Model 2000 Series Operators Manual
Contents
1. SPECTRASENSORS Precision Laser EZITE V Model 2000 Series Operators Manual Model 2000 Series 2001 SpectraSensors Inc Table of Contents Introduction Theory of Operation 3 Specifications 4 Installation Introduction 5 Initial Inspection 6 Location Requirements 6 Mounting Procedure 7 Gas Connections 8 Electrical Connection 9 Output Signal Connection 12 RS 232 Output 15 Calibration 15 Power up Sequence 16 Operation Specification of Proper Use 17 Keypad Functions 17 Modes User Password 19 Power down Procedure 27 Maintenance Reducing Contamination of Gas Sampling Lines 28 Cleaning Procedure 28 Troubleshooting Troubleshooting 33 Warranty Information 35 Service Contact If the above troubleshooting steps do not result in a resolution of the problem you should call the sales representative that sold it to you Always contact your sales representative before returning units to factory The representative can help with additional troubleshooting procedures and can diagnose whether the unit can be serviced on site or should be returned to the factory for repair Your sales representative is 2001 SpectraSensors Inc 2 Introduction About SpectraSensors SpectraSensors is located in Altadena California just a short distance from the California Institute of Technology s Jet Propulsion Laboratory JPL where the basic technology behind the products offered by SpectraSensors was developed Thi2. Gas flow rate 0 3 to 10 Liter minute Glycol contamination sensitivity None for gas phase glycols Sample cell construction 300 series polished stainless steel Input Voltage 100 250 VAC 50 60 Hz standard Current draw 120 VAC Outputs Moisture dew point CO pressure and temperature amp maximum 4 line LCD display RS 232 serial port 4 20 ma current loop concentration only Data Input 16 key keypad Weight 25 Ibs 11 5 kg Dimensions box Wide 18 8 in 478 mm Deep 5 3 in 135 mm Height 17 5 in 444 mm NOTE These are typical specifications Exact performance will vary depending on installation and operating environment 2001 SpectraSensors Inc 4 Installation Introduction The 2000 Series is a compact unit designed to provide years of accurate dependable gas monitoring All of the electronic controls are contained inside a NEMA 4X stainless steel enclosure The 2000 Series contains one or two sensitive measurement heads depending on number of target gases analyzed Each consists of a gas sample cell and an optical head assembly Inside the optical head assembly is a tunable diode laser and optical components that should be handled with extreme care AN CAUTIONI Do not hold or carry the unit by the measurement heads or sample cells Doing so may cause optical alignment problems affecting the performance of your sensor Key Hook
3. and shutoff valve on inlet line Ambient temperature 4 F 20 C to 122 F 50 C Ambient pressure 10 PSIA to 16 PSIA sample cell pressure 10 25 PSIA Mounting Procedure The 2000 Series is designed to be bolted to a wall or other flat surface that is free of vibrations Minimizing the gas volume of the sample system and using stainless steel tubing optimizes performance The only critical mounting issue is to mount the unit so that the inlet and outlet line will reach the inlet and outlet connections on the chassis and still have some flexibility i e the sample lines will not be under excessive stress To wall mount the 2000 Series gas sensor I SS Se Ne qe DD Unpack the 2000 Series from the shipping container Be careful not to shock the instrument by dropping it or banging it against a hard surface as this could disturb the optical alignment The 2000 Series has 4 mounting tabs with a 0 3 in hole in each tab see Figure 2 SpectraSensors recommends using 4 lag bolts or 4 20 machine screws if through bolted Position the unit where desired Mark the hole in one of the top tabs with a pencil Mark a second top screw location 8 over from the first Mark the lower screw locations 12 3 4 below the top holes Drill the appropriate size hole for the screws being used Hold the unit in place and insert the top screws Insert the bottom screws and tighten all four screws The unit should be very secure 10 T
4. be allowed for the walls of the absorption cell to dry completely before the 2000 Series will return to making accurate measurements especially when measuring frost points below 70 C 94 F Humidity levels higher than expected may be caused by leaks in the sample system or tubing leading to the analyzer All wetted parts should be of stainless steel wherever possible Materials such as vinyl rubber or PVC will dramatically impair the measurement performance of the instrument and will impact upon accuracy Pressure regulators installed upstream of the analyzer should be of high quality and fitted with stainless steel diaphragms Any hygroscopic material dust in the lines or absorption chamber can further increase the time needed to return the measurements to normal levels Contamination and long exposure to high humidity are valid reasons for cleaning the gas sampling lines periodically as outlined above Sampling Gas Temperatures and Pressures Errors can also arise from absorption cell temperature and pressure that exceed the ranges allowed by the software These ranges are 0 7 to 1 7 bar 10 3 to 25 0 PSI for pressure and 40 to 50 C 40 to 122 F for temperature Inlet sampling gas temperatures and pressures must stay within these ranges in order to obtain accurate measurements Electrical Noise High levels of electrical noise can interfere with laser operation and cause it to become unstable The 2000 Series should
