and conditioning Analog Output Channel 1 systems to suit applications Channel 2 Stream switching manual or automatic Channel 3 controlled by analyzer Warning Mode Fault Mode Note Custom configuration available to suit customer requirements Field Loop Check AO CH calibration IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 3 GENERAL SPECIFICATIONS gt 3 3 Performance Specification Precision Application Dependent Linearity Typically R 0 999 Response time 5 seconds plus transport time for extractive systems when applicable Drift Application Dependant Installation Specifications Hazardous Area Zone 1 Contact Yokogawa Zone 2 ATEX group II Cat 3G with purge system EEx pz II T5 20 Ta 50C By Design Class 1 Grp B C amp D Division 2 or Division 1 Purged Maximum Distance between Launch and Detect 30 m 90ft Maximum interconnecting cable 50m Wetted Parts Analyzer amp standard Alignment Flange 316 SS BK 7 Glass Teflon encapsulated Viton and Silicone RTV sealant Optional Isolation Flan
146. od but please ensure it is returned to normal rates An example could be the monitoring of a dirty process whereby transmission becomes very low during certain known process operating conditions The spectrum capture rate could be changed to 2 for a 1 hour per period when these conditions exist and then set back to 200 300 after This then gives a lot of spectrum data to review for the specific operating conditions IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 6 BASIC OPERATION 6 18 6 3 Non Process Parameters Non Process Parameters is the Yokogawa Laser Analysis Division term used to define regions of the optical path that may be purged with a gas containing the actual target measured gas The most common application of this is to use Instrument Air 20 9 as the purge gas for analyzers measuring Oxygen in the process Another common use of this feature is Line Locking whereby some target gas typically 96CO for CO CH4 combustion analyzers is locked into the validation cell at all times and therefore its absorption contribution must be accounted for The valve functionality of Line Locking has four stages as shown below Figure 51 IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 6 BASIC OPERATION 6 19 If measuring CO in the process gas and the purge gas is Instrument Air then these parameters are not applicable because the CO concentrations typically found in Instrument Air are below practical detection lim
147. 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 cutout measuring 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 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 20 to 80 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 Hemote Calibration Initiation Calibration Valve Driver Relays Laser Temperature and Current Control Board temperature DC Power I
148. omatic Automatic has selections for Local Initiate Remote Initiate Time Initiate as well as Settings for these options CHECK GAS 2 allows user to select and configure the on line validations for check gas 2 The configuration options include Manual or Automatic Automatic has selections for Local Initiate Remote Initiate Time Initiate as well as Settings for these options ADVANCED DATA MENU ALARM HISTORY shows chronological list of analyzer s most recent alarms 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 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 CAUTION By setting a high spectrum capture rate i e a low number between up dates the memory can very quickly fill up and because the system uses a First In First Out basis you may lose many data files for results res and spectrum spe As a guide spectrum is captured every 200 300 up dates and 1 5 every Warning and 1 5 every Fault The spectrum capture rate can be increased by lowering the up dates value on a short term basis for a particular monitoring peri
149. on 75 100 level to ensure correct mounting and alignment Note there is no means for alignment adjustment when mounted to the calibration cell other than as noted below Connect all purge tubes as required see below and leak check accordingly note that any haz ardous gases CO 25 CH4 etc should be vented to safe area in accordance with any local requirements Note any leaks can cause erroneous results and can present hazardous situations IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 8 VALIDATION AND CALIBRATION 8 4 Procedure for Alignment Optimization on Calibration Cell The launch unit should be adjusted so that the transmission is maximized for off line calibration 2 Ensure launch unit alignment nuts are securely fastened so that the launch unit cannot move it s alignment position 3 o optimize the detect unit alignment make small adjustments in alignment nuts of detect alignment flange while increasing the transmission value 4 When the transmission value is maximized observe the Raw Detector Signal to ensure the initial 20 data points are at the baseline condition i e flat data points Basic Spectra Raw Detect from 0 20 5 f the value of these 0 20 data points decline i e not a flat line then this is an indication of some small misalignment of the system 6 see POOR alignment example right Carefully make small adjustments in the alignment of launch unit to minimize the slope at
150. on the detector board R21 R22 R23 PROCEDURE 1 This procedure requires wearing a grounding strap connected to one of the grounding lugs of the analyzer to prevent any electrostatic damage 2 Open the detector enclosure and put on a grounding strap 3 Identify the gain resistors R21 R22 and R23 on the detector board as shown in the photo above They are all plugged in sockets instead of being soldered easy to be modified by a pair of small pliers The existing gain resistors have factory resistance values optimized on a calibration cell IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 6 BASIC OPERATION 6 29 Optional For a high process temperature application and if the current process temperature is higher than 600 C apply a multi meter to measure the voltage across R21 If the measured voltage absolute value is greater than 5V change R21 to the 1000 resistor from the resistor bag Keep the original R21 in the resistor bag as it can be used for future offline calibration Remove R22 and R23 from the detector board and replace them with the 11k resistors from the resistor bag Please keep the original R22 and R23 in the resistor bag as they can be used for future offline calibration Optimize the analyzer alignment for both the launch and detector sides Stop the alignment if Detector Signal High fault activates In the TruePeak user interface software navigate to Advanced Menu password gt Configure gt L
151. ons compensation factors I O configurations Valve control configurations signal processing etc This file is used by FACTORY PERSONNEL ONLY to evaluate if the configuration is appropriate for the analyzers intended use his System History oystem Configuration History in the form of A historical log of ASCII data files that can be opened with Microsoft configuration changes Notepad as simple txt file formats The content can then be copied and pasted into Microsoft Excel spread Each configuration change is logged with the date MM DD Y YY Y and time that it occurred the parameter e g opl and the new value Also whenever the analyzer is startedup 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 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 10 DATA FILES AND FORMAT gt 10 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 The content can then be copied and pasted into Microsoft Excel spread Each configuration change is logged with the date MM DD Y YY Y and time that it occurred the parameter e g opl and the new value Also whenever the
