NIRS XDS Process Analyzer SingleFiber Manual 8.928.
Metrohm AG CH-9100 Herisau Switzerland Phone +41 71 353 85 85 Fax +41 71 353 89 01 info@metrohm.com www.metrohm.com NIRS XDS Process Analyzer SingleFiber Manual 8.928.8002EN 03.
Teachware Metrohm AG CH-9100 Herisau teachware@metrohm.com This documentation is protected by copyright. All rights reserved. Although all the information given in this documentation has been checked with great care, errors cannot be entirely excluded. Should you notice any mistakes please send us your comments using the address given above.
Change Control Version Date Summary of Changes Initiation of Change Control on this manual Updated company address to 7703 Montpelier Road, Laurel, MD FOSS NIRSystems, Inc. added to page footers. 1.02 December 16, Updated Wavelength Linearization spectrum on page 55 with correct 2004 graphic. Updated section 10.4.3, page 59, to reflect use of calibrated XC-1300 Wavelength Standard used in transmission measurement. Updated fixture photos on page 57 to show current style.
Table of contents 1 2 3 4 5 6 7 Introduction ................................................................................................................... 6 1.1 Enclosure Styles ........................................................................................... 6 1.2 Fiber Optic Sample Cells ............................................................................... 8 1.3 Single Fiber Information............................................................................. 10 1.
8 9 10 11 12 13 7.1 Basic NEMA 4X Enclosure ........................................................................... 41 7.2 Purged Unit ................................................................................................ 41 7.3 AC Power Switch Settings .......................................................................... 45 RJ-45 Network Connection ........................................................................................... 47 8.
1 Introduction The XDS Process Analytics Single Fiber Multiplexer Instrument uses Near Infrared (NIR) energy to determine chemical and physical characteristics of the sample. The sample is illuminated with white light, and the signal returning is broken down into visible and NIR wavelengths for spectroscopic analysis. Single Fiber Optics provide for long runs to the sample point, which is typically a clear to semi-clear liquid.
The “X-Purge” unit comes in either the fan-cooled version (shown), the air-conditioned enclosure, or the Vortec-cooled version. The Vortec-cooled system may be used in Div. 1 areas as defined under NEC 500 standards, and in Zone 1 areas as defined by IEC/CENELEC and NEC 505 requirements. The air-conditioned unit is limited to Div. 2 areas.
1.2 Fiber Optic Sample Cells The cell type is vitally important to the success of the application. Among factors to be considered are pressure, temperature, pathlength, chemical resistance, thermal shock, mounting, and flow rate. Metrohm NIRSystems uses cells manufactured by Axiom Analytical, Inc., a company that specializes in cells for harsh environments. Axiom has extensive experience with difficult applications, and can supply cells for most any conditions.
FFV-320N-X Transmission Flow-Through Cell, showing fiber optic cables connected. The “cap” is a cleanout fitting. FFV-800N-XH Transmission Flow Cell: Cell Material: Hastelloy 276 (optional) Window Material: Sapphire Seal Material: Kalrez® Fiber Connector Type: SMA Pathlength: “X” mm Black dust caps are shown over the SMA connectors. The solvent stream flows through vertically, using flange-mounts. FFV-800N-XH Transmission Flow Cell, showing SMA connector and purge ports.
This wrench is made by Seekonk, and uses a 5/16” end. It is calibrated for 8 in-lb. The wrench “clicks” when correct torque has been reached. It may feel more like a “detent” and the open wrench end will be visibly angled. Do not tighten beyond this point. 1.3 Single Fiber Information Single fiber is composed of one 600-micron fiber, surrounded by cladding to protect the fiber from abrasion and damage. A single fiber is shown, compared to a “Micro-bundle.
A Fiber Optic Communication Modem is included with all Purged Systems. This permits communication by fiber optic communication pair, for safe operation in classified environments. Communication cable must be specified, of a length long enough for all runs, plus additional length for service loops. Communication cable should be handled carefully to avoid breakage. Avoid sharp bends, chafing, or other damage. Temperature probes are available, which offer the option of monitoring process temperature.
