Servomex Servotough Spectrascan (2400) Gas Analyzer User Manual

PROCESS ANALYZERS SERVOTOUGH SpectraScan (2400) Gas Analyzer User Manual Part Number: Revision: Language: 02400001A 0 US English The SpectraScan Analyzer is manufactured by Precisive LLC of Boston , MA, USA who assume responsibility for the product performance with regard to software and set up using appropriate gas mixtures for calibration. The methodology is patent protected and is the Intellectual Property of Precisive LLC. SERVOTOUGH SpectraScan User Manual TABLE OF CONTENTS 1  ABOUT THIS MANUAL ....................................................................................... 6  1.0  1.1  1.1.1  1.1.2  1.1.3  Introduction .......................................................................................................... 6  Symbols and Notices Used in this Manual .......................................................... 7  Hazard Notices .................................................................................................... 7  Hazard Labels Statement .................................................................................... 7  IEC and ISO Symbols.......................................................................................... 8  2  SYSTEM OVERVIEW ......................................................................................... 9  2.0  2.1  Introduction to the Analyzer ................................................................................. 9  Measurement Principle ........................................................................................ 9  3  SYSTEM SAFETY ............................................................................................. 12  3.0  3.1  3.2  3.3  3.4  3.4.1  3.4.2  3.4.3  3.4.4  3.4.5  3.4.6  General Precautions .......................................................................................... 13  WARNINGS AND CAUTIONS .......................................................................... 15  Suitability of Application..................................................................................... 17  Operator Training .............................................................................................. 17  Analyzer Hazards .............................................................................................. 17  Gases ................................................................................................................ 17  Heated Equipment ............................................................................................. 18  Over Pressurizing .............................................................................................. 18  Electrical Safety ................................................................................................. 19  Electrostatic Discharge ...................................................................................... 19  Ergonomic Considerations ................................................................................ 20  4  UNPACKING THE ANALYZER ......................................................................... 21  4.0  4.1  4.2  Component List ................................................................................................. 21  Removing the Analyzer from the Shipping Container ....................................... 22  Inspection .......................................................................................................... 22  5  MOUNTING CONSIDERATIONS ..................................................................... 23  5.0  5.0.1  5.0.2  5.0.3  5.0.4  5.0.5  5.1  Environmental Requirements ............................................................................ 23  Dimensions, Weight and Ventilation.................................................................. 24  Operating Temperature, Humidity and Pressure .............................................. 25  Combustion Hazard ........................................................................................... 26  Power Requirements ......................................................................................... 26  Fittings Requirements........................................................................................ 26  Mounting Procedure .......................................................................................... 26  6  ELECTRICAL CONNECTIONS ......................................................................... 29  6.0  6.0.1  6.1  6.2  6.2.1  6.2.2  6.3  6.4  I/O Panel Layout ................................................................................................ 30  Component Layout ............................................................................................ 32  Electrical Power Requirements ......................................................................... 34  Wiring................................................................................................................. 35  Power Wiring: 24 VDC....................................................................................... 36  Power Wiring: 120-240 VAC.............................................................................. 38  Communication Connection .............................................................................. 40  Spectrascan Networking and Software Configuration....................................... 42  02400001A/0 i SERVOTOUGH SpectraScan User Manual 6.4.1  6.4.2  6.4.3  6.4.4  6.4.5  Ethernet and TCP/IP ......................................................................................... 42  Finding the IP address of your instrument......................................................... 42  Setting a static IP address ................................................................................. 43  RS-422 connection ............................................................................................ 46  Modbus register ................................................................................................. 48  7  SAMPLE GAS CONNECTIONS ........................................................................ 49  7.0  7.0.1  7.0.2  7.0.3  7.0.4  7.0.5  7.0.6  7.1  7.1.1  Sample Line Connections ................................................................................. 50  Sampling Ports .................................................................................................. 50  Preparing Sample Gas Lines ............................................................................ 50  Sampling Gas from a Pressurized Source ........................................................ 51  Cleanliness of Sample Stream .......................................................................... 51  Stream Switching Using External Solenoid Valves ........................................... 52  Procedure for Connecting the Sample Lines..................................................... 54  Enclosure Purge Connections ........................................................................... 55  Purging of Enclosure Compartment .................................................................. 55  8  INSTALLATION CHECKLIST ............................................................................ 57  9  VERIFICATION ................................................................................................. 59  9.0  9.0.1  9.0.2  9.0.3  9.1  Procedure .......................................................................................................... 59  Setup ................................................................................................................. 59  Zeroing............................................................................................................... 60  Span Verification ............................................................................................... 60  Re-spanning ...................................................................................................... 60  10  MAINTENANCE ................................................................................................ 61  10.0  Light Source Assembly Replacement Procedure .............................................. 62  11  TROUBLESHOOTING ...................................................................................... 67  12  APPENDIX A: PRODUCT SPECIFICATIONS .................................................. 69  12.0  12.1  12.2  12.3  12.4  12.5  12.6  Measurement Specifications ............................................................................. 69  Physical Specifications ...................................................................................... 70  Communications Specification .......................................................................... 70  Sampling System Specifications ....................................................................... 71  Electrical Specifications ..................................................................................... 72  Environmental Specifications ............................................................................ 72  Manual Revision History .................................................................................... 72  13  INDEX ................................................................................................................ 73  14  CONTACT DETAILS ......................................................................................... 74  02400001A/0 ii SERVOTOUGH SpectraScan User Manual List of Figures Figure 1 - The Servomex SpectraScan Gas Analyzer ............................................................. 23  Figure 2 - Hole Dimensions of the Servomex SpectraScan Gas Analyzer.............................. 24  Figure 3 - I/O panel of the Servomex SpectraScan Gas Analyzer .......................................... 30  Figure 4 - Analyzer with Cover Open ....................................................................................... 31  Figure 5 - Interior of the Servomex SpectraScan Gas Analyzer .............................................. 32  Figure 6 - SpectraScan Interior Diagram ................................................................................. 33  Figure 7 - Example Rating Label ............................................................................................. 