152. or analyzers with Serial Tracking number XX 3xxx xx use IP address 10 0 30xx for example 23 3007 13 Ex would have an IP address 10 0 30 7 N DO NOT attempt to change of the Quick Options or any other settings on this menu Connection MR VNC Sever MIAE hast display host port Quick Options f AUTO Auto select best settings cornea ULTRA gt 2M bits Experimental Cancel t LAN gt TMbite s Max Colors t MEDIUM gt 128K bits Max Colors C MODEM 19 128K bites 256 Colors SLOW lt 19kKE bits 256 Colors Fuzzy View Only Auto Scaling Options Use D5MPlugin No Plugin detected Contig ProxyRepeater If the analyzer connection cannot be established see error message below then check the PC IP settings connection wires Cat5 cable and IP address VNC Viewer Status for 10 0 2 14 Connection WHE Server 10 02 14 Part 830r Status Connecting Ultr VNC Info A Failed to connect to server Encoder Speed 123 kbit s Traffic Bytes Sent OK ae Lak Bytes Hecerveed 0 Cancel IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 6 BASIC OPERATION 6 37 6 9 3 OPTIONAL Remote Interface Unit RIU The OPTIONAL HIU runs the Virtual Analyzer Controller VAC software described below 6 9 4 Virtual Analyzer Controller VAC Operating Software Map VAG Connect Select amp Session Connect Select amp Star
153. otomeaphere may be a D nal open when aneargized e Harari purged with Nilrogen MOTE Max Analyzer input pressure im O2 bart 4inch O IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 2 INTRODUCTION AND GENERAL DESCRIPTION 2 4 Ay CAUTION For Cleaning of the labels and LCD window please use wet cloth to avoid electrostatic condition NOTE ATEX Hazardous Area Operation Product MUST NOT be used in Zone 0 CAT 1 locations Product MUST NOT be used in Group Dust Grain locations Product MUST NOT be used in Group III Fibers locations Conditions of Certification On loss off purge an alarm shell be made to inform the user action shall then be taken by the user to ensure continued use is safe A functional test shall be carried out in accordance with clause 17 1 of EN 60079 2 2007 to verify the parameters of the Purge Control Unit when fitted A leakage test shall be carried out in accordance with clause 17 2 of EN 60079 2 2007 The manufacturer shall record and retain these results Only Lithium batteries specified in manual are to be used in this enclosure Special Conditions of Certification A suitability certified Purge Control Unit must be sued with the TDLS Analyzer that is capable providing the requirements listed on label certificate and that either provides a suitable exhaust through a particle barrier of to a safe area When installe
154. pectrum and coefficients at Calibration The factory calibration which can also be ume prem restored in the analyzer is named zero10 calibrations zero10 system las System Laser Laser related parameters for production service and At the time of current down troubleshooting including load Serial Number of module Laser temperature Ambient T Comp curves Thermister parameters Laser drive current parameters Laser temperature out of range Fault settings Laser driver resistor R18 for VCSEL R76 DFB memory res File Size Management FACTORY PERSONNEL ONLY used by for Results TruePeak software to manage the res files memory res File Size Management FACTORY PERSONNEL ONLY used by for Spectra TruePeak software to manage the spe files IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 10 DATA FILES AND FORMAT gt 10 5 10 1 Configuring Data Capture T Advanced Menu mi Select Data Expart data view laser detector Calibrate amp Validate information automatic spectrum capture sittings 53 To select the Spectrum capture stay in Advanced Menu user mode and the Data sub section select Spectrum Capture Alarm History Cal History Spectrum Capture To store spectrum automatically select Automatic If Advanced Data Spectrum Capture you do not wish to store any spectrum file during normal analyzer operation then select Manual mode Capture Mode Automatic Manual Pr
155. perture Optics ensure the detect system is correctly mounted and purged to prevent damage to the large optical element 2 2 Carefully mount the Launch and Detect Units to their alignment flanges using the quick connect coupling 2 3 Mount optional equipment such as Universal Power Supply UPS Universal Remote Display URD Remote Interface Unit RIU etc Ambient The analyzer and some accessories such as LAO RIU UPS URD alignment flanges etc are Temperature suitable for 20 to 500C ambient operating temperature Accessories and Options are available to increase these the operating conditions please consult Yokogawa for further details Ensure that all wiring will enable the analyzer launch and detect units to be freely moved from their process location to an adjacent off line calibration cell This will entail the use of tray rated cables and or flexible conduit and or other suitable armored cable Rigid conduit systems are not recommended Connect the appropriate electrical power supply e 24VDC to TB1 on the analyzer launch Unit backplane Check that the actual voltage is gt 23 5VDC otherwise the SBC and other devices will not function 110 240 50 60 Hz to UPS or URD then take 24 VDC to analyzer Connect the Launch to Detect interconnect cable supplied with analyzer according to the supplied wiring detail TB7 on the Launch and TB 13 on the Detect Unit Connect any analog I O signals to the analog I O B
156. placed such as laser module or FPGA board If the Zero reading appears incorrect then ensure all data results and spectra have been stored and send the files to Yokogawa Laser Analysis Division for further evaluation Apply zero gas using the appropriate gas flow path as show 1 CAPPED PORTS 2 ZERO GAS NITROGEN gt 99 3 SPAN GAS INSTRUMENT 4 ALL GASES MUST BE DRY 70 F DEWPOINT CLEAN 5 MICRON AND OIL FREE 5 ALL GASES ARE APPLIED AT 2 SLPM IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 8 VALIDATION AND CALIBRATION 8 6 Advanced TE Advanced Calo rate Cbron 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 cance this calibration H20 Concentration ppm 15 After Zero calibration is completed double check the absorption spectrum to ensure there is no ab sorption peak present or that there is no negative absorption peak indicating that the zero gas had not fully purged the optical path Perform the zero calibration again in either case or check with your local Yokogawa representative If there is reason to restore either zero calibration then please follow the on screen instructions Fj Advaacod Validate Am tj A
157. r 7 Fass i i i a Figure 57 Window Cleaning IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 7 ROUTINE MAINTENANCE 7 3 7 1 2 Replacing Windows If the windows are contaminated they may be cleaned using the following procedure e ftheanalyzer has not yet been shut down then please shut down the analyzer properly and remove power to ensure the laser if OFF e Remove Launch or Detect as appropriate from the process interface by removing the one fixed hole fastener 5 32 Allen Wrench loosening the remaining three fasteners and then twisting and pull off the unit e Remove the four retaining screws 3 32 Allen Wrench T Handle and lock washers from the window holder recessed inside the quick connect body e Remove the window that requires replacement Ensure the new replacement window is of the same specification as the window being removed Standard Windows are 0 25 Thick wedged BK 7 borosilicate crown glass mounted in stainless steel retaining ring e he window holder assemblies can only be installed in one way by virtue of the mounting hole placement e Ensure a new O Ring of same specification is installed at the same time Viton is the standard material however certain applications may require other materials check original specifications e With the new O Ring in position carefully locate the new window holder in place with the smooth glass surface against the O Ring e Carefully tig