2 Purged System for Hazardous Environments The XDS Process Analytics Instrument offers the option of a BEBCO purging system for hazardous environment use. This compact purging system is designed to meet European approvals as well as North American standards. The system permits use of the XDS Process Analytics Instrument in Div. 1 areas as defined under NEC 500 standards, and in Zone 1 areas as defined by IEC/CENELEC and NEC 505 requirements.
removes flammable vapors from a protected enclosure. This is accomplished by exchanging a known volume of protective gas, while maintaining a minimum positive enclosure pressure of 0.10 inches of water. 2.2 Class, Group and Division Ratings The 1993 edition of NFPA 496 recommends 4 volume exchanges for all enclosures and 10 volume exchanges for all motors. NOTE: The word “purging” is commonly used as a term to define the complete process of pressurizing protected enclosures in Class I areas.
2.3 Display / Interface Module The Display Interface Module is located on the Electronic Power Control Unit (EPCU). Status of power-up may be monitored using this display. The Display/Interface Module gives information about the purge control. Each LED indicates status of a specific function.
The flapper valve allows controlled air to escape from the XDS Process Analytics Instrument enclosure. The air exits through a spark arrestor, as shown. With the cover in place, this serves as a safe exit for purge gases. Do not disassemble the vent housing except as specifically instructed. This is not a user-serviceable item. Any alteration to the vent assembly will void the protection provided by the purging system. 2.4 Power-up Instructions These are the instructions provided on the BEBCO panel.
This shows the positions for the key used in steps 4, 5, and 6 above. The upper position is used to set enclosure pressure. The lower position is the locking position described in step 6. A Sequencing Diagram with LED operation is shown in the following pages, continuing through to system Fault Conditions. This sequencing diagram is provided by BEBCO Industries, Inc., to explain the operations sequence and LED status during purge operation. A graphic description is provided in the following pages.
2.4.1 Operations Sequence and Flow Diagram BEBCO Industries, Inc.
Sequence 4: Apply air to achieve Safe Pressure Safe Pressure Achieved When Safe Pressure Setpoint is achieved, Safe Enclosure Pressure LED is ON.
FAULT CONDITIONS Each of these conditions is considered abnormal.
HEP High Enclosure Pressure - When activated, the Rapid Exchange Solenoid Valve is disabled and the alarm relay is energized. IEC International Electrotechnical Commission - The IEC issues international standards for all areas of electrical, electronic and related technologies. ISA Instrument Society of America - ISA is an industry organization representing the interests of quality, safety, and productivity of measurement and control systems and equipment.
3 Instrument Specifications The XDS Process Analytics Instrument uses Near Infrared (NIR) energy to determine chemical and physical characteristics of the sample. The sample is illuminated with white light through a fiber optic bundle. The light is returned through a separate fiber bundle path, and the returning signal is broken down into visible and NIR wavelengths for spectroscopic analysis. The spectroscopic data is processed using a PC, and results are output in real time.
3.3 Weight System Type Pounds Kilograms Basic System: 93 lbs 41.9 With Vortec Cooler: 106 lbs 47.7 With Purge Control and Air Conditioning: 135 lbs 60.8 3.4 Operating Temperature Range System Type Fahrenheit Centigrade Basic System: 32-95º 0-35º With Vortec Cooler: 32-104º 0-40º With Purge Control and Air Conditioning: 32-125º 0-51º With Air Conditioning 32-125º 0-51º 3.5 Operating Humidity Range System Type % Relative Humidity All Systems: 10-90 % non-condensing 3.
Safe Pressure Flow Rate (both System Types) US: 0.31 to 11 SCFH Metric: NL/Minute 0.15 to 5.2 ¼” FPT NOTE: Large supply lines are recommended to permit adequate airflow. Some loss will occur due to internal friction. Use ½-inch to 1-inch (12mm to 25mm) supply lines. 3.7.1 Terminology SCFM: The term SCFM stands for Standard Cubic Feet Per Minute, referenced to a pre-specified pressure, temperature, and relative humidity. In most cases, SCFM is referenced to 14.7 PSIA, 68°F, and 0% relative humidity.
3.10 Data Interval • 0.5nm Data Interval 3.11 Clock/ Oscillator Frequencies • 10 MHz – Amplifier • 18.423 MHz, 25 MHz and 30 MHz – Mother Board • 20 MHz – Module Control Board 3.12 Power Supply Voltages • 15VDC, 250W Maximum • 12 VDC, 40W Maximum 3.13 Resistive Heater in Basic System and Vortec Cooled Systems • Two (2) 150W, 240VAC resistive heaters, operated at half power. 3.14 Air Conditioner Type • TECA 500 BTU, Solid State with Resistive Heaters. 3.