5. but the longer the response time Each spectrum adds about 0 25 sec to the response time RCalb lt SET PARAMETER MODE gt RCalb 2345 Enter a value RCalb is the gain calibration factor for the concentration measurement This number should not be changed from the factory setting unless calibration equipment is available and a full calibration procedure is followed Alarm Action lt SET PARAMETER MODE gt Alarm Action 0 0 gt 0 1 gt Full Scale This value determines whether the concentration value 1s set to zero or full scale in the event of an alarm condition 2001 SpectraSensors Inc 21 Zero Offset lt SET PARAMETER MODE gt Zero Offset 0 Enter a value For concentration measurements it 1s necessary to compensate for small amounts of background gas that adsorb some laser light causing an offset to be introduced into the measurements This number should not be changed from the factory setting unless calibration equipment is available and a full calibration procedure is followed Logger Rate lt SET PARAMETER MODE gt Logger Rate s 4 Enter a value For applications where an external data logger is used Logger Rate allows the operator to set the averaging time period used by the analyzer to match the data logger rate Longer periods results in cleaner data because of the effects of the signal averaging For example if you are logging data every minute it does not make sense to have t
6. hand 2001 SpectraSensors Inc 13 2001 SpectraSensors Inc Cseecer ict50 h 1 Figure 8 Replace block on base and check all terminals are tight 14 To connect the 4 20mA and serial outputs through a cable 1 Disconnect power from the unit 2 Open the enclosure cover being careful not to disturb the electrical assembly inside 3 Remove the cable strain relief fitting and replace it with a NEMA 4Xrated conduit hub 4 Run conduit to the gas sensor and pull signal wires through the conduit SpectraSensors recommends the use of shielded wire to prevent signal interferences 5 Follow steps 4 through 10 above for connecting the signal wires to the terminal block RS 232 Output The RS 232 presents a string of data to a serial device The serial device is typically a computer terminal running HypeTerminal or other serial port software The serial port should be set for 9600 baud 1 stop bit no parity and no handshake The RX output is connected to pin 3 on the computer s serial input The TX output is connected to pin 2 on the computer and the GND is connected to pin 5 The data string is space delimited with a carriage return at the end of each line The data are output in the following order Water vapor concentration if a water channel Dewpoint if a water channel CO2 concentration zero unless a CO2 channel is present Pressure Temperature 2F signal DC signal Peak Position In
7. monitoring their absorption of laser light at specific wavelengths in the near infrared near IR wavelength region near 2Um The human eye responds to light in the range of approximately 0 4um deep violet to 0 8um deep red but most molecules respond to light at longer wavelengths that are invisible to the human eye the infrared region By using a laser that operates precisely at a wavelength where H O or CO many other gases can also be measured using this technique absorbs it is possible to accurately determine the abundance of the gas by measuring the amount of light that is absorbed by the molecules SpectraSensors can provide references that describe in detail how our gas sensors operate However a detailed description is beyond the scope of this user manual 2001 SpectraSensors Inc 3 Table 1 Specification sheet Measurement Range Moisture Concentration H 0 0 to 20 Ibs MMscf Dew Frost Point Carbon Dioxide CO Reading Accuracy CO Response time Normal operating environment range Temperature Reading Accuracy H20 Specification Sheet for the 2000 Series Analyzer 70 to 30 C 94 to 22 F 0 10 2 of reading or 400 ppmv whichever is greater 2 of reading or 4 ppmv whichever is greater 1 second continuous software adjustable updates 20 to 50 C 4 to 122 F Pressure 0 7 to 1 7 Bar 10 3 to 25 0 PSA 3 Bar 30 PSIG absolute maximum
8. to measure very clean low water content gas no more than 20 Ibs MMscf SpectraSensors has other models available that are capable of measuring gas with higher moisture concentration The sample gas inlet line must have a coalescing filter to prevent contamination of the internal optical components Although the SpectraSensors Series 2000 gas sensor can tolerate significant loss of reflectivity from its mirror it may still be necessary to clean the optics Should gross contamination occur such as in the case of a filter failure the optics may become severely contaminated and the mirrors inside the sampling cells must be cleaned If you cannot or do not desire to clean the mirrors your local representative can provide on site service for a small fee Note that if the gas sensor has become contaminated the tubing and instrumentation up stream of the sensor is likely to be contaminated as well Be sure to clean or replace these parts when the sensor is cleaned to prevent recontamination of the sensor CAUTION It is extremely important that disassembly of the measurement cell take place in a clean area so that dirt or other 2001 SpectraSensors Inc 28 contaminants do not get on the optical components during the cleaning operation In addition the area should be well ventilated and personnel should wear protective gear to prevent accidental contact with cleaning solvent Read the directions on the solvent before using Be carefu