34  Figure 8 - Wiring the SpectraScan with 24 VDC ...................................................................... 36  Figure 9 - Wiring the SpectraScan with 120-240Vac ............................................................... 38  Figure 10 - Connecting the Ethernet TCP/IP communication cable ........................................ 40  Figure 11 - Location of the serial number tag .......................................................................... 42  Figure 12 - Location of debug RS-232 connector on MPU ...................................................... 44  Figure 13 - Sample session in which a static IP address is set using PuTTY to communicate with the MPU..................................................................................................................... 46  Figure 14 - Identification of RS-422 signals in instrument ....................................................... 47  Figure 15 - Location of RS-422 connector on system board ................................................... 47  Figure 17 – Typical Gas Connection Configuration ................................................................. 49  Figure 18 - Recommended Connections for Inlet Stream Switching ....................................... 53  Figure 19 - Accessing the Light Source ................................................................................... 63  Figure 20 - The Light Source Circuit Board ............................................................................. 63  Figure 22 - Mounting Hole for Light Source ............................................................................. 64  Figure 21 - The Light Source Assembly................................................................................... 64  Figure 23 - Dimensions of SpectraScan .................................................................................. 70  02400001A/0 iii SERVOTOUGH SpectraScan User Manual List of Tables Table 1 - Definition of Symbols Found on the Analyzer............................................................. 8  Table 2 - Hazardous Location Ratings..................................................................................... 12  Table 3 - Standard Fittings Used on the Servomex SpectraScan Gas Analyzer .................... 26  Table 4 - Wire Types ................................................................................................................ 35  Table 5 - SpectraScan Modbus register .................................................................................. 48  Table 6 - Diagnostic LED Indications ....................................................................................... 59  Table 7 - Troubleshooting ........................................................................................................ 67  Table 8 – Measurement Specifications .................................................................................... 69  Table 9 – Physical Specifications ............................................................................................ 70  Table 10 - Communications Specifications .............................................................................. 70  Table 11 - Sampling System Specifications ............................................................................ 71  Table 12 - Response Time Versus Gas Flow Rate ................................................................. 71  Table 13 - Electrical Specifications .......................................................................................... 72  Table 14 - Environmental Specifications.................................................................................. 72  02400001A/0 iv SERVOTOUGH SpectraScan User Manual This page intentionally left blank. 02400001A/0 v SERVOTOUGH SpectraScan User Manual 1 ABOUT THIS MANUAL 1.0 Introduction This manual provides information about the Servomex SpectraScan Gas Analyzer. TCP/IP enabled, the Servomex SpectraScan Gas Analyzer can monitor process gases remotely, unattended for extended periods of time. This manual presents all safety considerations of the Servomex SpectraScan Gas Analyzer first, and then provides instructions for unpacking, mounting and connecting the unit. An installation checklist ensures all the required tasks are performed. The verification test confirms span accuracy upon installation, and includes the zeroing procedure which may be repeated periodically. Short maintenance and troubleshooting sections are included in this manual. Product specifications are given in the appendix at the end of this manual. Before installing or operating your Servomex SpectraScan Gas Analyzer, carefully read and familiarize yourself with System Safety. In addition, observe and obey all Hazard Notices and Symbols provided for your safety throughout this manual.  02400001A/0 NOTES Read this manual in its entirety before attempting to perform any operations on the Servomex SpectraScan System. 6 SERVOTOUGH SpectraScan User Manual 1.1 Symbols and Notices Used in this Manual This manual contains attention symbols and notices which should be observed to ensure personal safety, as well as to protect the product and the connected equipment. Hazard notices are accompanied with text that identifies the hazard, advises you to avoid the hazard, and/or the probable consequences of NOT avoiding the hazard. Where applicable, within the notice box or near the paragraph text, the appropriate IEC or ISO symbol is used. Attention notices provide useful information pertinent to the operation of the analyzer. The following notices are displayed throughout Servomex documentation: 1.1.1 Hazard Notices Read this manual and ensure that you fully understand its content before you attempt to install, use or maintain the analyzer. Important safety information is highlighted in this manual as WARNINGS and CAUTIONS and NOTES, which are used as follows; WARNING Warnings highlight specific hazards which, if not taken into account, may result in personal injury or death. CAUTION Cautions highlight hazards which, if not taken into account, can result in damage to the analyser or to other equipment or property.  1.1.2 NOTES This highlights information which it is useful for you to be aware of (for example, specific operating conditions, and so on). Hazard Labels Statement Hazard labels indicate possible hazardous areas and identify the potential hazard on the analyzer. Hazard labels are applied to the access areas of the analyzer to caution the following:    Exposure to hazardous chemicals (gases, process materials or by-products, solvents/solutions) or physical conditions (heat or excessive cold) that may result in injuries Exposure to electrical energy that may cause electric shock or death Exposure to high temperatures that may cause injuries See Table 1 IEC and ISO Symbols on page 8 for definition of symbols. 02400001A/0 7 SERVOTOUGH SpectraScan User Manual 1.1.3 IEC and ISO Symbols The following symbols may be found on the Servomex SpectraScan Gas Analyzer and in the documentation: Definition of Symbols Found on the Analyzer and in this Manual | On (Supply) Off (Supply) Protective Earth (Ground) Protective Conductor Terminal IEC 60417, No. 5007 IEC 60417, No. 5008 IEC 60417, No. 5017 IEC 60417, No. 5019 Caution, hot surface Equipotentiality Frame or Chassis Terminal ISO 3684, No. 6043 IEC 60417, No. 5021 IEC 6041, No. 5020 Double or Reinforced Insulation IEC 6041, No. 5172 3 Direct Current Alternating Current Both Direct and Alternating Current IEC 60417, No. 5031 IEC 60417, No. 5032 IEC 60417, No. 5033 Three-phase Alternating Current Caution, refer to Caution, risk of electric shock ISO 3864, No.B.3.6 accompanying documents Out position of a bistable push control In position of a bistable push control ISO 3864, No.B.3.1 IEC 60417, No 5269 IEC 60417, No 5268 Table 1 - Definition of Symbols Found on the Analyzer 02400001A/0 8 SERVOTOUGH SpectraScan User Manual 2 SYSTEM OVERVIEW This chapter introduces the Servomex SpectraScan Gas Analyzer and explains its basic principle of operation. 2.0 Introduction to the Analyzer The Servomex SpectraScan Gas Analyzer is a non-contact, light absorption based gas analyzer capable of ppm to percent level concentration monitoring of multiple gas compounds. The system consists of a light spectrometer, a flow-through sample cell, a single-element photo-detector and the supporting electronics. The spectrometer uses a unique tunable Fabry-Perot assembly that provides wavelength scanning with high optical throughput. An advanced spectral processing algorithm computed in the embedded electronics provides highly accurate and robust quantitative measurements. The analyzer is configured and calibrated for a specific wavelength analysis region(s) depending on the application for which it is intended. It is designed to be a dedicated on-line monitoring system that is “plug and play,” not requiring any on-site configuration or calibration. The specific system configuration and calibration is denoted by the application code “-xyz” that can be found in the Calibration Verification Sheet delivered with the analyzer. Example applications of the Servomex SpectraScan Gas Analyzer include: Hydrocarbon gas composition monitoring Petrochemical process monitoring Specialty and chemical gas process and blending monitoring Catalysis and combustion process monitoring 2.1 Measurement Principle When a gas sample is introduced in the gas cell, the light radiation provided by a broadband light source is partially absorbed by the gas species present. The light absorption occurs at specific frequencies and magnitudes depending on the gas compound and the concentration of that compound. The Servomex SpectraScan spectrometer module scans the wavelength and measures the true absorption spectra and compares them with the pre-loaded calibration spectra. The onboard analysis algorithm computes the gas concentrations in real-time, which can then be output through the MODBUS TCP/IP protocol. In principal, the absorption spectrum of each compound is unique which acts as a “fingerprint” for identification or speciation analysis. In addition, the magnitude of the absorption is a function of the number of molecules of the gas. With a known path length, pressure and temperature, the magnitudes of the absorption spectra are then used to compute volumetric concentrations. This first principle based technique provides accurate and robust measurements with minimal span and baseline drifts. The analyzer employs an internal pressure transducer to measure the sample pressure in real-time enabling pressure variation corrections. The flow cell is heated to a constant temperature (default value is 60oC) with a sample preheat module to maintain both sample and optical sensor temperature at a constant calibrated temperature, thereby ensuring measurement accuracy and stability despite sample and environmental variations. 