4 Site Requirements The XDS Process Analytics Instrument specifications are given in section 3.0. These specifications include weight, AC Power (Mains) requirements, air supply, temperature, and humidity conditions. This section includes dimensional drawings and recommended space for service access. Dimensions of Basic XDS Process Analytics Instrument. Depth (front to back) is 14.25” (362mm). The upper mounting feet are positioned upward as shown, for best support of the hanging load.
Leave adequate mounting space for all installed options, as well as room for air circulation and wiring access.
5 Installation of Process Enclosure The basic types are shown here, for familiarization. Installation instructions follow. 5.1 Basic NEMA 4X Process Analytics Instrument The basic NEMA 4X, fan-cooled instrument is shown. Note the fiber mounting plugs at the top right. This is where the fiber optics are routed into the instrument. The window in the door permits the user to view the LED indicators and the temperature controller. The heat sink and fan chassis are shown on the right side.
This shows the Basic Unit with Vortec Cooler on the right side. The left side of the basic XDS Process Analytics Instrument shows the AC cable entrance and RJ-45 connection, indicated by arrows. The XDS Process Analytics Instrument is shipped with an AC cable for testing and lab use only, since many instruments are operated in a laboratory setting prior to implementation on the process line. This AC cable must be removed when the XDS Process Analytics Instrument is installed into the process location.
5.2 Vortec Cooled XDS Process Analytics Instrument The Vortec cooled instrument has a Vortec assembly on the right side, attached to the heat sink. An air curtain (inside the horizontal housing) directs the cooling flow over the full width of the heat sink. This instrument also has the vent for the purge system, mounted on top of the cabinet. Vent Housing Actuation Valve Vortec Cooler Filter This photo shows the inside of the Vortec cooler, where the air curtain is released.
5.3 Purged Enclosure for Hazardous Environments Vent Assembly LED Indicators Catastrophic Shutoff BEBCO Purge Unit Fiber Housing Monochromator Lamp Housing Vortec Cooler AC Power Block RJ-45 Communications fibers enter the purged system where shown in the photo, near the filter unit. The instrument air input to the filter is shown. AC Power enters the purged enclosure via the cable entrance at lower right in this photo.
5.4 Mounting of XDS Process Enclosure These steps explain physical mounting of the XDS Process Enclosure. Note that the enclosure may weigh as much as 135 pounds (60.8kg). It is imperative that the installers take precautions to avoid injury during installation. 1. Select a mounting area with a minimum of transmitted vibration which could affect the instrument. 2. Verify that the mounting area is able to support the full weight of the instrument, including options.
4. Mounting dimensions for the enclosure feet are as shown on the following page. The mounting bolts must be 3/8” (10mm) in size. The environment may require stainless steel due to industry or washdown requirements. 5. Lift the instrument onto the mounting bolts, seating both upper mounting brackets first. Enclosure Depth (front-to-back) is 14.
6. These photos show a mounting with 3/8” mounting studs, welded to a heavy backing plate. The mounting may also be a sturdy frame, or other method suitable to support the full weight of the instrument. Use extreme caution with the fiber optic cables when mounting the instrument. If possible, the cables should be coiled up and secured to the unit to avoid damage. Radius of coiled fibers should never be less than 6” (153mm). Diameter should be at least 12” (305mm).
5.5 Removal of Shipping Restraints The monochromator enclosure is mounted on wire rope shock absorbers to minimize the effect of vibration in the ambient environment. The monochromator is locked down for shipment, to prevent shipping movement from jostling the shock mounts beyond their normal range of motion. Release the shipping restraints as shown. The shipping restraints are three (3) captive screws, circled in the photo at right. Two are at the front of the monochromator box, and one is at the rear.
6 Installation of Single Fiber Optic Cable Single fiber optic cables are quite rugged, and are jacketed to protect the delicate optical fibers within. While protected, the fiber bundles are still somewhat fragile when not handled correctly. Always use care when routing and installing fibers. The fibers are not installed on the instrument. They must be installed before use. Handle very gently when moving and lifting, to avoid damage. Follow these guidelines: 1. Never bend in a radius of less than 6” (153mm).