9. up Details Gas Connection 14 O D Tube Power Cord Diameter 0 31 to 0 56 Signal Cable Diameter 0 31 to 0 56 Conduit Knock Hole 1 K O 2001 SpectraSensors Inc 5 Sample cell upper flange Optical head assembly LE E t i Le ns RL da PR CFE 4 rk HE Se a i I der Fins Fy wanian ENTRE EXT o T EF j Eric i 0 1 T if i lt afl EST I El mis I 4 CI 7 Wut L r g 1 FL FA ay FE E Sample cell Keypad Left sample cell gas line connection Sample cell i lovver flange hs Right sample cell gas line Serial and 4 20mA connection interface connections Figure 1 Main external components identified on 2000 Series gas sensor Initial Inspection The 2000 Series should be inspected for damage The contents of the container should include The 2000 Series stainless steel enclosure with measurement leads Operators Manual Inspect the unit for dents or dings in the enclosure and keypad Inspect the inlet and outlet connections for damage Report any damage to the shipping agent Location Requirements AC power 100 250VAC 50 60 Hz The 2000 Series is equipped with a universal power supply that will accommodate both US 110 VAC 60 Hz and European 250 VAC 50Hz AC power configurations Mounting surface wall mounted or tabletop mounted 2001 SpectraSensors Inc 6 Sampling lines with coalescing and particulate inline filters
10. EM TEST gt LASER POWER OK P T SENSORS OK SPECTR OK NULL OK If a failure is detected the LCD will display FAIL for that component If the LCD displays a failure for one or more of the components refer to the troubleshooting section Mode 6 Diagnostic Data Dump This mode is used to output to the serial ports the individual data points of both the DC and PP2F spectra that are analyzed by the instrument to calculate the gas concentration Viewing these data can be helpful in diagnosing potential problem with the instrument The data points along with intermediate calculation results are output to the serial ports whenever mode 6 is selected The data for the H2O channel is output on the H2O serial port and the data for CO2 in a two channel unit is output on the CO2 serial port See page 15 of the Operators Manual for wiring and protocol information for the serial ports Any computer terminal program that works with the RS 232 serial port can capture the serial port data The Hyperterminal program included with Microsoft Windows is a typical example of such a program Before entering Mode 6 the serial port should be connected to the computer being used for monitoring the serial port and the output stream should be showing on the screen The number of seconds between each line of data output should be the Spectrum Average number set in Mode 2 divided by 4 The factory default setting of Spectrum Average 4 gives a line of output
11. R MODE gt Password Enter password 2001 SpectraSensors Inc 19 Enter the user password on the keypad then press the Rey NOTE The user password is 3142 the first four digits of the value of x Mode 2 allows the operator to view and change the values of the following H O measurement parameters Note that prior to setting the zero offset or RCalb parameters suitable calibration gases must be available along with the tools necessary to hook them up to the analyzer Spectrum Average 1 16 Sets the number of scans that are averaged for each 2F spectrum RCalb 1000 3000 Sets gain calibration for H O or CO measurements Alarm Action 0 or 1 Determines 1f the concentration values goes to full scale or zero on an alarm condition Zero Offset 100 ppmv for Sets the zero offset for H O a 0 1 for or CO measurements CO default Logger Rate 1 300 seconds Sets the gas concentration for both H 0 and integration time CO Temperature unit Oor Sets the display unit for Temperature Pressure unit 0 1 or 2 Sets the display unit for Pressure Concentration unit 0 or Sets the display unit for the water concentration Table 3 2000 Series Keypad 2001 SpectraSensors Inc 20 Spectrum Average lt SET PARAMETER MODE gt Spectrum Average 4 Enter a value This value is the number of scans that are averaged for a spectrum calculation The more spectra averaged the less the noise
12. ary disconnect means for the gas sensor the AC 2001 SpectraSensors Inc 11 panel must be located within 10 ft of the gas sensor The gas sensor should be on a circuit that is protected at ISA or less 5 Pull Ground Neutral and Hot wires into the electrical enclosure 6 Attach the Neutral and Hot wires to the power terminal strip as shown in figure 3 Crimp a 10 ring terminal to the green ground wire Be sure that the terminal is the correct size for the gauge of wire being used Follow the terminal manufacturer s instructions for preparing and crimping the terminal AN CAUTIONI Failure to properly ground the gas sensor can create a high voltage shock hazard Follow the instructions carefully 8 Turn on power to the gas sensor circuit Output Signal Connection Procedure The 4 20mA and serial outputs are supplied from a mating terminal block inside the unit Connections can be made with a customer supplied cable through the strain relief fitting supplied with the gas sensor or by running the signal wires into the enclosure through a 12 conduit AN CAUTION Be sure the power to the unit is turned off before opening the gas sensor enclosure and making any connections Note that the 4 20mA outputs are factory set to source current If a passive current loop is required the jumper on the current loop board may be moved from the A active position to the P passive position To connect the 4 20mA and