02400001A/0 9 SERVOTOUGH SpectraScan User Manual 02400001A/0 10 SERVOTOUGH SpectraScan User Manual This page intentionally left blank. 02400001A/0 11 SERVOTOUGH SpectraScan User Manual 3 SYSTEM SAFETY A primary concern of Servomex is to ensure a safe working environment for all users of our system. The Servomex SpectraScan Gas Analyzer meets the following classifications; Hazardous Location Classification: Classification and Rating Class 1, Division 2, Groups A,B,C and D, T4 Class 1, Zone 2, AEx nA nC nL IIC T4 Gc Class 1, Zone 2, Ex nA nC nL IIC T4 Gc II 3G Ex ic nA nC IIC T4 Gc IP66 ITS12ATEX Ambient Temperature Rating: -20 < Tamb < 50°C (-4 to 122°F) Table 2 - Hazardous Location Ratings It is essential that all users become aware of the hazards associated with the start-up, operation and maintenance of this analyzer. Servomex SpectraScan users must observe all prescribed safety guidelines and adopt good general work practices to adequately protect themselves, fellow workers and the unit. Only trained and experienced users should start, operate and/or maintain the Servomex SpectraScan Gas Analyzer. WARNING The following general safety precautions must be observed during all phases of installation and operation of this analyzer. Failure to comply with these precautions or with specific warnings elsewhere in this manual violates safety standards of intended use of the unit and may impair the protection provided by the analyzer, exposing the user to the risk of injury or death and possibly causing damage to the analyzer. Servomex assumes no liability for the customer’s failure to comply with these requirements. 02400001A/0 12 SERVOTOUGH SpectraScan User Manual 3.0 General Precautions DO NOT SUBSTITUTE PARTS OR MODIFY THIS ANALYZER Do not install substitute parts or perform any unauthorized modification to the analyzer. Return the analyzer to Servomex for service and repair to ensure that all safety features are maintained. SERVICE BY QUALIFIED PERSONNEL ONLY There are no user serviceable components in the analyzer. Component replacement and internal adjustments must be made by qualified Servomex representatives only. GROUNDING THE PRODUCT This product is grounded through the grounding conductor of the power cabling to the ground lug inside the enclosure. This grounding is essential for safe operation. Upon loss of the protective ground connection, all accessible conductive parts (including knobs and controls that may appear to be insulated) can render an electrical shock. Dangerous voltages are contained within this analyzer. All electrical fittings and cables must be of the type specified, and be in good condition, and all electrical fittings must be properly connected and grounded. All cables entering the analyzer (24 VDC or 120/240 VAC power and communication) must be separately jacketed as they enter the analyzer to prevent mis-wiring. symbol for ground USING THE PROPER POWER CABLING This product is designed to be hardwired and has a 24 VDC model and a 120/240 VAC model. Use only power cabling that is in good condition and which meets the input power requirements specified in this manual. The power cabling used, whether for 24 VDC operation or for 120-240 VAC operation, must use a 3 conductor cable that is jacketed separately from the communications cable. The ground wire in this 3 conductor cable must be electrically connected to the earth ground lug in the analyzer. See Section 5.0.4 Power Requirements on page 26 and Table 13 - Electrical Specifications on page 72 for more information. Also see Table 4 - Wire Types on page 35. USING THE PROPER POWER SOURCE This product is configured at the factory to operate from a 24 VDC or 120-240 VAC power source, depending on the model. See labelling on the analyzer to determine which power source to use. Ensure that the power supplied to the analyzer is appropriate for the configuration of analyzer being installed. See Section 5.0.4 Power Requirements on page 26 for more information. 02400001A/0 13 SERVOTOUGH SpectraScan User Manual USE THE PROPER FUSE Use only a fuse of the correct type, voltage rating, and current rating, as specified for your product. See Table 13 - Electrical Specifications on page 72 and Figure 6 - SpectraScan Interior Diagram on page 33 for more information. DO NOT OPERATE IN EXPLOSIVE ATMOSPHERES To avoid explosion, do not operate this product in an explosive environment unless it has been specifically certified for such operation. If it has been certified for such operation, carefully follow the guidelines set forth in the Material Safety Data Sheets for the explosive chemical, as well as the product labelling on the Servomex SpectraScan Gas Analyzer. HIGH VOLTAGE DANGER Assume high voltage is present in the cable and in the analyzer whenever a power cord is connected. USE PROPER FITTINGS AND TIGHTENING PROCEDURES All connection fittings must be consistent with Servomex SpectraScan Gas Analyzer specifications, and compatible with the intended use of the unit. Assemble and tighten fittings according to manufacturer's directions. See Section 5.0.5 Fittings Requirements on page 26 for more information. CHECK FOR LEAK-TIGHT FITTINGS Carefully check all connections to ensure leak-tight installation. OPERATE AT SAFE INLET PRESSURES Never operate at pressures higher than the rated maximum and minimum pressure. See Section 3.4.3 Over Pressurizing on page 18 and Table 11 - Sampling System Specifications on page 71 for more information. KEEP THE UNIT FREE OF CONTAMINANTS Do not allow contaminants to enter the unit before or during use. Contamination such as dust, dirt, lint, glass chips, or metal chips may permanently damage the unit. 02400001A/0 14 SERVOTOUGH SpectraScan User Manual ALLOW PROPER WARM-UP TIME The unit’s gas cell is temperature-controlled and will only meet measurement accuracy specifications when sufficient time is allowed for the unit to meet and stabilize to the designed operating temperature. Warm-up time for the unit is approximately 30 minutes to 2 hours depending on the ambient temperature. The analyzer temperature shall be stable (default value is 60oC) prior to performing any measurement. The red “Warm-up” LED on the display extinguishes and the green “Run” LED lights when the unit has reached operating temperature. MAINTAIN INGRESS PROTECTION The Servomex SpectraScan unit has been tested to an Ingress Protection level of IP66, Type 4. In order to maintain this rating, a suitable 1” conduit connector must be used that will not compromise the existing IP Rating. 3.1 WARNINGS AND CAUTIONS This apparatus is suitable for use in Hazardous Locations as defined in Table 2 - Hazardous Location Ratings on page 12, or unclassified locations. WARNING LOSS OF SYSTEM INTEGRITY: Exposure to some chemicals may degrade the sealing properties. WARNING EXPLOSION HAZARD: Do not remove or replace fuses unless power has been disconnected or the area is known to be free of ignitable concentrations of flammable gases or vapours. WARNING EXPLOSION HAZARD: The ac and dc source must be located in an unclassified area. WARNING SYSTEM SAFETY: This analyzer is typed as permanently connected equipment and as such, must include a switch or circuit–breaker in the installation. This switch must be supplied and installed by the customer (not provided by Servomex. It must be suitably located and easily reached, and must be marked as the disconnecting device for the equipment. 02400001A/0 15 SERVOTOUGH SpectraScan User Manual WARNING EXPLOSION HAZARD: Do not disconnect while the circuit is live unless the area is known to be free of ignitable concentrations of flammable gases or vapours. WARNING EXPLOSION HAZARD: Substitution of components may impair suitability for class 1, division 2 and class 1, zone 2 installations. WARNING EXPLOSION HAZARD: Do not use screws that exceed the maximum screw penetration depth in any threaded holes. 02400001A/0 16 SERVOTOUGH SpectraScan User Manual 3.2 Suitability of Application It is the customer’s responsibility to determine the suitability of the Servomex SpectraScan Gas Analyzer for a given purpose. Servomex makes no representation that potential hazards presented here or elsewhere are the only hazards associated with this product and its start-up, operation or maintenance. 3.3 Operator Training All users should be fully trained in all applicable safety and emergency procedures. At a minimum:     Safe work practices and procedures Electrical safety Chemical safety and procedures for handling hazardous materials Proper use of personal protective equipment (PPE) 3.4 Analyzer Hazards The Servomex SpectraScan is designed to be safe. The following hazards are unavoidably present when operating or servicing the Servomex SpectraScan Gas Analyzer. All personnel connected to the operation, installation or maintenance of the Servomex SpectraScan Gas Analyzer must be familiar with the hazards intrinsic to the analyzer’s environment:       3.4.1 Gases Heated Equipment Over Pressurizing Electrical Safety Electrostatic Discharge Ergonomic Considerations Gases WARNING Imminent Danger of Personal Injury or Death: The Servomex SpectraScan Gas Analyzer is designed and can be configured to analyze some flammable or explosive gas mixtures. Do not use this unit with flammable or explosive gases unless it has been specifically certified for that application.  02400001A/0 NOTE Consult the gas manufacturer’s Material Safety Data Sheets (MSDS) for further details on the storage, use, and safe handling procedures applicable for these gases. 