1. Slide one end of the single fiber cable(s) to be pulled up into the cable netting. The netting may be “opened up” as shown for insertion. 2. Braid the strength members around the single fiber optic cable, for the length of the strength members. 3. Wrap electrical tape around the braided assembly for at least 4” (100mm) at the end of the strength members. It is advisable to tape all the way to the bottom of the netting, to ensure strength.
2. Install the O-ring onto the lower part of the ferrule as shown. Do not twist or distort the O-ring, or it may not seal properly. 3. Install the rounded nut over the SMA connector and push it back onto the fiber. 4. Install the rubber sealing boot over the SMA connector as shown. Push it back over the fiber. 5. Insert the Single Fiber, SMA end first, through the ferrule as shown. 6. Carefully slide the black sealing boot into the slotted area of the ferrule.
7. Install the assembly into the mounting hole in the XDS Process Analytics housing. TIP: With a multi-channel instrument, it is helpful to have a neat appearance inside the cabinet. Note where each fiber will attach, and use a mounting hole nearby. This avoids a “tangle” of fibers inside the housing. 8. Place the nut (flat side against the housing) over the Single Fiber. Thread onto the ferrule as shown. Tighten the nut using a ¾” (19mm) openend wrench.
10. Tighten the SMA connector using a calibrated wrench like that shown. This wrench has a “detent” when it reaches the torque setting, to ensure correct tightness. The setting is 8 in-lb, and the open end is 5/16” (8mm). 11. Gently tighten the rounded nut to ensure a tight seal around the Single Fiber entrance. TIP: Push about ½” (12mm) of fiber inward, to avoid stressing the fiber. Tighten the rounded nut hand-tight. Give a slight tug to assure good sealing – if the fiber moves, tighten further.
6.2 Assembly of Detector (return) fiber to multiplexer The “Channel” number for a given fiber bundle (or pair, if Transmission) may be determined by checking where the “return” fiber is screwed in to the multiplexer. The channel numbers are stamped into the sheet metal, but are quite difficult to read. This photo shows the channel positions. Position #10 is the internal reference fiber, from position #10 on the lamp box. The fiber at the center takes the light to the monochromator box.
7 Electrical Connection The XDS Process Analytics Instrument is shipped with an AC line cord, which is used for initial checkout testing only. When installed in a permanent location, the instrument is to be connected with a dedicated conduit drop, following all applicable electrical codes. AC Mains wiring is as follows: Power Requirements: • 100/240 VAC Selectable • 50/60 Hz • 2A / 1.5A With Air Conditioning (optional) 5A / 2.7A 7.
1. Loosen the 1/16” set screw that secures the round green housing to the base of the Electronic Power Control Unit (EPCU). (It is not tightened at the factory, and may not need to be loosened.) Rotate the green cast cover counter-clockwise until it can be removed from the square base. This takes about 8-10 turns. 2. When the green cast cover is removed, the Control Module Assembly will be exposed as shown.
5. Use a small flat-bladed screwdriver to loosen both screws holding the Encapsulated Intrinsic Safety Module (EISM) in place. These screws may be left loose in the module. Do not lose them. 6. Using proper anti-static (ESD) protection, pull the Encapsulated Intrinsic Safety Module (EISM) straight outward. Set the Encapsulated Intrinsic Safety Module (EISM) aside on a static-protected mat. Note the installer’s ESD Wrist Strap. 7. Note the connector at center right. This is Main Power Wiring Header P1.
11. Route AC Mains wiring into the housing, and in to the Main Power Wiring Header as shown at right. Terminals 3 and 6 should be left as is, with the black and white wires attached. Use table below for wire color codes. L1, Neutral L2, HOT Ground Intl: Blue Intl: Brown Intl: Green/Yellow US: White US: Black US: Green 12. Attach Grounds to the Ground Lug inside the Base Unit of the EPCU. 13. The wiring diagram on page 13 of the BEBCO Industries Series 4000 manual is shown for reference.