158. r diode is permanently attached to the module Collimating Lens is an optical Window component that collimates the diverging light source 4 4 Check Gas Flow Cell for On Line Validation and or Module gt Line Locking E Flow Cell The Check or Check Gas Flow Cell is a short chamber that exists between the laser collimating lens and the standard Process isolation window The cell is sealed with double O rings and is in series with the measurement optical path The body has two Figure 11 Check Gas Flow Cell owagelok style tube fittings welded on that serve as inlet and outlet ports for the nitrogen purge gas or calibration check gas as appropriate The Check gas flow cell is used for performing on line validations or Dynamic Spiking while the analyzer is mounted on the Process This feature allows for the analyzer to be validated without removing it from the Process location By introducing a gas of known target gas concentration at a given temperature and pressure the analyzer can determine if the Validation routine has been PASSED or FAILED This cell can also be used for Line Locking applications such as 96CO for combustion applications Refer to Non Process Parameters for details of how to configure the software when implementing a line locking application Please also refer to project specific drawings for detail of how to configure the tubing valving when implementing line locking The various parameters that enable the
159. r in some combustion applications measure CO and lock onto an adjacent H O peak There are two wavelength regions that need to be mathematically manipulated for an absorption spectrum reference peak region and concentration prediction region In the reference peak region the H O peak position is calculated for the laser wavelength lock In the concentration prediction region area integration is performed for NH concentration prediction For example the following spectrum is captured from a furnance test with a NH analyzer The reference peak region is at 150 180 and the measurement gas concentration prediction region is at 100 140 For Off Line Zero Calibration make sure to purge Nitrogen or dry Instrument Air everywhere through the optical path so that there is no NH or H O absorption in the spectra For span calibration it is best to leave the laser temperature control as it is there will be peak center out of range fault Factory software access can further allow a change of the reference peak position set point to 124 5 NH peak locking in the example shown below or use manual laser temperature control mode Absorption Spectrum at 200 degF 0 016 0 014 0 012 0 01 0 008 0 006 a 2 a D DUO 0 002 0 130 data points Figure 52 Typical Process Gas Spectra with NH and H O present IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 6 BASIC OPERATION 6 23 Following pages are the various Laser Spe
160. ransmission can be found Place setscrews so that the alignment is secure With the detector aligned begin vertical adjustments of the launch unit using the studs for small fine adjustments to attain maximum transmission Once maximum transmission has been found in the vertical position adjust the horizontal plane for maximum transmission With maximum transmission found in the horizontal position repeat the alignment in the vertical position for maximum transmission Once the maximum transmission has been found once again in the vertical direction align the horizontal direction again to finalize maximum transmission alignment With the analyzer at maximum transmission the beam needs to be centered on the detector Adjust the laser vertical plane till transmission is almost lost i e the edge of the beam is almost missing the detector lens Adjust the laser in the opposite vertical plane till the transmission is almost lost once again Take note on how many quarter turns that it takes to get from one side of the beam to the other Repeat back to the other side of the beam so that the transmission is almost lost once again Make sure that the number of quarter turns is similar Adjust the beam back by half the number of quarter turns needed The beam will be centered vertically Hepeat for the horizontal direction using quarter turns once again This will fully center the beam on the detector Now the detector will need to be aligned once again Make s
161. rature Gas pressure Transmission Laser Temperature in C Peak Position IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 6 BASIC OPERATION 6 3 Online Menu Level 1 Menu Level 2 Menu Level 3 Menu Level 4 Menu Level 5 Menu Password Protected Control Mode Manual Automatic Max Current Current New Laser Temp Set similar to Max Current Spectrum Capture LTSP Limits Low High Fast Update Enable Disable Calibration Offline Calibration Zero Calibraton pres temp opl gas type conc Local Initate Remote Initiate control channel Time Initate frequency Settings valve purge tiime AO mode gastype conc opl temp pres Restore Old Calibration Factory Calibration Current New Local Initiate Remote Initiate control channel Time Initiate frequency Settings conc opl temp pres Restore Old Calibration Factory Calibration transmission Peak Search Peak with Lower WL Opeak with Higher WL Offline Validation Validation Gas 1 Pres temp opi gas type conc Local Initate Remote Initate control channel Time Initiate frequency Validation Gas 2 Settings conc opl temp pres Two Gas Validation gastype valve purgetimes AO similar to Gas 1 mode Zero Offset Span Calibration Local Initate Remote Initate control channel Time Initiate frequency Settings conc opl temp pres gastype valve purgetimes AO mode Result Display Onl
162. rawn in to the process stack when the analyzer is removed from its interface Remove the detect unit by loosening three of the Allen screws 5 32 Allen wrench The three to loosen by one turn are top left top right and lower left The screw located lower right is to be fully removed Carefully twist the detect unit anti clockwise until the Allen screw heads align with their openings then pull the detect unit away from the alignment flange using an slight twisting action Take care not to damage the O Rings Carefully place the detect unit adjacent to the off line calibration cell taking care not to contami nate the window Hepeat same removal process for the Launch unit and place it VERY CAREFULLY adjacent to the off line calibration cell _ Check to see that there are three Allen Head screws in the top left top right and lower left positions and that they are backed out to clear the analyzer quick connect Attached the Detect unit to one end of the off line calibration cell Carefully slide the unit over the O Rings making sure the O Rings are not damaged cut during mounting Twist the analyzer in to the vertical position Hand tighten the three screws do not fully tighten at this time Insert the Allen screw to the lower right position and tighten Tighten all other Allen screws now also Hepeat same mounting process for the Launch unit and handle it VERY CAREFULLY With the appropriate user interface observe the transmissi