17 SERVOTOUGH SpectraScan User Manual 3.4.2 Heated Equipment The gas cell in the Servomex SpectraScan Gas Analyzer will be heated to a temperature that is higher than the gas being sampled to avoid condensation on the optical windows in the gas cell. WARNING Burn Hazard: The gas cell, though insulated, may be extremely hot. Use caution when handling the gas cell, sample lines or other heated equipment. 3.4.3 Over Pressurizing CAUTION Equipment Damage: Restricting the gas flow on either the intake or the exhaust side may cause the gas cell to over pressurize, causing damage to the analyzer. Care should be taken to remove any port caps or other flow barriers before connecting any sample line or switching on the analyzer. Also make sure the exhaust routing is appropriate for your specific application. When the gas is to be sampled from a pressurized source, such as a pressurized line, a pressure relief mechanism should be employed so as not to force or restrict the flow of gas into the unit. CAUTION Equipment Damage: Pressure relief mechanism should be employed when sampling gas from a source other than the ambient in order to avoid damage to the analyzer. 02400001A/0 18 SERVOTOUGH SpectraScan User Manual 3.4.4 Electrical Safety The Servomex SpectraScan Gas Analyzer is powered by voltages that could pose a hazard to the user. Before any maintenance work is performed, disconnect power from the analyzer and turn off the gas supply. Follow standard electrical safe work practices to prevent injuries. WARNING Electrical Hazard, Personal Injury and Equipment Damage: Do NOT perform maintenance on an energized or gas supplied analyzer. When performing maintenance on the unit, it is necessary to disconnect the power source from the unit, and turn off the gas supply lines (sample gas and zero gas). WARNING SYSTEM SAFETY: This analyzer is typed as permanently connected equipment and as such, must include a switch or circuit–breaker in the installation. This switch must be supplied and installed by the customer (not provided by Servomex) must be suitably located and easily reached, and must be marked as the disconnecting device for the equipment. 3.4.5 Electrostatic Discharge WARNING Electrical Hazard, Personal Injury and Equipment Damage: The control of ESD is critical when performing maintenance on the Servomex SpectraScan Gas Analyzer. To control ESD, users should wear ESD wrist straps and other grounding equipment between the analyzer and the skin. The wrist straps should be tested for ground continuity often. Also, ground the analyzer (through the frame chassis or the control rack) to protect against:    02400001A/0 Damage to sensitive electronic components, such as circuit boards Electrostatic discharge User injuries from electrical shock when contact is made with the energized equipment. 19 SERVOTOUGH SpectraScan User Manual 3.4.6 Ergonomic Considerations Ergonomic hazards are conditions that could result in harm to the operator or technician due to the physical circumstances of operating or servicing the analyzer. Ergonomic hazards of the Servomex SpectraScan Gas Analyzer include:   Lifting the analyzer Stretching or maintaining an awkward position WARNING Personal Injury: The Servomex SpectraScan Gas Analyzer weighs approximately 30 lbs (14Kg), presenting the possibility of personal injury if care is not taken when lifting and moving this unit. 02400001A/0 20 SERVOTOUGH SpectraScan User Manual 4 UNPACKING THE ANALYZER 4.0 Component List A standard Servomex SpectraScan Gas Analyzer is delivered with the following components:    02400001A/0 Servomex SpectraScan Gas Analyzer unit Installation Manual Calibration Verification Sheet 21 SERVOTOUGH SpectraScan User Manual 4.1 Removing the Analyzer from the Shipping Container WARNING Personal Injury: The Servomex SpectraScan Gas Analyzer weighs approximately 30 lbs (14Kg), presenting the possibility of personal injury if care is not taken when lifting and moving this unit.  NOTE Do NOT discard any packaging material. All of the original packaging material is required to return the unit to Servomex. The use of unsuitable packaging material during shipping will void the analyzer’s warranty. To remove the system from the shipping box, perform the following steps: 1. Open the top flaps on the cardboard shipping box and fold them out of the way. 2. Lift the unit together with the inner packaging materials, keeping the shock absorbing foam pieces around the unit. 3. Set the unit (with the inner packaging still around it) on a flat workbench or table. 4. Carefully remove the foam packaging, the plastic bag and the desiccant (if applicable) from the unit. 5. Return all of the packaging material to the box and store in a safe place for future use. 4.2 Inspection Servomex has carefully packed the Servomex SpectraScan Gas Analyzer with the intent of reaching its destination in perfect operating condition. Upon unpacking the unit, check for defects, cracks, broken connectors, etc, to be certain that damage has not occurred during shipment. If you find any damage, notify your freight carrier and Servomex immediately. 02400001A/0 22 SERVOTOUGH SpectraScan User Manual 5 MOUNTING CONSIDERATIONS 5.0 Environmental Requirements The following considerations are described in this section:  Dimensions, Weight and Ventilation  Operating Temperature, Humidity and Pressure  Combustion Hazard  Power Requirements  Fittings Requirements Figure 1 - The Servomex SpectraScan Gas Analyzer 02400001A/0 23 SERVOTOUGH SpectraScan User Manual 5.0.1 Dimensions, Weight and Ventilation The Servomex SpectraScan Gas Analyzer weighs approximately 30 lbs (14kg) and is designed to be wall mounted. It requires a space 17 ¼” wide, 12” high (top to bottom) with an additional 6” of clearance around the bottom for piping and electrical connections, and 7” wide (front to back) with an additional 10 ½” clearance out the front to allow opening of the cover (when installing electrical connections, or to make internal repairs or component replacements). WARNING Personal Injury: Improper installation can result in serious personal injury. Make sure that the mounting structure can support a redundant weight factor four times the total weight of the analyzer. If not, reinforce the structure before installing the analyzer. The mounting structure must be made of metal, or at minimum ½” plywood. Dimensions of the mounting holes along the top and bottom edges of the analyzer are given in Figure 2 below. The Servomex SpectraScan Gas Analyzer must be mounted with eight 3/8”-16 x 1” UNC bolts and matching lock washers and nuts. Figure 2 - Hole Dimensions of the Servomex SpectraScan Gas Analyzer See Figure 3 - I/O panel of the Servomex SpectraScan Gas Analyzer on page 24 for a view of the bottom of the analyzer, showing electrical and pipe connections. 02400001A/0 24 SERVOTOUGH SpectraScan User Manual  NOTE The sample, power and signal connections require at least 6” of clearance for safe operation. WARNING Personal Injury: The Servomex SpectraScan Gas Analyzer weighs approximately 30 lbs (14Kg), presenting the possibility of personal injury if care is not taken when lifting and moving this unit. The Servomex SpectraScan Gas Analyzer should be mounted in a well-ventilated area. WARNING Personal Injury: Operate the Servomex SpectraScan Gas Analyzer in a wellventilated area to prevent the build-up of potentially harmful gases. Do NOT vent sample cell exhaust into an area where it may be inhaled. 5.0.2 Operating Temperature, Humidity and Pressure The Servomex SpectraScan Gas Analyzer can operate in a wide range of ambient temperature and humidity, as shown in Table 14 - Environmental Specifications on page 72. The analyzer should be operated in a non-condensing environment to avoid condensation on the optical windows in the gas cell. In addition to the ambient considerations, the Servomex SpectraScan Gas Analyzer has specific requirements for the sample gas and zero gas being piped into it. Both sample gas and zero gas have the same acceptable flow rate, pressure, humidity and temperature ranges. See Table 11 Sampling System Specifications on page 71. Refer to the Applications Manual for more sample pressure recommendations. There are overpressure considerations for the sample and zero gases entering the analyzer to avoid injury and damage to the unit. See Section 7.0.3 Sampling Gas from a Pressurized Source on page 51. The sample and zero gas must be clean and free of particulates. A 10 micron particulate filter on the supply side is recommended. 02400001A/0 25 SERVOTOUGH SpectraScan User Manual 5.0.3 Combustion Hazard The Servomex SpectraScan Gas Analyzer is rated for certain combustible environments. Ensure that the installation location of the analyzer aligns with the certifications listed on the product’s labelling. 5.0.4 Power Requirements The system is designed for 24 VDC operation. An optional AC Power Module can be installed at the factory for use with 100-240 VAC. The main power board is fused for use with a 24 VDC supply. Refer to Table 13 - Electrical Specifications on page 72 for more detailed information. 5.0.5 Fittings Requirements The Servomex SpectraScan Gas Analyzer comes standard with ¼” male Swagelok tube fittings on the sample inlet and exhaust ports. Only ¼” female Swagelok tube fittings should be used on the incoming and outgoing sample lines, to mate with the Servomex SpectraScan sample inlet and exhaust ports. Use of stainless steel tubing for the incoming and outgoing sample lines is recommended. Instructions for installing the female Swagelok tube fittings onto the incoming and outgoing sample lines are provided in Section 7 SAMPLE GAS CONNECTIONS on page 49. Other fitting sizes and styles are available from Servomex to be installed on the inlet and exhaust ports as a special order. The underlying connector is a ¼” NPT. CAUTION Equipment Damage: Provide adequate support for the tubing. The weight of the tubing must not exert torque on the gas cell as it may cause the fittings to fail and leak. All of the fittings requirements for the Servomex SpectraScan Gas Analyzer are summarized below. Connector on the Analyzer Required Fittings to Mate with Analyzer Additional Comments Sample Inlet And Exhaust Ports: ¼” male Swagelok ¼” female Swagelok 10 micron particulate filter on the inlet side is recommended. Electrical Conduit: 1” female 1” male conduit Must maintain Ingress Protection level of IP66, Type 4. Purge Ports (use is optional): ¼” female NPTF ¼” male NPTF Either side can be used as inlet. Table 3 - Standard Fittings Used on the Servomex SpectraScan Gas Analyzer 5.1 Mounting Procedure 1. After choosing the appropriate space and structure for the Servomex SpectraScan Gas Analyzer by satisfying all of the Environmental Requirements on page 23, prepare the unit for mounting by clearing the mounting space, readying the analyzer (consider its weight and 02400001A/0 26 SERVOTOUGH SpectraScan User Manual if you will need an assistant to support it while mounting), and having the mounting hardware and appropriate tools nearby. WARNING Personal Injury: The Servomex SpectraScan Gas Analyzer weighs approximately 30 lbs (14Kgs), presenting the possibility of personal injury if care is not taken when lifting and moving this unit.  