15. Rotate the Main Power Wiring Header to the correct position to snap in place in the base unit. This will require arranging the wires neatly out of the way to place the header in position. Snap firmly into the base unit. (Refer to step 7 to see the original position.) 16. Using proper anti-static (ESD) protection, push the Encapsulated Intrinsic Safety Module (EISM) straight inward, using the guide slots. Push firmly into place. 17.
This photo shows the switch prior to air conditioner installation at the factory. This is included to help the installer understand the switch location and positions.
8 RJ-45 Network Connection RJ-45 Cable Connection applies to the non-purged instrument, and is detailed below. For the purged unit, fiber optic modems are provided, to meet hazardous location requirements. 8.1 Basic Process Instrument RJ-45 Connection The Basic XDS Process Analytics Instrument (non-Purged) has an RJ-45 cable entrance on the left side of the box, toward the bottom. It is shown, with cable connected. The plug shown is a water-tight, dust-tight connector with O-ring seals.
Install the O-ring onto the cable connector housing as shown. Do not damage or distort the O-ring during installation. Slide the cable connector housing onto the RJ45 cable as shown. Using the correct type of crimping tool, crimp the RJ-45 connector jack onto the cable. Be sure the conductors are arranged in the proper order and are in the designated positions for crimping. Push the RJ-45 jack fully into the connector housing. Install the locking clip as shown to hold the jack to the connector housing.
Slide the knurled collar up onto the connector housing. The final assembly is shown. To attach to the instrument, insert the connector jack (tab down) into the plug on the side of the instrument. Push until it “clicks” into place. Thread the knurled collar onto the threaded portion of the mating assembly. Tighten handtight. Be sure the knurled collar is tightened enough to compress the O-ring, to seal out contaminants.
8.2 Purged Unit Instrument RJ-45 Connection The Purged Enclosure uses different AC Power and communication entrances. The instrument air is routed to the entrance on the filter, as shown. AC (“mains”) power is provided to the lower entrance on the box where shown in this photo. This shows the temporary AC power cord. A permanent installation must use dedicated wiring, in accordance with local codes. The RJ-45 fiber optic communication lines enter the enclosure.
The cable is plugged into the converter, and the bayonet bezel is turned to lock in place. Note that this fiber is plugged in to the port marked “TX.” The other is marked “RX.” These must be configured properly. See below. The “UTP” RJ-45 cable entrance on the right side is configured inside the XDS Process Analytics Instrument, during factory set-up. Modem connections and settings are as follows: (Cable color refers to the color of the molded strain relief, not the actual cable.
9 Temperature Controller Set-up The XDS Process Analytics Instrument contains a temperature controller to maintain internal temperature of the enclosure. This is normally set to 38.0 degrees C (100.4 degrees F). Temperature is read in degrees C. A temperature-sensing device is embedded in the instrument cabinet, and this is used as a method to control the internal temperature.
The enclosure temperature is displayed in the Status Bar of Vision, as shown. This is not adjustable from Vision. In this case, the instrument temperature had not yet reached the set point of 38 degrees C. It is shown for operator information.
10 Vision Software Operation This section describes the steps required to establish communication with the XDS Process Analytics Instrument. It explains how to run set-up diagnostics, and run routine instrument assessment diagnostics. The Vision Software Manual provides information on quantitative and qualitative operation. Communication between the computer (with Vision Software loaded) and the XDS instrument may be handled in one of several ways.
3. To begin, a new project must be created. The project is used to store data and calibrations for a given type of analysis. Multiple projects may be used, to keep spectra, calibrations and other data separate and well-organized. Assign the project some meaningful name, to make it easy to remember. For our purposes, we simply called this “project7”. Please use a more descriptive name. Vision will assign a Location; leave this blank. 4. Vision asks if the default directory location is acceptable.
1. Select Configure, Options from the menu bar. 2. The menu shown at right is the set of selections. A brief explanation follows: Instrument must stabilize before data acquisition: This prevents spectral acquisition if the instrument is cold. Performance Test must pass before data acquisition: This prevents the user from taking data on a non-functional instrument. Run performance test after wavelength linearization: Forces user to run test sequentially. This is not necessary with XDS.
Use Window Correction Select this when using XDS Process instrument with Transmission Pair. When calibration or library transfer (between instruments) is anticipated, be sure that Reference Standardization and Instrument Calibration are selected, BEFORE creation of a DCM. These features assure best method transfer between similar instruments. When finished, click on the “OK” button. 10.3 Connect to Instrument This section covers instrument communication.