13. ation For H2O concentration display there are the following options e Press 0 for ppmv e Press 1 for Lb mmscf This is the last parameter Press 1 to return to Normal Measurement Mode Mode 3 CO Measurement Parameter Change 8 When CO2 is not being measured the Normal Mode will be displayed Mode 3 allows the operator to access and change parameters for CO measurements in the same manner as Mode 2 is used to alter the parameters for the H O channel The menus for Mode 2 and Mode 3 are identical The only difference is the unit of measurement used when entering parameters For CO the Zero Offset and Span Limit parameters must be entered in percent while for H2O these values are entered in either ppmv Zero Offset or Ibs MMscf span limit Follow the instructions for Mode 2 These numbers should not be changed from the factory setting unless calibration equipment is available and a full calibration procedure is followed Mode 4 System Diagnostic Parameters for Water Mode 4 displays System Diagnostic Data for water These values may be useful when trouble shooting the system PP2F 1536 POWER 2854 INDEX 280 ZERO 8 2001 SpectraSensors Inc 24 PP2F shows the value of the concentration signal is A D counts A normal range is 0 to 6000 depending on the concentration of water present Power show the laser power detected at the absorption peak Acceptable limits are 1000 to 4000 A low number may
14. d a 120VAC power cord through the strain relief fitting supplied with the unit See figure 3 The power cord must be the three wire grounding type The power cable should have at least 16 gauge conductors The strain relief fitting is designed to accommodate cords with outside diameters from 0 31 to 0 56 Power supply access point Figure 3 Thread power supply through the right side access point at the bottom of the enclosure 2001 SpectraSensors Inc 9 Neutral terminal connection Hot or Line terminal connection Figure 4 Connect neutral line to terminal marked NEU and hot line to terminal marked LINE Remove at least 8 of the jacket to expose the three conductors within 4 Cut the black wire line or hot and the white wire neutral about 2 from the jacket and strip off 3 8 of insulation from the ends 5 Loosen the terminal screw marked LINE insert the black wire and tighten the terminal screw Be sure that the terminal is contacting the conductor and not clamped onto the insulation See figure 4 6 Loosen the terminal screw marked NEU insert the white wire and tighten the terminal screw Be sure that the terminal is contacting the conductor and not clamped onto the insulation 7 Crimp a 10 ring terminal to the green ground wire in the cord Be sure that the terminal is the correct size for the gauge of wire being used and the crimp holds both the insulation and the wire Foll
15. dex Null Calibration The instrument is calibrated at SpectraSensors against standard assayed gas mixtures and should not be adjusted in the field Unlike aluminum oxide or electrolytic sensors that are in contact with the sample gas the laser used to make the measurement in the 2000 Series simply passes through the sample cell and there are no sensors in contact with the gas So drift or contamination from contaminants such as glycols or amines in the gas phase 1s not possible If however there is any question or doubt about the 2000 Series readings a calibration using a Certified Master Class Calibration Standard or a chilled 2001 SpectraSensors Inc 15 mirror hygrometer may be used to verify measurement accuracy Note that any H O calibrations must be performed with the same type of background gas that is used in normal operation Power Up Sequence When the 2000 Series gas sensor has been mounted the gas sampling lines connected and checked for leaks and the optional output signal wires connected the unit is ready to apply AC power It is possible to apply AC power before the gas lines are connected to ensure the unit is functional but ambient air contains levels of water vapor that are much higher than the instrument is designed to measure Therefore valid HO readings cannot be obtained until sample gas is flowing through the sample cell To power up the 2000 Series Apply AC power by plugging in the gas se
16. display as zero NOTE To activate any functions on the keypad press the XY key and then press a number to select Mode or the TEST key If the key is not pressed before pressing a Mode or function Key there will be no response When the HF key is pressed the word MODE will be displayed on the LCD At this point the unit will wait for a second Key to be pressed before responding 2001 SpectraSensors Inc 17 2001 SpectraSensors Inc SPECTRASENSORS Precision Laser Technology Bee amp 5 a B a Figure 10 2000 Series Keypad 18 Modes The following modes can be accessed from the keypad by pressing the key and then entering 1 2 3 4 or Test Mode 1 is Normal Display Mode Mode 2 provides change of parameters for H2O measurement Mode 3 provides change of parameters for CO2 measurement Mode 4 displays System Diagnostic Parameters for H2O Mode 5 displays System Diagnostic Parameters for CO2 Mode 6 outputs spectra and calculations to serial port Mode Test displays H2O System Test parameters Mode 1 Normal Display Mode a 1 Mode 1 continuously displays updated measurements lt NORMAL MODE gt H20 120 62pmv CO2 2 33 DP 41 00C P 1011 8mb T 23 20C Mode 2 H20 Measurement Parameter Change jor 2 After pressing the Rey and then 2 Rey the LCD will prompt the user to enter a numeric password lt SET PARAMETE