163. re 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 Backplane Circuit Board Power amp Signal Routing The Back Plane carries out several routing functions for both power and signals I O for Detect Unit is routed through the Back Plane from one set of pluggable field terminals located lower left hand of Back Plane to the appropriate destination Terminals are provided for e Analog DC power x3 e Raw Detector Signal differential voltage x2 e Detect Unit Temperature differential voltage x2 Analog I O Board outputs the analyzer 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 0 20mA They can be assigned to measured values Oxygen Transmission or compensation signal re transmission e Input Channels two are used by the analyzer to read active values for process gas temperature 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 IM 11YO1BO1 O1E A 5th Editio
164. resistor First try the new resistor by molding and clipping the resistor leads to fit into the socket Then carefully insert the resistor into the socket on the detector board Since the analyzer is still powered on please take extreme caution to prevent a short circuit on the board i e loose wires or touching adjacent components with pliers or tool used to install resistor e Please keep the factory original gain resistors in the resistor bag as they will be used in the future for offline calibration or test e raw detector signal MAX MIN is proportional to R21 R22 R23 Usually R21 is maintained as factory value H22 and R23 are optimized in the field We want to avoid the situation where one of R22 and R23 resistors has extreme low resistance and the other one has extreme high resistance The analyzer gives best performance when R22 and R23 are balanced Based on this relation between raw detector signal and gain resistors service technician or customer can select R22 and R23 faster with the help of a calculator e Multiple alignment actions might be needed if Detector Signal High fault happens Reduce the gain resistor first as described in STEP 8 a and then optimize the alignment again 6 6 Valve Control Logic The TDLS200 has three valve driver outputs 24VDC 11W max each available at Launch unit connection terminal TB 3 those can be used for calibration validation functions and or stream switching functions if being used in an
165. rge gas and contaminate the window e Contact on the window by an incompatible gas such as HF on the standard BK 7 Borosilicate crown glass e Contamination of the purge gas supply either by particulate matter oil or other If the windows are contaminated they may be cleaned using the following procedure e Remove analyzer from process isolate etc if necessary e Useaclean dry instrument air or nitrogen pressure supply to first blow off any particulate matter e Using warm water and mild soap detergent gently clean the window surface with a soft non abrasive cloth e fthe deposits do not come off then use a small amount of IPA Isopropyl Alcohol and a soft non abrasive cloth e Use the same clean dry instrument air or nitrogen pressure supply to blow dry the surface e Carefully check the entire surface of the window from different angles to ensure it is thoroughly cleaned and ready for service e fthe window does not appear to clean up well then replace the window assembly with a new one e fthe window appears to have an etched surface then it has probably been contaminated with HF or other similar corrosive gas IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 7 ROUTINE MAINTENANCE 7 2 Window surface to be cleaned Figure 56 Window Replacement O ring correctly seated in position Offset screw position for window TEES Y va dela d s 1 ai Pr Cr gs x rea
166. s and decreases in transmission strength to aid in the alignment MEE When it has been maximized at the launch side adjust the detect unit accordingly Further adjustment can be made by maximizing the raw detector voltage signal available at test points on both launch and detect The signal should be maximized and will not exceed 5 3V DC for low temperature 600C process 9 9V DC for high temperature gt 600 process Detector Gain For Large Aperture Optics LAO systems please refer to the Detector Gain Adjustment section of this User Guide to ensure correct functionality and adjustment Configure By way of the appropriate user interface the correct process parameters and other parameters can BASIC now be entered i Enterthe Basic Menu and go to Configure _______ 8 5 If any other parameters are required to be set such as analog I O ranges alarms levels Auto Validation sequences then the Advanced Menu needs to be accessed Advanced Menu access is Password protected and should only be used by skilled and trained persons Contact Yokogawa Laser Analysis Division or Local Agent if any doubts IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 1 QUICK START 1 3 Configure Using the correct password Default 1234 enter in to the Advanced Menu then the Configure ADVANCED Select the desired measurement units English or Metric selected an individual parameter basis Optical Path 9 2 E
167. s Instruction Manual The TDLS200 Tunable Diode Laser TDL Analyzer 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 warranties If there is any doubt about any aspect of the Instrument or its use please contact Yokogawa Laser Analysis Division and or your authorized Representative Distributor IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 2 INTRODUCTION AND GENERAL DESCRIPTION 2 1 2 INTRODUCTION AND GENERAL DESCRIPTION The TDLS200 TDLS analyzer is designed to measure selected target gases in gas phase samples directly at the process point across stack across pipe etc close coupled by pass leg or in full extractive systems flow cell The analyzer measures free molecules on a path averaged basis Unless there is an extractive sampling system up stream that removes water or other condensables then the measurements are considered to be on a Wet Basis Measurements are possible with correct analyzer configuration at the following conditions e Gas temperatures up to 1500 C 2730 e Gas pressures up to 10 BarG 145 psig e High Particulate loading as a function of mea surement path length Each application may differ in maximum limitations depending upon the combination of gas temperature gas pressure optical path length and concentration of the gas being measured The sta
168. s for RIU or URD Field I O 4 3 Laser Assembly The laser assembly contains Laser Diode Collimating Lens Module Body Window Laser Assembly Body Laser Assembly Body is a stainless steel mechanical pipe housing that accommodates the module and protects it from the environment The body has two Swagelok style tube fittings welded on that serve as inlet and outlet ports for the nitrogen purge gas The body attaches to the Main Electronics Housing with an O Ring seal and several stainless steel fasteners At the other end of the body there is a standard adaptor piece welded in place This adaptor can fit several different Process interface systems as well as an off line calibration cell The adaptor also accommodates the standard Process isolation window holder Figure 9 Laser Assembly Laser Module Laser Module is a mechanical component that holds both the laser diode and the lens holder The assembly is factory set up permanently configured and can be replaced in the field if necessary Figure 10 Laser Module IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 4 ANALYZER COMPONENTS gt 4 7 Laser Diode is either a Vertical Cavity Surface Emitting Laser VCSEL or Distributed Feedback DFB that outputs at wavelengths in the 750nm to 2400nm range invisible depending on the target gas being measured The primary output wavelength of the laser is controlled by a thermoelectric cooling module Peltier Element The lase