3. This box allows the user to select the instrument identified by the instrument serial number. The number in front of the instrument S/N is the IP (Internet Protocol) address assigned to the XDS instrument. If no instrument is shown, of if it is not “Available”, click “Retry” to clear the communication ports. Use the drop-down arrow of the IP Address box, and select the correct instrument. The instrument must show “Available” to be selected. 4.
7. Click on Acquire, Connect. 8. A Data Collection Method (DCM) selection box will appear. It is empty, so no selection is available. Click on the “New” button. A blank DCM screen will be displayed. An example of a DCM for this instrument is shown on the next page.
9. When this DCM screen is shown, the Method is blank. Fill in the name with a meaningful description. In this case we will name the method “Single Fiber MPX,” for the type of instrument. Any meaningful name is acceptable. The Single Fiber Multiplexer has a nominal selection Range of 800-2500nm. This is shown as selected. (Performance Test range is 850-2200nm, or 850-2100 for fibers over 6 meter length.) Always set the Range correctly before proceeding to the next step. Click on the “Mux Table” button.
11. Click on the drop-down arrow beside the Tip Type box. This shows supported types of probe configurations. For transmission cells (as shown) choose “Transmission Pair”. 12. For probe types shown above, choose “Single Pass Probe”. 13. Click on the drop-down arrow next to Fiber Count. Supported types are Regular Bundle, Micro Bundle, and Single Fiber. In this case select “Single Fiber”. Scans defaults to 32 scans for a spectrum.
14. Fiber Length depends on the fibers used in the system. The default is 0-3 Meters. Most Single Fiber Systems use fiber lengths “Greater than 6 meters.” 15. Now click on Channel 2. By default, Channels 2-9 are marked “Not Used”. If a channel is used, be sure to click “Used” for that channel. Continue through all channels and verify the correct setting. Click on OK when finished. This returns the user to the DCM screen. 16. Verify that the name is entered for the DCM. Click OK when finished. 17.
18. Once the instrument is successfully connected, the amber “Communications” LED (middle position) will light. 19. Upon connection, the Instrument Configuration is shown for verification. If correct, click on “OK”. Accepting this screen tells Vision to set up a branch of the Diagnostic Database for this instrument configuration. When the user disconnects and re-connects to the instrument, Vision may ask the user to re-confirm this screen. When this occurs, click “OK” to proceed.
Wavelength Linearization uses internal wavelength materials to determine a set of internal, arbitrary peak positions that the instrument will use to maintain repeatability of wavelength response. Wavelength Linearization is performed on the internal reference fiber located in the XDS Process enclosure. The NIR wavelength positions of these peaks appear as shown. The scale of this display is marked in encoder pulses, which do not relate to nanometers directly.
10.4.2 Reference Standardization, Transmission Pair Reference Standardization with Transmission Pair ends uses an innovative means to adjust each channel to a repeatable, transferable level of spectroscopic response. The fiber ends are screwed into a fixture, the response is measured, and the signal is “normalized” using a spectral correction. This shows the fixture. When Reference Standardizing, this fixture holds the two single fiber ends in alignment, at a predetermined distance.
4. Select the channel. From the menu bar, click on Acquire, then Select Channel. Use the spinner to select the correct channel, then click on “OK”. This must be performed for each channel. Always verify the channel before proceeding with the test. 5. Select Diagnostics, Reference Standard, Create Reference Standard. Vision takes an instrument reference scan. The XDS instrument has an internal reference fiber, which is selected for this operation. 6. Vision requests that the correction file be located.
10.4.3 Instrument Calibration, Transmission Pair First select the channel. From the menu bar, click on Acquire, then Select Channel. Use the spinner to select the correct channel, then click on “OK”. This must be performed for each channel. Always verify the channel before proceeding with the test. Instrument Calibration uses a traceable, stable, standard, of known wavelength response, as a method to establish wavelength scale response of the instrument.
This dialog box is displayed. Next a scan is taken (on the reference) and this box is displayed. This takes about 20-30 seconds. Wavelength Linearization is performed in two sections, each of which takes about 15 seconds. Following Wavelength Linearization, the user is asked to select a standard file. This is located on the computer in the Vision directory, as shown. Select the file “TSS3Wxxx” and click on “Open”.