17. e surface of the mirror when it is sprayed Hold the solvent can vertically while spraying Gently spray the surface of the mirror and flange starting from the top and flushing the solvent down while spraying Less than five seconds of spraying should be sufficient to clean normal contamination from the mirror Do not touch the mirror with the spray nozzle 5 Allow the solvent residue to evaporate from the mirror surface Inspect the mirror for residual contamination If contamination is not completely removed repeat the spraying process 6 When the mirror looks clean blow off any solvent that has been trapped in the space between the mirror and flange using the air duster can 7 Set the mirror assembly aside in a clean area 8 Gently spray some solvent onto the o ring and wipe it clean with a clean dry lint free wipe 9 Puta small dab of non outgasing grease on the o ring and wipe it off 2001 SpectraSensors Inc 30 10 Replace the o ring into the mirror assembly Do not touch the mirror with the o ring 11 Disconnect the measurement head cables from the top of the control box One cable is for the optical head and the other if applicable is for the temperature and pressure probes 12 Remove the six screws holding the optical head assembly to the top of the sample cell Note the arrangement of the washers and lock washers so that the flange can be attached the same way on reassembly 13 Leave the
18. each second To save the data from the serial port use the capture feature on the terminal 2001 SpectraSensors Inc 26 program For Hyperterminal use the Transfer Capture Text function and enter a file name to identify the data to be captured Once capturing is taking place enter mode six by pressing 6 Mode 6 will display Dump Stats Mode Index 0 The index will count by 50s from 0 to 511 in a few seconds and the screen will display MODE Press to return to normal operation When normal operation has resumed stop the capture of the serial data For the Hyperterminal program press Transfer Capture Text Stop This file can be imported into a spreadsheet program such as Excel and the data plotted At the end of the spectrum data there is a section that displays the intermediate calculations This information can be valuable to the factory if troubleshooting is necessary Power down Procedure The power down procedure is simple Remove the power cable from the AC outlet or disconnect power from the gas sensor circuit in the case of a hardwired system There is no specific sequence beyond that for shutting down 2000 Series gas sensors If the unit is going to be shut down for some time it is recommended that the sampling gas line shut off valve be turned off Also disconnect AC power to prevent damage from lightning strikes 2001 SpectraSensors Inc 27 Maintenance The 2000 Series re
19. he analyzer report the data every second because only one data point every 60 seconds is being collected by the data logger By changing the value entered for the Logger Rate the analyzer output can be matched to the data logger sample rate resulting in optimum signal averaging The setting can vary from 1 to 300 seconds Enter a numeric value in seconds and press the key to accept the new value The system will cycle to the next adjustable parameter If no changes are desired to the Logger Rate just press the key 2001 SpectraSensors Inc 22 Temperature Unit lt SET PARAMETER MODE gt Temperature Unit 0 O SC 1 gt F This enables the user to choose the unit to display for temperature measurement and dew point Choose between C or F The default value is C When the key is pressed the display will cycle to the next parameter Pressure Unit lt SET PARAMETER MODE gt Pressure Unit 0 Enter a value This enables you to choose the unit to display for Pressure measurement Choose among the follovving choices e Press O for millibar e Press 1 for Torr e Press 2 for Pascal e Press 4 for Pounds per Square Inch Absolute When the key is pressed the LCD will cycle to Concentration unit Concentration Unit lt SET PARAMETER MODE gt Concentration Unit O ppmv 1 lb mmscf 2001 SpectraSensors Inc 23 This enables you to choose the unit to display for water concentr
20. he unit is now ready to receive the inlet and outlet sampling gas lines Foot of mounting bracket identical on each rear corner of enclosure Figure 2 Main external components identified on 2000 Series gas sensor 2001 SpectraSensors Inc 7 Gas Line Connection Procedure The 2000 Series is configured to accept 4 O D sampling lines inlet and outlet via compression fittings mounted on the chassis AN CAUTIONI The inlet line should be equipped vith a membrane or coalescing filter to prevent liquid from entering the sample cell and possibly accumulating on the internal optics It is important that the internal optical elements remain clean for proper readings The inlet line should also have a shutoff valve to prevent gas flow into the analyzer when it is not in use The outlet line of the 2000 Series 1s connected to a 14 in O D stainless steel line that vents the sampled gas to ambient air outside the sampling station After the inlet and outlet lines have been connected the connections should be checked for leaks The minimum flow rate through the analyzer should be 0 3 liters per minute L min Optimum sample cell pressure is just above ambient pressure for the installation location Sample cell pressure is displayed on the front panel LCD AN CAUTIONI The pressure in the sample cell must not exceed 30 PSIG 3 Bar A Higher pressures will cause catastrophic damage to the instrument We recommend that there be no