NOTE The Servomex SpectraScan Gas Analyzer must be mounted with eight 3/8”16 x 1” UNC bolts and matching lock washers and nuts. 2. Consider the order of installation: mount the analyzer onto the mounting surface first; then make electrical connections inside the box with the cover open. 3. Place the Servomex SpectraScan Gas Analyzer on the mounting structure and align the eight mounting holes with holes in the structure. Support the analyzer if necessary. 4. Install eight 3/8”-16 x 1” UNC bolts through the mounting holes and through lock washers, and secure with eight nuts. Tighten securely. 02400001A/0 27 SERVOTOUGH SpectraScan User Manual This page intentionally left blank. 02400001A/0 28 SERVOTOUGH SpectraScan User Manual 6 ELECTRICAL CONNECTIONS All of the required electrical connections are described in this section: Electrical Power Source Communication over Ethernet TCP/IP  NOTE The Servomex SpectraScan Gas Analyzer must be mounted with eight 3/8”16 x 1” UNC bolts and matching lock washers and nuts. WARNING Personal Injury or Death: Wiring of the analyzer must be in accordance with local regulations. 02400001A/0 29 SERVOTOUGH SpectraScan User Manual 6.0 I/O Panel Layout Figure 3 - I/O panel of the Servomex SpectraScan Gas Analyzer  NOTE The sample, power and signal connections require at least 6” of clearance for safe operation. The Red Circle in the figure above identifies the conduit fitting through which the power, communication and external stream switching solenoid valve cables are to be connected. The Green Circle in the figure above identifies where the sample inlet and exhaust lines are to be connected. The Blue Circles in the figure above identifies where the optional purge lines can be installed. 02400001A/0 30 SERVOTOUGH SpectraScan User Manual Figure 4 - Analyzer with Cover Open 02400001A/0 31 SERVOTOUGH SpectraScan User Manual 6.0.1 Component Layout Figure 5 - Interior of the Servomex SpectraScan Gas Analyzer  02400001A/0 NOTE See Figure 6 for detail of SpectraScan internal components 32 SERVOTOUGH SpectraScan User Manual Display Cable Enclosure Lid Enclosure Spare Fuses Ground Lug Fuse Plate AC Power Module (optional) Circuit Board Earth Ground Lug Motor Assembly Power Terminal Block Light Source (beneath blue cover) Power Cable Sensor Head (in blue cover & TCP/IP partially beneath Jack plate and circuit board) Heater Wires TCP/IP Cable Purge Port Sample Inlet Conduit Conduit Sample Exhaust Purge Port Figure 6 - SpectraScan Interior Diagram 02400001A/0 33 SERVOTOUGH SpectraScan User Manual 6.1 Electrical Power Requirements The Servomex SpectraScan Gas Analyzer operates at 24 VDC or 100-240 VAC depending on the model configuration. Be sure to adhere to the Power Rating Label on the analyzer to determine which power source to use, and connect the correct power source. Figure 7 - Example Rating Label WARNING SYSTEM SAFETY: This analyzer is typed as permanently connected equipment and as such, must include a switch or circuit–breaker in the installation. This switch must be supplied and installed by the customer (not provided by Servomex) must be suitably located and easily reached, and must be marked as the disconnecting device for the equipment. WARNING Electrical Shock and Equipment Damage: The main circuit board in the analyzer must have the proper fuse installed prior to connecting power. Installing the wrong fuse in main circuit board may result in electric shock or death and may result in damage to the analyzer. To avoid injury and equipment damage, ensure the proper fuse is used. See Table 13 - Electrical Specifications on page 72. Servomex provides the proper fuse and two spares with every analyzer. See Figure 6 - SpectraScan Interior Diagram on page 33. 02400001A/0 34 SERVOTOUGH SpectraScan User Manual 6.2 Wiring All cables entering the analyzer (24 VDC or 120/240 VAC power and communication) must be separately jacketed as they enter the analyzer to prevent miss-wiring. The power cabling used, whether for 24 VDC operation, or for 120-240 VAC operation, must use a 3 conductor cable. The ground wire in this 3 conductor cable must be electrically connected to the earth ground lug in the analyzer. Connection Wire type Power (AC) 600V, 3 wire, 16AWG, Jacketed Insulation must be rated to at least 75°C Power (DC) 600V, 3 wire, 16AWG, Jacketed Ethernet (TCP/IP) CAT 5 Standard 300V Solenoids (DC) 600V, 3 wire, 18AWG RS485 Data Data Cable 24 AWG, 300V Optional Heater 600V, 3 wire, 18AWG Table 4 - Wire Types 02400001A/0 35 SERVOTOUGH SpectraScan User Manual 6.2.1 Power Wiring: 24 VDC Figure 8 - Wiring the SpectraScan with 24 VDC 02400001A/0 36 SERVOTOUGH SpectraScan User Manual To connect 24 VDC supply power to the analyzer, perform the following steps: (Refer to Figure 8) 1. Open the cover of the SpectraScan using a large, flat-headed screwdriver turn the latch ¼ turn counter-clockwise, and open the cover. 2. Bring a 3 conductor, separately jacketed cable with 24V supply into the enclosure through the conduit fitting. Make sure that the power is not on (wires are not live) at this point. WARNING Maintain Ingress Protection: The Servomex SpectraScan unit has been tested to an Ingress Protection level of IP66, Type 4. In order to maintain this rating, a suitable 1” conduit connector must be used that will not compromise the existing IP Rating. 3. Strip the cable jacketing back and secure the jacketed portion of the cable to the anchor point provided inside the enclosure using a cable tie. Be sure to leave enough slack in the cable so the red and black wires reach the power terminal block on the main board and the green wire reaches the ground lug on the enclosure wall. 4. Strip 10mm (0.4”) of insulation from the positive (red) and negative (black) leads of the cable, and also from the ground (green) wire. 5. Connect the positive (red) cable to the positive side of the terminal block on the main PCB and the negative (black) cable to the negative side of the input power terminal block. 6. Connect Earth Ground: a. Connect the green wire to the earth ground lug on the enclosure wall. b. Check the two factory installed ground wires, at both ends, for loose connections; resolve any that are found. Ensure that both are secured to the enclosure anchor point with a cable tie. The factory installed ground wires are: i. PCB to earth ground ii. Enclosure lid to earth ground 7. Close and latch the cover. 02400001A/0 37 SERVOTOUGH SpectraScan User Manual 6.2.2 Power Wiring: 120-240 VAC Figure 9 - Wiring the SpectraScan with 120-240Vac 02400001A/0 38 SERVOTOUGH SpectraScan User Manual To connect 100-240 Vac power to the analyzer, perform the following steps: (Refer to Figure 9) 1. Open the cover of the SpectraScan using a large, flat-headed screwdriver turn the latch ¼ turn counter-clockwise, and open the cover. 2. Bring a 3 conductor, separately jacketed cable with AC supply into the enclosure through the conduit fitting. Make sure the wires are not live at this point. WARNING Maintain Ingress Protection: The Servomex SpectraScan unit has been tested to an Ingress Protection level of IP66, Type 4. In order to maintain this rating, a suitable 1” conduit connector must be used that will not compromise the existing IP Rating. 3. Strip the cable jacketing back and secure the jacketed portion of the cable to the anchor point provided inside the enclosure using a cable tie. Be sure to leave enough slack in the cable so the ends reach the input terminals on the AC Power Module. 4. Strip 10mm (0.4”) of insulation from the line (black), neutral (white) and ground (green) leads of the cable. 5. Connect Earth Ground: a. The terminal tabs on the AC Power Module have three positions:  Down: terminal locked closed  Middle: terminal closed with spring tension  Up (or to the left): terminal locked open b. Connect the ground (green) wire to the Earth Ground terminal on the AC Power Module. Do not disturb the factory installed power-supply-to-earth-ground wire that is also inserted into the Earth Ground terminal on the AC Power Module. c. Check all three factory installed ground wires, at both ends, for loose connections; resolve any that are found. Ensure two of the wires are secured to the enclosure anchor point with a cable tie. The three factory installed ground wires are: i. Power supply to earth ground ii. PCB to earth ground (secured at anchor point) iii. Enclosure lid to earth ground (secured at anchor point) 6. Connect the neutral (white) wire to the Neutral terminal on the AC Power Module. 7. Connect the line (black) wire to the Line terminal on the AC Power Module. 8. Close and latch the cover. 02400001A/0 39 SERVOTOUGH SpectraScan User Manual 6.3 Communication Connection Figure 10 - Connecting the Ethernet TCP/IP communication cable 02400001A/0 40 SERVOTOUGH SpectraScan User Manual To connect the communication cable to the analyzer, perform the following steps: (Refer to Figure 10) WARNING Electrical Hazard, Personal Injury and Equipment Damage: Do NOT perform any internal service on an energized or gas supplied analyzer. When performing maintenance on the unit, it is necessary to disconnect the power source from the unit, and turn off the gas supply lines (sample gas and zero gas). 1. Turn off the main power, disconnect and turn off all gas supply lines that are connected. 2. Open the cover of the SpectraScan using a large, flat-headed screwdriver turn the latch ¼ turn counter-clockwise, and open the cover. 