When prompted, position the WST3WCAL Wavelength Standard in the standard area as shown. Always orient the standard in the same direction. Click “OK” to continue. This test takes about 45 seconds. The wavelength response for each defined peak is adjusted, to assure precise wavelength registration between instruments. At the same time, bandwidth (bandpass) is measured, and is iteratively adjusted to an optimum value for the peaks measured.
10.4.4 Window Correction, Transmission Pair Window Correction is a method to permit the user to calibrate the single fiber optic path using a calibration fixture. Next, the single fibers are attached to the actual sample cell, and the optical differences are mapped. This gives a clear, repeatable measure of the optical difference between the two geometries. This window correction method offers a large advantage to users running with sample cells permanently installed.
The TSSZERO file is shown as a spectral plot. The spectrum is a flat line at 0 AU. Vision takes a reference using the fiber optic probes. This spectrum is plotted (not shown here.) When this message appears, click on “OK”. Vision plots the TSSZERO.da file on screen. Click on “OK”. The correction file is plotted. Click “OK” to see the final correction, overlaid onto the certified TSSZERO spectrum. The two spectra should overlay perfectly. Click on “OK”. When finished, the user may print the report.
10.4.5 Performance Test, Transmission Pair 1. Select Performance Test from the Diagnostics menu bar. 2. Select the channel to be used for the test. In this case, we select “SAMPLE”. The sample cell or fixture should be protected from stray light for this test. This tests the sample channel, and provides a comprehensive test of instrument performance. Vision provides a split-screen display that details instrument performance. The lower right quadrant shows tabulated data.
11 Maintenance of the XDS Process Instrument The XDS Process Analytics Instrument is designed to be trouble-free, with a minimum of maintenance. These guidelines should always be followed: Keep the outer enclosure as clean as possible, to maintain heat transfer characteristics. Do not allow dirt buildup in the heat sink fins. These should be blown clear of any dirt or obstructions on a regular basis. Be extremely careful of the fiber optic bundles.
The monochromator is mounted on wire rope shock mountings to absorb vibration and assure a low noise instrument. One of these wire rope shock mounts is shown at right. The instrument must be operated in the upright position to take advantage of the shock mounting. The thumbscrew to the left of this wire rope mount is a shipping lockdown. It should be locked down when transporting the instrument. It must be released when operating.
The multiplexer is shown in close-up. The channels are marked, but are quite hard to read. This diagram shows the channel numbers where the “return” fibers attach. The fiber at the #10 position connects to the #10 position on the lamp box. The fiber at the center is the internal reference channel, and runs to the monochromator box. The instrument contains a catastrophic shutdown temperature control, shown at right. This instrument is set at 120 degrees F.
Fiber Optic Cables connect at the top of the enclosure as shown. This instrument has only one channel, mounted at the rear-most entrance. Stainless-steel plugs seal the unused entrances. Up to nine channels may be used, when the multiplexer is installed. When optional temperature probes are used, the number of fiber optic channels may be reduced, as the temperature probes exit using these openings. A fiber optic modem is available for the XDS Process Analytics Instrument.
11.2 Lamp Replacement Lamp replacement is quite simple with the XDS Process Analytics Instrument. Lamp replacement should normally be scheduled at factory shutdown intervals, to avoid unexpected downtime during peak production. Lamp instructions are as follows: 1. Shut off AC Power to the instrument. If the location has a “Lockout Policy” it must be followed. 2. Using a large, flat-bladed screwdriver, open the door latches. Turn counter-clockwise to open. When open, the slot is verticallyoriented.
3. The lamp may be very warm. Give it at least 15-20 minutes to cool down before attempting replacement. The lamp housing is the stainless steel cover at in the lower part of this photo. Note the four (4) captive thumbscrews. When the housing is cool to the touch, loosen the four thumbscrews. 4. Carefully lift the cover off as shown. The lamp is now visible. 5. Loosen the two lamp screw terminals. Slide the lugs out from under the screws. Do not remove the screws from the terminal strip.
6. Twist the lamp retaining ring to the right, and lower it from the heads of the shoulder screws. Remove the lamp assembly from the instrument. 7. Carefully remove the ring from the lamp wires. This ring will be re-used with the new lamp.