21. indicate that the optics require cleaning Index is the position of the absorption peak within the wavelength scan It should normally be between 250 and 350 Zero is the detector signal value when the laser is turned off It should be in the range of 40 to 40 Mode 5 System Diagnostic Parameters for CO2 Function Key Test Key 8 Mode 5 displays the System Diagnostic Parameters for CO2 The description and normal ranges are the same as for Mode 4 The Function Key F1 is reserved for factory and service personnel diagnostics It is not meant to be used by operators although depression of this key will not result in any affect on the device for the user j The TEST key provides basic diagnostic test results for laser power pressure and temperature sensors and the infrared spectrum that is recorded by the system for analysis The LCD will display the following for a dual channel system lt TEST MODE gt ENTER SELECTION 1 H20 2 CO2 2001 SpectraSensors Inc 25 Select the entry for the channel you want to display In the case of a single channel system this screen is not shown and one of the screens below will be displayed instead To view the water channel press 1 and the LCD will display the following lt H20 SYSTEM TEST gt LASER POWER OK P T SENSORS OK SPECTR OK NULL OK To view the carbon dioxide channel press 2 and the LCD will display the following lt CO2 SYST
22. ising from the use of this equipment Liability is limited to replacement and or repair of defective components 2001 SpectraSensors Inc 35
23. l not to touch any of the optical surfaces Do not use air from an air compressor to blow off the optics It may contain either liquid or solid contaminants and the high velocity of some nozzles may propel dust into the mirror surface Always remove power from the equipment before cleaning Method SpectraSensors recommends using a solvent rinse cleaning process to avoid the possibility of scratching the optics In most cases this should be sufficient to restore the optics to usable condition A suitable cleaning kit is available from your local sales representative The kit includes mirror safe spray solvent an ultra pure air duster lint free wipes non outgasing o ring grease hex wrench spare screws and washers and spare fuses Process see illustrations where shown for each step 1 Mark the mirror flange and the end flange of the sample cell so that the mirror can be reinstalled with the same rotation 2 Remove the six screws holding the mirror assembly to the bottom of the sample cell Note the arrangement of the washers lock washers and nuts so that the flange can be attached the same way on reassembly 2001 SpectraSensors Inc 29 3 Carefully remove the o ring from the mirror assembly and place it on a clean surface 4 Hold the mirror assembly over a sink or bucket test bucket first to ensure compatibility with the solvent to catch any drips Position the mirror vertically so that the solvent flows down th
24. never be operated with the front cover open see Warranty and should always be connected to a properly grounded AC power source NOTE If the pressure and temperature readings or any readings on the LCD are suspect they should be checked against the specifications in the Specifications Sheet in the Operations section of this manual 2001 SpectraSensors Inc 33 Further Undetectable Problems If the above issues do not seem to be affecting a suspected problem with the Series 2000 gas sensor the user should consult the following final self troubleshooting guide before contacting a sales representative for service Table 3 Final Troubleshooting Table Non Operation at start up Is the AC power connected to both 2000 Series and AC power source j Non Operation after start up Switch On Is the AC power source good 100 to 250 VAC 50 60 H2 Check fuse Contact sales representative for further troubleshooting Power Fail Error Check optical head cable connections Do not disconnect or reconnect any optical head cables with the power connected Possible mirror contamination issue See maintenance section for cleaning procedure If you cannot or do not desire to clean mirrors contact sales representative for service Spectrum Fail Error Check optical head cable connections Do not disconnect or reconnect any optical head cables with the power connected Contact sales representative P T Fail Err
25. nsor if cord connected or by energizing the circuit if the gas sensor is hard wired Note that there is a 500 mA slow blow fuse located on the bottom right hand side of the chassis When AC power is applied to the 2000 Series the system will go through a 15 second initialization period The LCD on the keypad will display the word INTIALIZING and then start counting down from 15 The keypad will not respond to key presses during this time period Allow 3 additional minutes for the 2000 Series to stabilize before recording measurements Normal operation is indicated by continuous updates of the measurement parameters on the LCD See Figure 9 The LCD displays four lines of alphanumeric data In the normal operational mode Normal Mode the LCD readout displays lt NORMAL MODE gt H20 120 62pmv CO2 2 33 DP 41 00C P 1011 8mb T 23 20C Figure 9 2000 Series LCD on the keypad 2001 SpectraSensors Inc 16 Operation Specifications for Proper Use The 2000 Series is designed specifically to measure levels of moisture and carbon dioxide in a gas stream It also reports dew point temperature and pressure of the sampled gas Although the unit can easily be dismounted and moved from one sampling station to another it is designed to be a stationary measuring device It should be securely mounted during normal operation Opening of the main enclosure cover is required for installation only Thereafter you will rarel