169. s for the user through an RIU running VAC software to initiate the Auto Validation sequence The operator would be at the RIU in this case IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 8 VALIDATION AND CALIBRATION 8 24 Selecting Automatic Validation Initiation From Online Validations Automatic menu the following options may be selected e Local Initiate will start the automatic online validation sequence when selected It will use the existing Settings see below for details on Settings e 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 e 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 Advanced Calibrate amp Validate DES Advanotd Calibrate amp Valdain Autometer Local Initiate Remote Initiate Time Initiate Settings for Validation There are several critical parameters that must be preconfigured in the TDLS200 software when using the automatic validation sequence These parameters MUST be correctly set otherwise the analyzer will report false incorrect validation results The settings are configured as below Advanced Calibrate amp Validate DES Advanced C
170. s 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 feinen 10 Oxygen or when a line locking gas is being used such as CO for combustion CO CH applications gt gt Alarm Selection Disabled input parameter values for fhe measured gas in the optical path that is catcide of the process path nd nila a NON PROCESS PATH LENGTH This is the optical path length between the laser and detector excluding the process path length The factory values entered include the analyzer internals and the alignment flanges The distance of process isolation valves and process nozzles on both Launch and Detect sides MUST be added to the existing factory values New Input new air purge optical path length NON PROCESS PRESSURE This is the pressure of the non process gas Typically this will be close to atmospheric pressure of 1 01 BarA or 14 7 Current PsiA Check the actual operating conditions and enter the appropriate value Contact Yokogawa if unsure New Input new air purge pressure IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 Change Ar Purge Tempersture Mode Fixed ActiveA Modify air purge temperature F T kirmadi Come Change Air Puge Tampararure Mode Fixed Actives Modify air purge ambient process coefficient Change Ar Purge measurement gas concentration
171. ss sectional area duct circumference If neither situation exists or is possible then distribution of the unimpaired section of duct should be 66 on the inlet side and 34 on the outlet side Profiling of the proposed measurement point may be required to ensure that a correct installation point is selected e Process Gas Temperature It is recommended that the analyzer be installed at a location where temperature 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 10 C 18 F then an Active input signal should be used for compensation Ensure the analyzer has been selected and configured to suit the maximum operating gas temperature 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 pressure of the gas at the point where the analyzer is to be installed is to vary by more than 0 05 Bar 0 725 psi 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 e Process Dust Particula
172. supply to activate calibration solenoid valves for zero span and dynamic spiking validation gas Maximum load 1A max 10W valve for zero and span gas and dynamic spiking 2x 4 20 mA inputs for Temperature and Pressure Compensation for loop powered or mains powered 115 220 VAC mA transmitters for pressure and temperature Ethernet IEEE 802 3 10 100 mbps 45 USB1 and USB2 connection for data transfer using memory stick data storage in CF card result files soectra capture configuration data etc Capture rate is configurable 5 min for functioning 60 min for full operation within specifications 24 VDC 4A 100 240 VAC 50 60 Hz can be supplied to Universal Remote Display URD Utility Panel s Optical Power Supply Unit These devices all supply 24 VDC to power the TDLS Analyzer L Optical Path Length Insitu standard up to 30 meters allowed Minimum OPL 5 meter Flow Cells bypass installation 5 meter recommended Note End User may supply 23 5 to 24 5 VDC direct to analyzer tyo 4A Optional heat trace system may require additional and or alternate power supplies Environmental Specifications A Ambient Temperature B Humidity C Area Classification D Weather resistance E Cable entries F Gas Connections G Enclosures H Sample Gas Temperature Sample Gas Pressure J Mounting Flanges K Mounting Angle L Weights approx M Particulate loa
173. t Hemote Access using VNC via network external computer Hemote Access using optional Remote Interface Unit RIU with VAC software Whether directly connected or connected via network operating the analyzer with an external connection allows two basic functions e Remote control of the analyzer via TDLS200 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 e Data transfer via VIRTUAL ANALYZER CONTROLLER VAC software allows download of data files to from the analyzer IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 6 BASIC OPERATION 6 35 6 9 1 Instructions for Connecting an External Computer to the Analyzer Hequires Windows 98SE or later on computer to be connected to the analyzer and crossover Ethernet cable The analyzer is provided with a CD that includes the VNCviewer program Windows 7 will support the Ultra VNC software and associated functionality Contact your local Yokogawa agent for a free copy of the necessary VNCviewer exe file that will enable the VNC connection with the analyzer This VNCviewer exe file should be loaded on to the connecting PCs desktop ready for use when connecting with the analyzer e From Control Panel Network Connections make sure Ethernet Local Area Connection is set to Enabled status Disable wireless and any other networking connections e Connect crossover Ethernet cable fro
174. t Copy Connect Data Copy Data Return to Main Menu Create Config Conneccion nem Pile ae Password Cennectiern Protected i Name amp IP Select Connection VAC Connection Options Manu Enter New password Exit Return to i Main Manu Return to EN Return t Abo bout Main Menu shutdown Return to Main Menu IM 11Y01B01 01E A 5th Edition Feb 9 2012 00 6 BASIC OPERATION 6 38 6 9 5 OPTIONAL Virtual Analyzer Controller VAC Operating Software Guide ALWAYS END VNC SESSION TO ANALYZER WHEN DONE THIS WILL PREVENT THE ANALYZER AND OR RIU FROM HANGING DO NOT LEAVE THE RIU PERMANENTLY CONNECTED TO ANALYZER CONNECT ONLY WHEN IN USE 6 9 6 Virtual Analyzer Controller VAC Operating Software Guide Lien ii iat YOKOGAWA Virtual Analyzer Controller Copy Contguraten 4 Heip CmHFl Shutdown Fox OQ om err E 01 24 SIVl amp FATADASSE YOKO GAWA gt Virtual Analyzer Controller Select ice ca rye In TT Connect S vey teo v t wl SIS Dea THSS YO KOGAWA 20 Virtual Analyzer Controller Select rons IP Address The RIU VAC software is designed to allow communication between an analyzer and an appropriate interface The primary functions of the software are Create a virtual network computing connection to an analyzer thus allowing for control of the ana