8. Place the new lamp retaining ring over the new lamp assembly. The wires must run through the center hole of the bracket as shown. 9. Carefully lift the lamp upward into the lamp bracket. Place the lamp retaining ring over the heads of the shoulder screws, then rotate to the left to lock in place. Be sure all three shoulder screws are securely seated on the lamp retaining plate. There is no rotary orientation of the lamp. It may be installed in any orientation.
11. Install the lamp cover back onto the lamp housing. The widest part faces the user. Do not try to install in the wrong orientation. 12. Tighten the four (4) captive thumbscrews on the lamp cover. Do not use tools to tighten these screws, as the heat cycling of the instrument may make them hard to remove. Hand-tight is sufficient. 13. Close the instrument. Apply power to warm up the instrument. 14. Enter Vision Software and connect to the instrument. 15. Run Wavelength Linearization. 16.
11.3 Fuse Replacement Fuse Replacement is an unusual event, and usually is caused by some electrical fault. The electrical fault should always be investigated and repaired before fuse replacement. Once the fault is found and corrected, this procedure should be followed: 1. Turn off electrical power and follow any required lockout policy. 2. Using a large, flat-bladed screwdriver, open the door latches. Turn counterclockwise to open. When open, the slot is vertically-oriented.
4. Gently lift the tab to open each fuse position. Spare fuses are included in the instrument Accessory Kit. Fuse Ratings: • 250 VAC, 5 x 20mm, Slo-Blo • (2) Required • Non-Air Conditioned: • Air-Conditioned: Order spare fuses immediately, to have on hand. 5. Remove each fuse from the clip. It may help to push the fuse, using a pencil eraser, from the side shown, and then grasp the fuse to fully remove. Inspection of the blown fuses may provide some information about the type of fault.
7. Push down the fuse door firmly until it snaps into place. Be sure this has been performed for both fuses. 8. Close and latch the door of the XDS Process Analytics Instrument. 9. Restore power to the instrument. 10. Connect to the instrument from Vision. Allow time for Purge System activation (if so equipped) plus about 20 minutes for temperature stabilization. 11. Run Performance Test to verify instrument operation. Because no optical components were changed, there is no requirement to run other tests.
12 Safety Information SAFETY NOTICE A separate electrical shutoff is required for this instrument for safety purposes. The shutoff must break both sides of the line (“Allpole”) and be electrically grounded. The shutoff box must be adjacent to the unit for ease of shutoff for maintenance or emergency purposes. If your plant codes require “lockouts” on electrical equipment, the shutoff should accommodate the lockout devices to prevent inadvertent power-up.
All major electrical components used in the instrument meet UL, CE, CSA, or TUV certification. Usage is as defined by the manufacturer, to assure safe performance. Wire sizes, colors, and terminations meet CE requirements. All connectors meet CE safety standards. Shielding is provided to avoid user contact with hazardous voltages during use of the instrument. Additional safeguards have been taken to avoid defeating these shields and interlocks.
13 Troubleshooting The XDS Process Analytics Instrument is a dependable, trouble-free instrument, designed for many years of service in your facility. In spite of the rugged design, problems may arise that require attention. This guide is intended as a means of diagnosing minor problems. There are no user-serviceable parts inside the instrument enclosure, except for the lamp. Because of this design, we emphasize that under no circumstances should the user attempt to service any part other than the lamp.
1. Verify that the RJ-45 cable is plugged in at both the instrument interface, and at the network jack. 2. Verify that the RJ-45 cable is plugged in at both the computer and at the network jack. (NOTE: Direct connection is explained in a separate document for non-network users. This requires a special “UTP Crossover” cable. 2 No communication between Vision and the instrument. 3. Verify that the instrument is powered on. (See previous Observed Problem.) 4.
1. Temperature and/or humidity may be changing rapidly during the test. This can usually be observed as large spectral activity between 13001400nm and 1800-1900nm. Be sure the instrument enclosure is closed and locked. Allow to stabilize. 5 Instrument Fails Performance Test. 6 Instrument fails Instrument Calibration. 7 Instrument Gain is excessively high in Gain Test. 2. Instrument may be located near grinders, stirrers, or other equipment which produces vibration or mechanical disturbance.