3. Bring the communication cable into the enclosure through the conduit fitting. WARNING Maintain Ingress Protection: The Servomex SpectraScan unit has been tested to an Ingress Protection level of IP66, Type 4. In order to maintain this rating, a suitable 1” conduit connector must be used that will not compromise the existing IP Rating. 4. Plug the communication cable into the network jack on the front edge of the PCB, as shown. 5. Secure the cable to the anchor points provided inside the enclosure using cable ties. 6. Close and latch the cover. 7. Restore power and gas supply, as applicable. 02400001A/0 41 SERVOTOUGH SpectraScan User Manual 6.4 Spectrascan Networking and Software Configuration 6.4.1 Ethernet and TCP/IP Getting an IP address using DHCP As delivered, the instruments are configured as DHCP clients. This means each instrument's IP addresses given to it by an external DHCP server, typically a router running on your network. The IP address is assigned dynamically when the instrument is powered up. To enable networking and get a dynamic IP address, do the following: 1. Attach the instrument to your network via Ethernet cable to the connector labelled “ETHERNET” on the instrument's system board. 2. Make sure your network has a DHCP server running. 3. When the instrument is powered up, it will issue a request for an IP address via DHCP. The DHCP server will answer the request and provide an IP address to the instrument. The instrument will remember that IP address for as long as it remains powered up. Note that the IP address assigned via DHCP will be lost if the instrument is powered down. The next time you power up the instrument it may get the same IP address, or it may get a different one depending upon the exact details of your network's configuration. 6.4.2 Finding the IP address of your instrument Each instrument is programmed with a hostname. The hostname is of the form “oxsXXXXXX”, where XXXXXX is the six-digit serial number assigned to the instrument. The serial number is printed on a label attached to the bottom mount-plate in the vicinity of the stepper motor (Figure 11 Location of the serial number tag). The serial number is identified by the prefix S/N. Figure 11 - Location of the serial number tag 02400001A/0 42 SERVOTOUGH SpectraScan User Manual  NOTE The location of serial number tag is circled in red. If you look carefully, you can see this instrument's serial number is 100072. Therefore, this instrument's hostname is “oxs100072”. Once you know the hostname of your instrument, you may find its IP address in the following way: 1. On a Windows PC attached to the same sub-network as the instrument, open an MS DOS command prompt. 2 In the command prompt, type “nslookup ”, where is the instrument's hostname as described above. 3. Nslookup will return all information about the instrument pertinent to networking, including the IP address it has been assigned. 6.4.3 Setting a static IP address Some customers prefer to assign a static IP address to their instruments. Assigning a static IP address requires that you have physical access to the system board. Connecting to the system board via RS-232 requires the following items:     Windows PC A special serial cable from Servomex. On one end this cable is terminated by a connector mating to the RS-232 connector on the system board. On the other end, the cable is terminated by a DB-9 connector. If your computer does not have an RS-232 port, you will need an RS-232 to USB converter. The RS-232 side of the converter should be terminated with a DB-9 connector. A terminal program running on your PC, such as Hyperterm or PuTTY. You may configure your instrument to use a static IP address in the following way: 1. Open the instrument, and locate the MPU debug connector. The connector is shown in Illustration 2. This connector provides access to the MPU via an internal RS-232 port. 02400001A/0 43 SERVOTOUGH SpectraScan User Manual Figure 12 - Location of debug RS-232 connector on MPU 2. Connect a Windows PC to the MPU debug connector using the SpectraScan RS-232 cable (and an RS-232 to USB converter, if required). 3. On your PC, determine which COM port is associated with the serial connection. Do this by opening the Windows device manager and looking at the COM port configuration. 4. On your PC, run your terminal program and configure it to use the COM port you found in the device manager. Also configure the terminal program with the following settings:      Baud rate = 115200 Data bits = 8 Stop bits = 1 Parity = None Flow control = None. (No software nor hardware flow control.) 5. In the terminal program, start a terminal session to the MPU. Hit a few times and you will get a command prompt from the MPU. The command prompt is “#”. 6. At the command prompt, type the command “ip-config” followed by . When the program starts it will tell you the current IP configuration of the unit. Also, if the unit is already configured for static IP address, it will give you the option to leave the program. 7. Next, the program will give you three options to modify the IP address settings. Choose option 2, “static IP”. 8. The program will 9. When prompted, type in your desired IP address is DD.DD.DD.DD format. (Here, DD signifies the digits comprising each of the four decimal numbers making up the IP address.) 10. Next, you will be prompted for the desired netmask. Enter it using the DD.DD.DD.DD format. 02400001A/0 44 SERVOTOUGH SpectraScan User Manual 11 .Next, you will be prompted for the desired gateway address. Enter it using the DD.DD.DD.DD format. 12. Next, you will be prompted for the desired broadcast address. Enter it using the DD.DD.DD.DD format. 13 .Finally, you will be asked to reboot and accept the changes, or to cancel. If you have entered all information correctly, choose reboot. The system will then store the new IP configuration data, shut down, and then restart. 14. The system requires roughly 1 minute to reboot. Once the system has rebooted, you will be presented with a command prompt, “#”. 15. You may now disconnect the RS-232 cable from the MPU debug port and close the instrument. A screenshot showing a typical session is shown in Illustration 3 below. In this session, an instrument is configured to use the static IP address 192.168.0.29 with netmask 255.255.255.0, gateway 192.168.0.1 and broadcast IP address 192.168.0.255. 02400001A/0 45 SERVOTOUGH SpectraScan User Manual Figure 13 - Sample session in which a static IP address is set using PuTTY to communicate with the MPU. 6.4.4 RS-422 connection The RS-422 link uses a 4-wire connection, 2 wires for receive and 2 wires for transmit. The RS-422 port supports only a point-to-point link. Do not bridge the receive and transmit pairs – the instrument cannot be used in multi-drop bus configurations. Connecting the instrument's RS-422 port to an external RS-422 device requires a 5 conductor cable. The cable should include two twisted pairs for the receive and transmit data, and a single wire for data ground. The configuration is shown in Drawing 1. Connection to the system board is made using the connector labelled “RS-485” at the corner of the board. 02400001A/0 46 SERVOTOUGH SpectraScan User Manual Figure 14 - Identification of RS-422 signals in instrument This is shown in Illustration 4. Connect the cable to the individual push-down connectors as shown in the figure. (NOTE: Although the board label says “RS-485”, this port will not function in multidrop bus mode. It will only work as a point-to-point link with a 4-wire RS-422 device.) Figure 15 - Location of RS-422 connector on system board The RS-422 port parameters are as follows:  Baud rate = 57600  Data bits = 8  Stop bits = 1  Parity = None 02400001A/0 47 SERVOTOUGH SpectraScan User Manual 6.4.5 Modbus register The SpectraScan communicates to the external controller via Modbus. The instrument acts as a Modbus server, the external controller is the client. Modbus runs either over RS-422 or Ethernet interfaces. The instrument is configured in the following way:   Modbus protocol: RTU Modbus device address = 1 The Modbus register map used by the SpectraScan is shown below. Table 5 - SpectraScan Modbus register 02400001A/0 48 SERVOTOUGH SpectraScan User Manual 7 SAMPLE GAS CONNECTIONS SpectraScan Gas Analyzer 10 Micron Particulate Filter Purge Gas Supply Manual Valve Zero Gas Supply Manual Valve Purge Gas Exhaust Sample Gas Exhaust Pressure Relief Mechanism NC Zero Gas Solenoid NO Sample Gas Solenoid Manual Valve Sample Gas Supply Figure 16 – Typical Gas Connection Configuration  02400001A/0 NOTE The specific configuration of sample, purge and zero gases may vary depending on application. 49 SERVOTOUGH SpectraScan User Manual 7.0 Sample Line Connections 7.0.1 Sampling Ports Both sample intake and exhaust ports are fitted with male ¼” Swagelok® compression tube fittings. Only properly mated, female ¼” Swagelok® compression fittings should be used on the sample intake and exhaust lines. CAUTION Equipment Damage: Restricting the gas flow on either the intake or the exhaust side may cause the gas cell to over pressurize, causing damage to the analyzer. Care should be taken to remove any port caps or other flow barriers before connecting any sample line or switching on the analyzer. Also make sure the exhaust routing is appropriate for your specific application. CAUTION Equipment Damage: Provide adequate support for the tubing. The weight of the tubing must not exert torque on the gas cell as it may cause the fittings to fail and leak. 7.0.2 Preparing Sample Gas Lines Instructions for installing female ¼” Swagelok tube fittings on the sample incoming and exhaust lines: 1. Insert the tubing into the ¼” female Swagelok tube fitting. Tubing should rest firmly on the shoulder of the fitting. The nut should be finger tight. 2. Hold the fitting body with a backup wrench and tighten the nut 1¼ turns. 