26. o ring in the top of the flange on the sample cell 2001 SpectraSensors Inc 31 14 Clean the window on the bottom of the optical head assembly using the same procedure as for cleaning the mirror 5 Position a bucket below the sample cell on the side of the electronics box Flush the inlet tube outlet tube and the inside walls of the sample cell with the solvent letting it drip down into the bucket 6 After flushing for 5 to 10 seconds blovv off any residual solvent residue 7 Re attach the optical head assembly to the top of the sample cell 8 Re attach the mirror assembly to the bottom of the sample cell aligning it the same way it was to begin with 19 Re connect the measurement head cables 20 The gas sensor is now ready to power up 2001 SpectraSensors Inc 32 Troubleshooting Gas Leaks Probably the most common cause of erroneous measurements is outside air leaking into the inlet sampling line It is recommended the inlet lines be leak tested periodically especially if the unit has been relocated or if the unit has been replaced or returned to the factory for service and the sample lines have been reconnected High Humidity Excessive High humidity or condensation of water may cause temporarily high readings If the 2000 Series is exposed to these conditions for long periods of time sampling lines may take a long time to completely outgas Sufficient time should
27. or Check Pressure Temperature cable connections Contact sales representative Test button on keypad indicates a Contact sales representative failed component LCD display does not update Unit is Switch off AC power wait for 30 locked up seconds then switch AC power back on 2001 SpectraSensors Inc 34 Warranty The Manufacturer warrants the items delivered shall be free from defects latent and patent in material and workmanship for a period of one year after delivery to the Buyer The Buyer s sole and exclusive remedy under this warranty shall be limited to repair or replacement Defective goods must be returned to the Manufacturer and or its Distributor for valid warranty claims This warranty shall become inapplicable in instances where the items have been misused or otherwise subjected to negligence by the Buyer Notwithstanding any other provision of this contract no other warranties whether statutory or arising by operation of law expressed or implied including but not limited to those of merchantability or fitness for particular purpose shall apply to the goods or services hereunder other than the repair and replacement warranty above Seller shall in no event be liable to buyer or any third party for any damage injury or loss including loss of use or any direct or indirect incidental or consequential damages of any kind Disclaimer SpectraSensors accepts no responsibility for consequential damages ar
28. ow the terminal manufacturer s instructions for preparing and crimping the terminal 8 Remove the grounding screw at the bottom right of the electrical panel See figure 5 Insert the screw through the ring terminal on the green wire of the power cord through the ring terminal of the internal grounding wire and tighten it into the panel _ CAUTION Failure to properly ground the gas sensor can create a high voltage shock hazard Follow the instructions carefully 2001 SpectraSensors Inc 10 Figure 5 Connect the green wire to the ground contact in the lower left corner of the enclosure 9 Tighten the strain relief mechanism so that it is grips the power cord 10 Close and lock the enclosure door 11 Plug the power cord into an AC socket The socket should be fused for 15A or less Because the plug on the power cord is the primary power disconnect means the AC socket must be located within 10 ft of the gas sensor To hardwire power to the unit through a conduit AN CAUTIONI Before attempting to attach the pover viring to the gas sensor be sure that there is no power present on the wires 1 Open the enclosure door being careful not to disturb the electrical assembly inside 2 Remove the cord strain relief fitting from the power knockout Replace the strain relief with a NEMA 4X rated conduct hub 4 Run conduit from the AC panel to the conduit hub Since the breaker or switch in the AC panel will be the prim
29. quires very little regularly scheduled maintenance In fact the unit itself requires no maintenance that can be performed by the user However there are some external conditions that can affect the measurement Reducing Contamination of Gas Sampling Lines Contamination in the gas sampling lines can contaminate the optics and absorption cell causing problems To keep the sampling lines clean and improve response at very low humidity 1 Make sure the coalescing filter is operating and replace if necessary Small amounts of glycol or amine in the gas phase should not cause problems as they will be swept out of the sample region by the gas flow and they do not affect the measurement in any way But if liquid enters the cell and accumulates on the internal optics the system will not operate correctly Pressure TEST on the keypad will indicate a failure in laser power if the mirrors become contaminated 2 Disconnect the gas sampling inlet and outlet lines from their respective connections on the 2000 Series 3 Wash the sampling lines with water or acetone and blow dry with mild pressure from a dry air or nitrogen source It may be desirable to heat the lines for a few minutes to clear residual water from the lines 4 Reconnect the gas sampling lines by tightening the connection finger tight and then tightening an additional 34 turn with a 9 16 in open end wrench Procedure for Cleaning Contaminated Mirrors The 2000 Series is intended