175. te Matter It is recommended that the analyzer be installed at a location where dust loadings are minimized Dust and other particulate matter will reduce the optical transmission of the measuring laser beam Within limits the loss of optical transmission does not effect the measurement however a Warning alarm will be initiated when the transmission falls below allowable limits The amount of dust loading is also dependant upon the optical path length Consult Factory for further details Lower dust loads generally lead to better measurements IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 lt 5 INSTALLATION AND WIRING 5 2 5 2 Position of Process Flanges for Launch and Detect Units Process flanges should be located on the process such that the Launch and Detect Units can be installed accessed and removed in a safe and convenient manner The following criteria Check List should be met at a minimum Good Safe Engineering practices Local codes and regulations for such equipment installation Appropriate hazardous area if applicable precautions Owner Company best practice and engineering standards Access for personnel to stand in front of launch and Detect Units Clearance for installation and removal of Launch and Detect see below Clearance for installation and removal of purge insertion tubes if applicable Access to process isolation valves oafe routing for interconnecting cables Ambient conditions in accordance with
176. te peak center position PCP 167 There is no NH absorption in the spectra Process OPL 20 ppm NH Zero H O Analyzer Purge N In this Absorption Spectra view there is practically zero process H O absorbtion peak in the approximate peak center position PCP 167 region There is approximate 20 ppm NH approx PCP 120 absorption in this spectra based on 72 6 cm OPL ambient temperature and ambient pressure IM 11Y01B01 01E A 5th Edition Feb 9 2012 00 6 BASIC OPERATION 6 25 On Line Process Conditions Analyzer Purged with Nitrogen When purging with Instrument Air as opposed to ambient air the H O levels are much smaller due to it having been dried and having a dew point typically in the order of 40 C and therefore the H O concentration is not large enough to produce an absorption peak that can be seen Ob Process OPL Zero NH Zero H O S98 22 Det ty see io 1 a EEE rU DUE epe P eae Analyzer Purge Air typical 2 4 Raw Detector Signa Absorgoon Spectrum In this Absorption Spectra view the analyzer air purge H O absorption peak can be seen at approximate peak center position PCP 167 NH3 Tere Control Mode 008 There is no NH absorption in the spectra Trans d LN MERC 89 69 13 453 LT degC Peak Pos ieri ESTERI DEI Process OPL 20 ppm NH Zero H O ced Analyzer Purge Air typical 2 4 Rew Detector Signal Absorp
177. ted equipment upon the loss of purge pressure The CYCLOPS 2 Purge Indicator is used to provide safe monitoring of electrical equipment in Division 2 and Zone 2 hazardous areas which can be used to prevent the possibility of fire or explosion inside the enclosure of energized electrical equipment a protective gas supply is used to dilute potentially flammable materials to an acceptable level creating a safe area for the electrical equipment within the enclosure Positive pressure prevents the ingress of flammable materials in the surrounding atmosphere from entering into the enclosure as long as positive pressure is maintained After the enclosure is purged power may be manually applied to the protected electrical equipment The CYCLOPS Z Purge Indicator provides an objective evidence of the presence of adequate positive purge pressure within the electrical equipment enclosure A normally open differential pressure switch continuously compares the pressure inside the monitored electronics enclosure with respect to the atmospheric pressure surrounding the electronics enclosure When the monitored electronics enclosure register s a pressure of at least 0 20 inches H O 0 50 mbar above the reference atmospheric pressure a manually controlled dilution time cycle may then begin Typically a minimum dilution time cycle is specified to ensure that at least five times the volume of free space in the electronics enclosure is exchanged before power is ma
178. the angles very slightly to see if any stronger signal can be obtained If after adjusting the direct angle between the two units there is still no transmission then the laser diode and or detector has failed Please contact Yokogawa Laser Analysis Division for further assistance and information pertaining to Laser Module replacement If a weak signal is achieved then this is an indication that the laser module has weak output power Please contact Yokogawa Laser Analysis Division as this may be caused by dirt contamination on one of the internal optical surfaces usually caused by contaminated purge gas 9 1 2 Off Process or Off Line e Clean Process Windows Visually inspect and clean analyzer windows e Check Analyzer with Validation Standard Mount the analyzer on a calibration or flow cell and perform Basic Menu zero and span check capture spectrum for each condition e Record Results Download data files from the analyzer for e mail to Yokogawa Laser Analysis Division 9 2 Field Up Gradable Files and Software from Factory The analyzer has the capability to upload certain software and files that are supplied by the factory for field use Any files that are to be uploaded to the TDLS 200 should be done so via the factory supplied SanDisk USB memory stick and only when instructed to do so by factory or factory authorized personnel Please also ensure that the USB is inserted only into the allocated analyzer for which the files were inten
179. the flow rate could be anywhere from 5lts min to 50lts min 10 SCFH to 100 SCFH Ensure the purge gas line is clean and dry prior to connecting to the flange to ensure any condensate or debris is not blown on to the windows at initial start up The same applies to both Launch Unit and Detect Unit process flanges with and without any insertion purge tubes installed 5 6 Mounting the Process Interface standard 2 3 4 150 ANSI RF or DN 50 80 Alignment Studs x4 Analyzer Mounting Flange Alignment Nuts x8 N d Process Flange Window Purge Port x2 C Analyzer Quick Connect Alignment Bellows Figure 29 3 150 Welded Metal Bellows Alignment Flange Shown above with analyzer quick connect IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 lt 5 INSTALLATION AND WIRING 5 7 5 7 Typical Purge Gas Configuration In Situ Please refer to project specific details the following is a typical standard in situ configuration LAUNCH DETECT Zn CAPPED PORTS ALIGNMENT ALIGNMENT HT en sim m cm s a m m s ns mm a wE GAS a fen PURGE BH PURGE 0 ECH LAU CH UNIT TER PURGE DETECT UNIT WINDOW PURGE C AHALYTZER WIHDCN ANAL T Figure 30 5 8 Typical Purge Gas Configuration Extractive trace ppm 20 system Please refer to project specific details the following is a typical standard enhanced flow cell configuration 1 CAPRIS D PLUG ES
180. the optical path length of the offline flow cell typically 20 30 40 60 or 80 please check the flow cell configuration for details Check Gas Temperature can be selected for either Fixed or Active lf Active Temperature then follow on screen instructions This is typical for a heat traced controlled flow cell that has an active 4 20mA signal proportional to the cell temperature If Fixed Temperature then enter 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 please allow sufficient time for volume exchanges to ensure only the validation gas is being measured and that all previous process gas has been thoroughly purged out Process Gas Purge Time specifies how long process gas Will purge the flow cell before up dating the results and making the 4 20mA signals real time Please ensure that the time is sufficient to ensure all validation gases have been purged from the flow cell and that only process gas is being measured as the 4 20mA outputs will re