02400001A/0 50 SERVOTOUGH SpectraScan User Manual 7.0.3 Sampling Gas from a Pressurized Source When the gas is to be sampled from a pressurized source, such as a pressurized line, a pressure relief mechanism should be employed so as not to force or restrict the flow of gas into the unit. Refer to the Applications Manual for sample pressure recommendations. See Table 11 - Sampling System Specifications on page 71 for allowable pressure, temperature and flow rate. WARNING Personal Injury and Equipment Damage: Sample allowable pressure must not be exceeded, or may cause the gas cell to over pressurize. Care should be taken to review Table 11 - Sampling System Specifications on page 71. CAUTION Equipment Damage: Restricting the gas flow on either the intake or the exhaust side may cause the gas cell to over pressurize. Care should be taken to remove any port caps or other flow barrier before switching on the analyzer. Also make sure the exhaust routing is appropriate for your specific application. CAUTION Equipment Damage: Pressure relief mechanism should be employed when sampling gas from a source other than the ambient in order to avoid damage to the analyzer. 7.0.4 Cleanliness of Sample Stream CAUTION Equipment Damage: The sample stream must be clean of particles that could block the light path and potentially accumulate on the windows, and potentially damage the unit. It is ultimately the user’s responsibility to ensure a clean sample stream. We recommend an inline 10 micron particulate filter for most applications. Contact Servomex for more information. 02400001A/0 51 SERVOTOUGH SpectraScan User Manual 7.0.5 Stream Switching Using External Solenoid Valves The Servomex SpectraScan Gas Analyzer is equipped with three relays connected to the 24 VDC supply, which may be used to control external solenoid valves for the purpose of stream switching. By default, the first two relays are used for automatic zeroing: upon initiating, a software “zero” command the relays energize, providing 24 VDC power to external solenoid valves. Upon completion of the zeroing process, the relays return to their default “0” state. The analyzer supplies power to the solenoid valves at the following specifications: Voltage: 24 VDC Maximum current: 0.5 A WARNING Personal Injury: Solenoids that will be driven from the Servomex SpectraScan solenoid output must be safety agency approved. 02400001A/0 52 SERVOTOUGH SpectraScan User Manual The diagram below depicts the recommended pipe work and electrical connections to utilize the stream switching relays. Note that solenoid labels “NC” and “NO” denote normally closed and normally open respectively. Solenoid lines 1, 2, 3 and 4 should be connected to the rightmost connector bank on the front-edge of the PCB, to connector ports SOL1, GND, SOL2, and GND respectively, as shown in the diagram below. Cables should be anchored with cable ties inside the enclosure and exit the enclosure through the electrical conduit (along with the power and communication cables). Figure 17 - Recommended Connections for Inlet Stream Switching 02400001A/0 53 SERVOTOUGH SpectraScan User Manual 7.0.6 Procedure for Connecting the Sample Lines Refer to Figure 16 WARNING Electrical Hazard, Personal Injury and Equipment Damage: Do NOT perform any internal service on an energized or gas supplied analyzer. When performing maintenance on the unit, it is necessary to disconnect the power source from the unit, and turn off the gas supply lines (sample gas and zero gas). 1. Turn off the main power disconnect and turn off all gas supply lines. 2. Remove the port caps and any other obstructions from the sample path (inlet and exhaust ports). 3. Install the appropriate fittings on the sample supply and exhaust lines (see Preparing Sample Gas Lines on page 50). 4. Install a pressure relief mechanism if necessary (if sampling from a pressure other than ambient). 5. Ensure a clean sample stream – install a 10 micron particulate filter on the inlet side of the sample plumbing if necessary. 6. Install/connect stream switching lines and solenoids if applicable. 7. Connect sample supply and exhaust lines to the Servomex SpectraScan sample inlet and exhaust ports. 8. Ensure proper sample gas and zero gas temperature and conditioning. In general, sample conditioning is application dependent, see the Application data for more specific information. However, samples entering the Servomex SpectraScan Gas Analyzer must be “clean and dry” free of liquids and particulates. Sample cell is heated to 60°C. Any sample above 50°C may have condensation or overheating risks. CAUTION Equipment Damage: The sample stream must be clean of particles that could block the light path and potentially accumulate on the windows, and potentially damage the unit. It is ultimately the user’s responsibility to ensure a clean sample stream. We recommend an inline 10 micron particulate filter for most applications. Contact Servomex for more information. 9. Check sample path (lines and connections) and zero gas path for leaks, by alternately turning one on and the other off. Repair or replace to resolve any leaks that are found; the Servomex SpectraScan Gas Analyzer must be operated in a leak-free environment. 10. Turn on the main power (at the disconnect). 11. Set supply and exhaust valves in the proper configuration for remote operation. 02400001A/0 54 SERVOTOUGH SpectraScan User Manual 7.1 Enclosure Purge Connections 7.1.1 Purging of Enclosure Compartment Certain installations may require the use of purge gas to flow through the enclosure. There are two female ¼” NPTF ports located on the analyzer for this purpose. (See Figure 3). To add a purge to the enclosure, remove the plugs installed at the factory on the purge inlet and purge outlet ports (either port can be used for inlet or outlet). Connect purge gas lines to the ports using male ¼” NPTF connectors, or use fittings to adapt the purge ports on the analyzer to the connectors on the gas purge lines. One purge port on the analyzer (acting as an inlet) should be connected to a continuous supply of clean and dry inert gas such as nitrogen or air. The other port should be connected to an exhaust line for the purge gas. Make sure the exhaust line is open, open the purge gas line, and check for leaks. WARNING Personal Injury or Death: Do not connect sample lines to the purge fittings as you could fill the enclosure and local area with potentially harmful or explosive gases, exposing the user and others in the vicinity to the risk of injury or death. . 02400001A/0 55 SERVOTOUGH SpectraScan User Manual This page intentionally left blank. 02400001A/0 56 SERVOTOUGH SpectraScan User Manual 8 INSTALLATION CHECKLIST The following list gives a brief summary of all the steps needed to correctly install the Servomex SpectraScan Gas Analyzer. It is not a substitution of the procedures, precautions and hazard definitions that appear elsewhere in this document.  NOTE Read this manual in its entirety before attempting to perform any operations on the Servomex SpectraScan system. 1. Reviewed System Safety beginning on page 12. 2. Unpacked Servomex SpectraScan Gas Analyzer from shipping crate and inspected for damage. 3. Chose appropriate mounting space and structure considering all Environmental Requirements beginning on page 23. 4. Mounted the analyzer securely on the mounting structure. 5. Connected power source and communication cabling. 6. Connected sample inlet and exhaust lines, zero gas supply line and stream switching circuitry as applicable. 7. Tested all gas paths for leaks and resolved. 8. Connected enclosure purge system (optional) and tested for leaks. 9. Supply gases properly conditioned for temperature, pressure, cleanliness and flow rate. 10. Supply and exhaust valves and electrical power disconnect are set in the proper configuration for remote operation. 02400001A/0 57 SERVOTOUGH SpectraScan User Manual This page intentionally left blank. 02400001A/0 58 SERVOTOUGH SpectraScan User Manual 9 VERIFICATION The purpose of this procedure is to verify span accuracy upon installation of the Servomex SpectraScan Gas Analyzer. This procedure is also performed at periodic intervals throughout the effective life of the unit. This procedure has three parts: Setup, Zeroing and Span Verification. Zeroing is a measurement on a zero (inert) gas. Span verification is a measurement on the customer’s trusted, certified mixture(s). 9.0 Procedure 9.0.1 Setup 1. Communicate with the analyzer via Modbus/TCP: Refer to the Modbus register map in the Applications Manual to be used to configure customer’s Modbus Master Program (not provided by Servomex.) 2. Ensure that the Servomex SpectraScan Gas Analyzer is sufficiently warmed-up. Warm-up: The unit’s interior is temperature-controlled and will only meet measurement accuracy specifications when sufficient time is allowed for the unit to meet and stabilize to the designed operating temperature. The red “Warm-Up” light on the display will remain on until the unit is warmed-up. Warm-up time for the unit is approximately 30 minutes to 2 hours depending on the ambient temperature. Do not begin to take data until the “Warm-up” light goes off and the “Run” light (green) comes on. LED codes are as follows: LED Label on System Cover Functional Description Power Lights green when power is connected. Warm-up Lights red while warming up, goes out when operational temperature is reached. Run Lights green when operational temperature is reached. Fault Lights red when a fault is detected in the system. Table 6 - Diagnostic LED Indications . 02400001A/0 59 SERVOTOUGH SpectraScan User Manual 9.0.2 Zeroing See Stream Switching Using External Solenoid Valves on page 52 for information on controlling the external valves. 1. Purge the cell with the appropriate zero gas: turn off the sample gas and turn on the zero gas (through software). Refer to the Application data for the appropriate Zero gas specifications. 2. Make sure that the gas cell is completely purged with the Zero gas by allowing an extra amount of time in purging (See Table 12 - Response Time Versus Gas Flow Rate). 3. Initiate the command “Zero” from Modbus Master or controller. (On the Test HMI software, a “Zero” toggle is on the “Configuration” tab.) 9.0.3 Span Verification Purge the cell with your trusted, certified mixture of sample gas, or verification mixture as follows: 1. Connect the verification gas of choice to the sample inlet supply line if sourcing verification gas from a cylinder. 2. Turn off the zero gas and turn on the sample gas (either through software in the case of automated sample-switching configuration or manually). 3. Start collecting data. 4. Wait until data values from the analyzer stabilize. See Table 12 - Response Time Versus Gas Flow Rate for more information. 