30. restrictions in the output vent line of the sample cell and that a pressure relief valve be used on the input line in case of regulator failure To make the gas line connections 1 To avoid initial contamination entering the analyzer establish the gas flow and blow any contamination from the line before connecting 2 Align the inlet and outlet tubing to gas sensor inlet and outlet connections 3 Be sure that there is no stress on the tubing when it is aligned to the gas Sensor 4 Install union type swage fittings to connect the inlet and outlet tubes to the gas sensor 5 Follow manufacturer s recommended procedure for tightening the fittings Open the shutoff valve on inlet line 7 Check the connections for gas leaks 2001 SpectraSensors Inc 8 Electrical Power Connection Procedure Electrical power can be connected to the unit with either a power cord or through a conduit A 2 knockout is provided at the lower right of the unit to accomplish this The 2000 Series is equipped with either a universal power supply that will accommodate both US 115 VAC 60 Hz and European 240 VAC 50Hz AC power configurations or a DC input power supply CAUTION Before attempting to attach the power wiring to the gas sensor be sure that there is no power present on the wires To connect an electrical power cord to the unit 1 Open the enclosure door being careful not to disturb the electrical assembly inside 2 Threa
31. s technology was first utilized for accurate measurements of gases in the Earth s atmosphere in the early 1980s and recently was incorporated into miniaturized and space qualified instruments for Mars research SpectraSensors obtained the commercial rights to this NASA technology and is now offering state of the art gas sensors About the Model 2000 Series Gas Sensor The 2000 series of gas sensors are Tunable Diode Laser TDL absorption spectrometers operating in the near infrared wavelength region Each 2000 sensor contains a TDL light source and detector configured to allow high sensitivity in a compact package microprocessor based electronics and software incorporating advanced operational and data processing algorithms This manual will use the two channel system as a reference for description All comments also apply to the single channel sensors except where indicated The 2000 Series is designed for use at natural gas sampling stations extractive analysis installations or wherever fast response and high accuracy measurements are required over a wide measurement range It is a high performance instrument capable of measuring moisture and carbon dioxide in methane and other gases without regard to corrosive gases and contamination from other gas phase constituents in the stream Several patents protect the TDL absorption technology incorporated in SpectraSensors gas analyzers Theory of Operation Both HO and CO are measured by
32. serial outputs through a cable 1 Disconnect power from the unit 2 Open the enclosure cover being careful not to disturb the electrical assembly inside 3 Thread the signal cable through the strain relief fitting into the enclosure The strain relief fitting is sized to accommodate cables with outer diameters from 0 31 to 0 56 SpectraSensors recommends that a cable with an individually shielded pair for each signal be used for the signal connections 4 Strip back the jacket and insulation of the signal cable enough that it can be connected to the mating terminal block 5 The mating terminal block can be pulled up from its base to make cable connection easier See figure 6 2001 SpectraSensors Inc 12 6 Table 2 shows the pin number for each of the output signals Note that there is a single ground connection shared by all of the signals 6 CHI Current Loop 8 CH2 Current Loop 9 CH2 Current Loop Table 2 Output Signal Connections 7 Connect the output wires to the desired terminals See figure 7 8 Reinsert the matting terminal block into the base and verify that the terminals are tight See figure 8 9 Cinch the strain relief mechanisms so that they are snug with the outside of the enclosure 10 Close and lock the enclosure cover Power supply block 4 20 mA and serial 4f outout block I 4 20 mA and serial outout block base Figure 6 Remove the mating terminal block from base by
33. y need to open the cover of the main enclosure for inspection or maintenance Subsequent to installation do not open the enclosure for this purpose unless directed to do so by a service representative The measurement heads may be disassembled for cleaning purposes see the Maintenance Section of this manual The two main parts of the measurement head are the gas sampling cell and the optical head assembly The gas sampling cell may be separated from the optical head assembly and can be further disassembled for mirror cleaning purposes from time to time In no case however will the operator need to disassemble the optical head assembly CAUTION Note the enclosure seal used to prevent inadvertent tampering with the device It is imperative that the operator not attempt to compromise the seal of the optical head assembly enclosure Doing so will result in loss of device sensitivity and inaccurate measurement data Repair of this situation must be handled by the factory and is not covered by warranty Keypad Functions The keypad allows the operator to modify certain parameters that control the 2000 Series However once the unit has been properly installed and normal operation has been established there should be no need to alter the operational parameters Measurements of H20 CO Dew Point Temperature and sample cell Pressure are continuously displayed on the LCD display For single channel H O only systems the CO value will always
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