181. the peak area remaining is that of the validation gas at 4 OPL ambient temperature and pressure This area measured for validation gas should therefore match the expected value because all other parameters are known If the measured true peak area matches that of the calculated peak area then the analyzer passes On Line Validation The On line Validation interval is user selectable m Figure 61 Weekly Bi weekly Monthly TruePeak Reading Concentration Validation Concentration Process Concentration Process Concentration Daily Recommended for low level or critical applications IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 8 VALIDATION AND CALIBRATION 8 18 8 5 Performing Manual OnLine Validation This will require the appropriate valves tubes and tubes fittings such that the integral on line check gas flow cell can be purged with either normal purge gas typically Nitrogen or the check gas instrument air is acceptable for Oxygen analyzers in most applications The flow path shall be as below Analyzer Purge 1 NC Online Check Gas N Gas Inlet Flow Cell Inlet TYP 2LTS min Max 3 psig TYP 2LTS min Figure 62 Manual On Line Validation manual valve actuation Via the user interface laptop PC and VNC Viewer or installed 6 5 Display and Keypad follow this sequence Enter into the Advanced Menu Calibrate amp Validate section Enter On Line Validations then Manual Validation
182. the product itself prepare it separately e 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 gt WARNING This symbol indicates that the operator must refer to the instructions in this manual in order to prevent the instrument hardware or software from being damaged or a system failure from occurring gt CAUTION This symbol gives information essential for understanding the operations and functions gt Note This symbol indicates information that complements the present topic This symbol indicates Protective Ground Terminal i 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 produ
183. tion In this Absorption Spectra view the H O absorption analyzer air purge peak can be seen at approximate peak center position PCP 167 NH3 ppm Tere Contro Mode Center 1951 12000 There is approximate 20 ppm NH absorption approx 120PCP pum Pres bara LTS degC in this spectra based on 72 6 cm OPL ambient temperature and ambient pressure LT wiz Peak Pos KITE EZE 10 60 18 SJS2 TOTASARe ee ae Process Zero NH 2 H O Raw Detector Signal Absorption Spec Analyzer Purge Air typical 2 4 In this Absorption Spectra view the process gas H O 296 0 7 m Q STP and analyzer air purge H O absorption peak can be seen at approximate peak center position PCP 167 NHI ppm Tere C Control Node Cur Trans Pres vers LTS degC There is no NH absorption in the spectra Capture LT degC Peak Pos LTSP Lands A TI 5 2 5 IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 6 BASIC OPERATION 6 26 6 5 Large Aperture Optics For in situ application typically large scale combustion systems the optical path lengths are generally very long 7 30 m for large scale combustion and ethylene furnaces Standard TDLS optics and laser beam configurations are unsuitable because of the mechanical stability of these large scale combustion systems Yokogawa Laser Analysis Division therefore designed and developed the concept of a diverging beam i e a laser
184. to 20mA channel to output Concentration Transmission Gas Temperature Gas Pressure or None NOTE Channel 2 DOES NOT follow the Block Track Hold modes and is typically assigned to Transmission 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 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 AO CH CALIBRATION Pre Calibrated at factory and not normally required Allows calibration of 4 to 20mA output channels follow onscreen instructions 2 SYSTEM I O ANALOG INPUT Field Checking x Review the displayed mA values to field check the incoming analog signals IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 6 BASIC OPERATION 6 11 Shee S SYSTEM 1 0 DIGITAL OUTPUT Setting of Digital Output assignments DO 1 3 CHANNEL 1 WARNINGS Setting of levels that will trigger analyzer warning and subsequent DO CHANNEL 2 FAULTS Setting of levels that will trigger analyzer fault and subsequent DO anne lt CHANNEL 3 USER ALARM Setting of either Concentration or Transmission level high or low calibration validation status Channel 3 User Alarm that will trigger analyzer user alarm DO status FIELD LOOP CHECK allows for con
185. to suit the desired measurement installation The available Remote Interface Unit RIU can be located typically up to 100m 330 away from the Launch Unit The RIU also requires a 24VDC power supply The RIU connects to the Launch Unit on Ethernet 10 base T 10 100 via CAT5e field rated cable The available Universal Remote Display URD can be located typically up to 40m 120ft away from the Launch Unit The URD requires an AC power input that is connected to a universal power supply with 24VDC output power supply for the analyzer The URD connects to the Launch Unit via multipair sheilded twisted pair cable IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 4 1 Launch Unit Main Electronics Housing e Back Plane circuit board e Single Board Computer SBC e FPGA signal Processing board e Analog O circuit board e Field electrical terminals are located on Back Plane and optional Analog l O board e Optional Mini Display 4x20 VFD shown Figure 5 Launch Unit Optional Keypad and Display YOROGAWA 4 998 eu Figure 6 Launch Unit Optional Keypad amp display 4 ANALYZER COMPONENTS 4 2 Check Gas Flow Cell Short cell gas tight chamber allows Zero Gas or Span gas to flow through the measuring path for on line validation Laser Housing and Laser Module e aser diode and collimating lens assembly e aser module designed to be field replaceable and purged to prevent ambient air ingress e Housed in a st
186. tor 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 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 FPGA Relay Coil TTL out Drive Circuit Relay Coil Helay Contacts 24VDC to C C to NO 24VDC to external solenoid valve when relay is engergized Figure 8 Calibration Valve Relay Diagram IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 4 ANALYZER COMPONENTS 4 5 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 temperatu
187. turn to live mode when the validation is completed Analog Output Mode specifies Block Track or Hold of all 4 to 20 mA output during offline check Note that the mA value of the Block mode can be set elsewhere in the software F Advanced Voldate Select Anaeg Ouipul Mode During Offline valicidtion Block Track Hold Block output signals will be heki at above mA when cal val is on Track output signals will continue tracking the measured value Hold present output signals will be held until cal val is finished IM 11Y01B01 01E A 5th Edition Feb 9 2012 00 8 VALIDATION AND CALIBRATION 8 13 8 2 Off Line Calibration for Reference Peak Locking Applications Zero and Span calibrations MUST be performed as per normal off line procedures without using and Reference Line locking gases oem gmav7pb5ski 10 0 0 15 FELTI 2 NH3 ppm Temp Control Mode Bi Automatic Trans 96 Pres bara 89 82 LT degC Peak Pos cem gmas7pb5ski 10 0 0 15 EREET EPEE NH3 ppm Temp EON EON Trans Pres bara 39 20 f ior LT deg Peak Pos LTS degC Control Mode Manual NEG Cur Center 04 08 7008 14 52 10 10 0015 Cur Center 12000 Capture 01 55 Process Calibration OPL N2 Analyzer Purge N2 This is how the absorption spectra will appear when there is neither NH3
188. ub sese 8 1 8 1 Off Line manual Automatic Checking and Off Line 8 2 8 2 Off Line Calibration for Reference Peak Lacking AppliCation ccccccccsseeeeeeeceeeeseeeesaeeeseeeesaeeens 8 13 Go ONCE Vala Misstep E m xem 8 14 8 4 On Line Validation Overview ccccccccsccccsccccseecseeeceaeeesaucecaueeceeeeceueesseeseueeseueescueeesaeeesaeeesanesssaesseeess 8 14 8 5 Performing manual On Line Validation cccccccssececeseeceececeeeeseeecseeceueeceueeeseeeeseeeesaeeeseueetsneesneess 8 18 8 6 Performing Automated On Line Validation cccccccccsececesceceececeeeecsueeceeeeseeeeseeeeseeesaueesueesseeeseeess 8 21 Bir e 9 1 9 1 Common Troubleshooting Steps cccccccccssscccssecssseeceseeceeeceuceceueecsueeseuseseeeecseessaeeeeaeeesueessaeesseeesegs 9 2 9 2 Field Up Gradable Files and Software from FactOry cccccssccccssececceeeeeeeeeeeeeeeeeeeeeeeeseeeeesaeeeesaeeeesnees 9 9 9 3 PUAN ZOE Warnings Qus true ii una E maou aa aE Taide 9 9 94 a 9 10 Data Files Negpeme 10 1 10 1 Config ring 1