5. Record values. Compare data with known values of your trusted, certified verification mixture. 6. Complete Verification procedure or adjust span values as needed (see next section below). 9.1 Re-spanning The customer may modify the factory set span values (default values of “1”) for any measurement channel. This span modification can be done via Modbus/TCP. The span values are multiplied with the original measured values to produce the final measurement values. For example, adjusting the span value of a certain channel to 1.05 would adjust the measurement value up by 5%. Similarly, adjusting the span value to 0.95 would adjust the measurement value down by 5%. Note that the new span values are NOT stored in the analyzer’s memory, rather, it relies on the Modbus master program (customer control system) to supply the information. 02400001A/0 60 SERVOTOUGH SpectraScan User Manual 10 MAINTENANCE The Servomex SpectraScan Gas Analyzer is designed to be maintenance free for extended periods of time. In a normal installation, it will operate unattended in its intended environment for 18 months with no physical intervention. Typically every 18 months, the spectrometer light source needs to be replaced. Recommended maintenance and operation verification of the Servomex SpectraScan Gas Analyzer consists of:  Monthly re-zeroing (performed remotely through software).  Light source assembly replacement (every 18 months or when light indicator shows < 40% output). The replacement procedure is described in Section 10.0.  Gas cell window replacement if necessary when prompted by fault signal. 02400001A/0 61 SERVOTOUGH SpectraScan User Manual 10.0 Light Source Assembly Replacement Procedure Light source replacement is recommended every 18 months or when the light indicator shows < 40% output. Neither the light source nor its circuit board can be repaired. The light source assembly is a small circuit board with a light source under it, which attaches to the top of the sensor head via a mounting hole for the light source and four bolts with lock washers. Access only requires peeling back a corner of the blue bag surrounding the cell, and Velcro makes this easy. Removal of the assembly is executed by disconnecting its connector and removing the four bolts that hold it into place. Heat sink compound is applied to the light source prior to inserting it into the cell. WARNING Electrical Hazard, Personal Injury and Equipment Damage: Do not perform maintenance on an energized or gas supplied analyzer. When performing any procedure that involves opening the unit, it is necessary to disconnect the power source from the unit, and turn off the gas supply lines (sample gas and zero gas). 1. Turn off all gas supply lines and turn off power to the analyzer before performing any service procedure. 2. Open the cover of the SpectraScan using a large, flat-headed screwdriver turn the latch ¼ turn counter-clockwise, and open the cover. 3. Expose the light source assembly from underneath the blue bag: Refer to Figure 5 - Interior of the Servomex SpectraScan Gas Analyzer on page 33 to identify the location of the light source assembly. 4. Peel back the cover by opening the Velcro on the upper and right edges of the blue bag, as shown in Figure 18. 02400001A/0 62 SERVOTOUGH SpectraScan User Manual Figure 18 - Accessing the Light Source 5. Remove the connector with the green wires from the bottom edge of the light source circuit board as shown in Figure 19. The black connector has a squeeze tab to prevent accidental release of the connector. Figure 19 - The Light Source Circuit Board 6. Using a 3/32” hex wrench, loosen and remove the four bolts and four lock washers at the corners of the light source circuit board. Lift the blue light source circuit board up and out of its mounting hole. This circuit board with the light source on the other side of it is the light source assembly (see Figure 20). 7. The light source assembly shall be replaced as a whole. It shall not be reduced to smaller components or repaired. The old assembly can be discarded in accordance with appropriate local regulations. 02400001A/0 63 SERVOTOUGH SpectraScan User Manual Figure 20 - The Light Source Assembly 8. Apply heat sink around the perimeter of the new light source, and push the assembly back into the mounting hole provided on the sensor head, making sure to orient it properly (connector end toward I/O panel). Figure 21 - Mounting Hole for Light Source 9. Replace the four bolts and four lock washers to secure the circuit board to the sensor head. Tighten the bolts in a cross pattern. 10. Replace the connector back into its socket on the light source circuit board. The tab will snap in place to lock the connector into position. 11. Re-close the blue bag by sealing the Velcro strip along its edges. 12. Close the cover and lock by rotating the latch. 02400001A/0 64 SERVOTOUGH SpectraScan User Manual 13. Turn on power and gas supply. 14. Wait for at least 30 minutes and until the cell temperature stabilizes at the set operating temperature (indicated by the green “Run” light on the display). 15. Perform Verification (refer to Section 9 Verification). 02400001A/0 65 SERVOTOUGH SpectraScan User Manual This page intentionally left blank. 02400001A/0 66 SERVOTOUGH SpectraScan User Manual 11 TROUBLESHOOTING See Table 6 - Diagnostic LED Indications for a general description of each indicator status. Below are some common problems/symptoms and possible causes. Problem Possible cause(s) Power LED not lit No or insufficient power. Check Fuse Warm-up light still lit after 2 hours of warm up period Environment is too cold to allow stabilization at the operating temperature Negative concentration reading Zeroing on sample gases or insufficient purging prior to zeroing Excessive drift Analyzer has not fully warmed up or sensor head temperature is higher than its intended operating temperature (default 60° C) Unable to communicate with the analyzer Incorrect IP address Low light indicator (<50%) Dirty windows or light source has degraded No measurement response or unchanging measurement values Unconnected or improperly connected sample line, blocked flow Slow measurement response Low flow rate due to blockage Table 7 - Troubleshooting 02400001A/0 67 SERVOTOUGH SpectraScan User Manual This page intentionally left blank. 02400001A/0 68 SERVOTOUGH SpectraScan User Manual 12 APPENDIX A: PRODUCT SPECIFICATIONS 12.0 Measurement Specifications Measurement Technique Light absorption spectroscopy Gas Cell Volume / Path Length 100 mL / 35 cm Zero Drift <0.2% of full scale (FS) per month (typical) Intrinsic Error (Accuracy) <1% FS (typical). Higher accuracy available upon request Repeatability <0.1% (typical) Table 8 – Measurement Specifications 02400001A/0 69 SERVOTOUGH SpectraScan User Manual 12.1 Physical Specifications Figure 22 - Dimensions of SpectraScan Size 17.25”x 12” x 7” deep Weight 28 lbs. (14 kg) Installation Wall Mounted See Dimensions, Weight and Ventilation on page 24 for installation considerations Vibration Immunity Resistant to low amplitude vibration Table 9 – Physical Specifications 12.2 Communications Specification Communication Modbus TCP/IP Ethernet Table 10 - Communications Specifications 02400001A/0 70 SERVOTOUGH SpectraScan User Manual 12.3 Sampling System Specifications Item Value 0 to 15 ltr/min (higher ranges available upon request) Allowable Flow Rate 0 to 30 psig (standard) Allowable Gas Cell Pressure Allowable Sample Temperature and Humidity Material Of Wetted Parts 0 to 80 psig (optional) Refer to product labelling for model-specific information. 0 to 50°C (32 to 122°F) standard 5 to 95% rH non-condensing Contact Servomex for higher temperature requirement Nickel plated or anodized aluminium gas cell, (stainless steel gas cell is optional) Stainless steel tubing and fittings, Viton O-rings, BK7/quartz/sapphire/CaF2/ZnSe optical windows Table 11 - Sampling System Specifications FLOW RATE T90 (SECONDS) T95 (SECONDS) T99 (SECONDS) 0.5 SLM 25 35 60 1 SLM 20 25 40 5 SLM 4 5 6 Table 12 - Response Time Versus Gas Flow Rate 02400001A/0 71 SERVOTOUGH SpectraScan User Manual 12.4 Electrical Specifications Power Rating and Fuse Information Base Input Power 24 Vdc, 5.0 A max Optional Input Power 100-240 Vac (+/-) 10%, 50-60 Hz, 3.0 A max* Fuse (24Vdc replaceable) 125V, 10A Table 13 - Electrical Specifications *See Table 4 - Wire Types on page 35 for important wire rating information. 12.5 Environmental Specifications Ambient Operating Temperature/Humidity Range -20 to 50°C (-4 to 122°F) (5 – 95% rH non-condensing) System Cooling None required Storage/Shipping Temperature/Humidity Range -20 to +60°C (-4 to 140°F) (5 – 95% rH non-condensing) Altitude 0 – 2000m (0 – 6560 ft) Overvoltage Category Category II Pollution Degree Pollution Degree 3 Dust Protection Rating (Except for Gas Sample Path) IP rating = 66 (unit interior is protected against dust) Table 14 - Environmental Specifications 12.6 Manual Revision History Draft Description Effective Date 0 Initial Release May-13 02400001A/0 72 SERVOTOUGH SpectraScan User Manual 13 INDEX combustion hazard, 26 communication requirements, 70 connections communication, 40 electrical, 29 plumbing, 41–55 power, 34 solenoid relays, 53 wire types, 35 dust protection rating, 72 Fittings Requirements, 26 fuse, 72 hazard notices, 7 hazards over pressurizing, 18 ventilation, 24 weight, 24 LED codes, 59 measurement principle, 9 power AC, 38 DC, 36 power rating, 72 power rating label, 34 power requirements, 26, 34, 52, 72 allowable gas cell, 71 purging, 55 regulation, 12 sample cleanliness, 51 ports, 51 pressurized source, 51 solenoids, 52 specifications communication, 70 electrical, 72 environmental, 72 mounting, 23–27 physical, 70 sampling, 71 wiring, 35 standards in the industry, 12 stream switching, 52 symbols found on the analyzer, 8 temperature allowable sample range, 72 operating range, 72 shipping and storage range, 72 ventilation, 24, 25, 55 warm-up time, 15 pressure 02400001A/0 73 SERVOTOUGH SpectraScan User Manual 14 CONTACT DETAILS Servomex Group Limited Jarvis Brook Crowborough East Sussex TN6 3FB United Kingdom TEL +44 (0)1892 652181 Fax +44 (0)1892 662253 www.servomex.com  02400001A/0 NOTE All analyzers returned to Servomex or one of its appointed agents for servicing, or any other purpose must be accompanied by a completed decontamination certificate. 74