189. ure that all backing nuts and setscrews are securely fastened Carefully check the detector Large Aperture Optics bevel mounting seal is not leaking at the perimeter this can happen if too much bias is asserted For oxygen analyzer and combustion processes with negative pressure this will cause false high readings as ambient air 20 9 O2 is drawn into the optical path via a gap at the bevel seal edge please clamp down all bolts and adjust the large bevel flange to ensure a gas tight seal is maintained at all times IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 6 BASIC OPERATION 6 28 6 5 2 Adjustment of Detector Gain for Large Aperture Optics This section of the User s Guide gives the guidance and procedures to adjust the detector board gain after the analyzer is installed and powered up This operation should be done by qualified personnel Read instructions fully before starting this operation Any doubts or questions please contact Yokogawa PHOTOS OF DETECTOR BOARD HESISTOR BAG For a TDLS200 analyzer with diverging laser beam configuration either with or without large aperture detector lens a resistor bag is attached inside the detector box The resistor bag contains the resistors with the following values All of them are 4 W 5 tolerance metal film through hole resistors Resistor Bag for Analyzers With Diverging Beam Optics 2 2 2 2 fe e le e Please record the factory gain resistors currently installed
190. using on line validation 5 11 4 Purging Analyzer and Universal Power Supply and or URD not using On Line Validation e NEC CSA Class 1 Division 2 Groups A D e ATEX Zone 2 CAT 3 Dual regulators must be used on the inlet The block diagram below shows the sections of the analyzer that require nitrogen purging Z Type purge control system is fitted the Launch Unit and it includes a local indicator Bright Green rugged light and pressure switch alarm contacts open on loss of purge pressure The purging should be carried in sequence typically as shown below All purge gas connections od Tube fittings rocess ace P Inte Figure 50 Purging Analyzer for Hazardous Areas NO On Line Validation IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 lt 5 INSTALLATION AND WIRING 5 22 5 12 Cyclops Division 2 Zone 2 Purge Indictor with switch Type Z purging reduces the classification within a protected electronics enclosures from Division 2 or Zone 2 to nonhazardous Failure to maintain pressure within the protected enclosure shall be detected by an alarm or indicator at the electronics enclosure The dilution purge time shall be a manual operation and once the electronics enclosure has been purged of ignitable or flammable concentrations only positive pressure of at least 0 20 inches H O 0 50 mbar is required to be maintained within the electronics enclosure and it is not necessary to remove power from the protec
191. validation are all configurable within the TDLS200 software Refer to the Validation and Calibration section of this User Guide for further details IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 4 ANALYZER COMPONENTS gt 4 8 4 5 Detect Unit Detect Electronics Housing Detect unit e Detector Circuit Board Detect Process Interface Electronic Housing Detect el LJ a LJ A333 AAAAAM 95 Detector Housing and Detector Module e Detector and focusing lens assembly e Detector module designed to be field replaceable and purged to prevent ambient air ingress e Housed in a stainless steel body with O rings seals attached to the detect electronics housing Figure 12 Detect Unit Detect or Electronics Housing The Enclosure is die cast copper free aluminum grade AL Si 12 alloy 4413 0 with a powder coat exterior finish The copper free aluminum alloy is particularly resistant to salt atmospheres sulfur gases and galvanic corrosion A removable cover lid incorporates a weather tight gasket seal and four captive fastening screws stainless steel The external dimensions are approx 7 W x 7 H x 4 D 180mm x 180mm x 100mm The environmental protection rating is considered IP65 EN 60529 or NEMA 4X The cable entry located on the bottom face of the enclosure It is typically a 94 Myers hub that has a 34 NPT female thread It has a ground lug to facilitate the grounding of cable s
192. venient field loop checking of the digital alarm output contacts follow the on screen directions Channel 1 Warnings CHANNEL 1 WARNINGS Menu allows setting of various analyzer WARNINGS conditions WARNING is an event that will indicate that maintenance is require and the analyzer is still operational PLEASE ADJUST WITH ONLY FACTORY ASSISTANCE WARNINGS CONDITIONS ARE IMPORTANT SETTINGS Process pressure out of range oul of range DETECTOR SIGNAL LOW lower raw detector signal limit TRANSMISSION LOW lower limit of transmission Note when transmission falls below this value the automatic peak tuning we eh Pn function is disabled This is to prevent excessive noise caused D O Werning Delay by low transmission interfering with correct peak tuning SPECTRUM NOISE HIGH factory set do not adjust PROCESS PRESSURE OUT OF RANGE typically set for the min max expected process pressure Note if operating outside the known conditions measurement accuracy may be affected PROCESS TEMPERATURE OUT OF RANGE typically set for the min max expected process temperature Note if operating outside the known conditions measurement accuracy may be affected CONCENTRATION OUT OF RANGE set for any desired alarm points BOARD TEMPERATURE OUT OF RANGE used to indicate excessively hot cold ambient conditions for the analyzer DO WARNING DELAY to avoid single event alarms that have proven to be short terms events ent
193. yboard with Windows key no longer required as in older software versions ADJUSTABLE RESISTORS After detector gain adjustment in the field these values should be entered these values are then stored to the syste cfg file SETTINGS USED ONLY FOR STORING FACTORY DATA Analyzer S N Laser S N Software Version Analyzer S N System Temperature VALVE CONTROL Typically used when the analyzer is configured with a flow cell in an offline application These values can also be used manually to introduce on line validation gases Valve configuration conflicts will be noted on screen if applicable VALVE 1 Manual On Off Toggle Time Sequence next valve and time seconds to next valve or Remote Control select 4 ON mm channel for control capability follow the on screen directions to program Valve 1 VALVE 2 Manual On Off Toggle Time Sequence next valve and time seconds to next valve or Remote Control select channel for control capability follow the on screen directions to program Valve 2 VALVE 3 Manual On Off Toggle Time Sequence next valve and time seconds to next valve or Remote Control select channel for control capability follow the on screen directions to program Valve 3 IM 11YO1BO1 O1E A 5th Edition Feb 9 2012 00 6 BASIC OPERATION 6 15 Advanced Conti Laser Spechra amp Control LASER SPECTRA amp CONTROL Displays Raw Detector Signal and Absorption Spectrum as well as Gas Con

User`s Manual - Northwest Instruments & Controls INC

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User`s Manual - Northwest Instruments &amp; Controls INC

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User`s Manual - Northwest Instruments & Controls INC