User’s Manual TDLS200 Tunable Diode Laser Spectroscopy Analyzer IM 11Y01B01-01E-A Yokogawa Corporation of America Yokogawa Corporation of America 2 Dart Road, Newnan, Georgia U.S.A.
i Introduction Thank you for purchase the TDLS200 Tunable Diode Laser Analyzer. Please read the following respective documents before installing and using the TDLS200. Notes on Handling User’s Manuals • • • • This manual should be passed on to the end user. The contents of this manual are subject to change without prior notice. The contents of this manual shall not be reproduced or copied, in part or in whole, without permission.
ii Safety Precautions Safety Precautions Safety, Protection, and Modification of the Product Safety, Protection, and Modification of the Product • In order to protect the system controlled by the product and the product itself and ensure safe operation, • observe In order tothe protect theprecautions system controlled by the in product and the productWe itselfassume and ensure safe operation, safety described this user’s manual.
iii TDLS200 CAUTION SAFETY should be considered first and foremost importance when working on the equipment described in this manual. All persons using this manual in conjunction with the equipment must evaluate all aspects of the task for potential risks, hazards and dangerous situations that may exist or potentially exist. Please take appropriate action to prevent ALL POTENTIAL ACCIDENTS.
• • • If any protection or safety circuit is required for the system controlled by the product or for the product itself prepare it separately. Be sure to use the spare parts approved by Yokogawa Electric Corporation (hereafter simply referred to as YOKOGAWA) when replacing parts or consumables. Modification of the product is strictly prohibited. The following safety symbols are used on the product as well as in this manual.
TOC-1 Table of ConteNtS Introduction........................................................................................................................................................... i Safety Precutions................................................................................................................................................ ii 1 Quick Start...........................................................................................................................................
TOC-2 6.6 Valve Control Logic............................................................................................................................6-30 6.7 Introduction for H2Oppm measurements in Methane Gas................................................................6-32 6.8 Introduction to Gas Temperature Predictions with High Temperature Oxygen Measurements........6-38 6.9 Controlling the Analyzer Remotely or Locally via external PC/Laptop2............................................6-34 6.9.
<1 QUICK START> 1-1 1 QUICK START Step Title Description 1.0 Preparation Carefully un-pack and check equipment for any obvious damage. This includes flanges, Cables, Power Supplies, manuals and any other supplied options. NOTES: There are 14 ferrules in the accessory bag for tubing-piping. The number of ferrule that are required for actual tubing-piping are different by application. Please see tubing-piping figure specific to project for exact detail. 1.
<1 QUICK START> 1-2 Leak-check all connections and ensure pressure ratings are not exceeded! 4.4 Power-Up 5.0 Apply power to the analyzer and using a multi-meter, check for 24VDC power at TB1 on the launch unit back plane. 5.1 Use the internal On-Off switch to power-up the analyzer. 5.2 Observe the various LED clusters on the backplane and FPGA boards. All blue LEDs located on the lower right side of the back-plane should be on. 5.3 Observe the Green power indicator on the SBC. 5.
<1 QUICK START> 1-3 2-3 9.0 Configure ADVANCED 9.1 Using the correct password (Default 1234), enter in to the Advanced Menu, then the Configure. Select the desired measurement units (English or Metric selected on an individual parameter basis). 9.2 Optical Path Enter in the correct optical path length. 9.3 Gas Pressure Select Fixed or Active. If Fixed, enter in the correct process gas pressure. If Active, enter in the 4-20mA input signal range proportional to the pressure range.
<2. INTRODUCTION AND GENERAL DESCRIPTION> 2-1 2 INTRODUCTION AND GENERAL DESCRIPTION The TDLS200 TDLS analyzer is designed to measure selected target gases in gas phase samples directly at the process point (across stack, across pipe, etc.), close coupled/by-pass leg or in full extractive systems (flow cell). The analyzer measures free molecules on a path averaged basis.
<2. INTRODUCTION AND GENERAL DESCRIPTION> 2-2 2.1.1 Measurement Current ramp to laser Figure 1. Current ramp to laser • Current ramp to laser Signal at Detector • • • • • During measurement the laser is held at a fixed temperature. This is the coarse wavelength adjustment. A current ramp is fed to the laser. This is the fine wavelength adjustment. Figure 1. The current is ramped to scan across the wavelength region desired.
E: For products used within the European Community or other ries requiring the CE mark and/or ATEX classification, the ing labels are attached (as appropriate): <2.
<2. INTRODUCTION AND GENERAL DESCRIPTION> 2-4 CAUTION - For Cleaning of the labels and LCD window, please use wet cloth to avoid electrostatic condition.
<2. INTRODUCTION AND GENERAL DESCRIPTION> 2-5 Maintenance Work by Qualified Personnel Unqualified work on the product may result in severe personal injury and/or extensive damage to property. If the Warnings contained herein are not adhered to the result may also be severe personal injury and/or extensive damage to property. This product is designed such that maintenance work must be carried out by trained personnel.
<3. GENERAL SPECIFICATIONS> 3-1 3 General Specifications 3G with purge system EEx pz II T5 Class 1 Div.2 Group BCD with integral purge kit KC mark: KCC-REM-YCA-EEN999 0.5A@125 VAC USB1 and USB2 connection for data transfer using memory stick, data storage in CF card (result files, spectra capture, configuration data, etc.) Capture rate is configurable typical capacity for results and spectra is 14 days. 2”, 3” or 4” 150# ANSI RF or adaptors for DN50 PN16, and DN80 PN16 2” 150# Alignment flange 4.
<3. GENERAL SPECIFICATIONS> 3-2 Performance Specification Basic System Configuration Repeatability: Application Dependent The TruePeak can be installed in a number of ways depending on process requirements. The most typical installation types are shown below, however other installation methods are possible, please contact Yokogawa with your application details.
<3. GENERAL SPECIFICATIONS> 3-3 Standard Accessories Calibration Cell: Flow Cells: Isolation Flanges: Display and Software Functions -U sed for off-line calibrations and validations - Stainless steel 316 with free standing frame - Connects Launch and Detect with 72.6cm (28.6") OPL TruePeak Software has multiple levels, the default (or start page) is the Main Menu: -U sed for extracted sample streams at any location - 316SS low volume fixed alignment; 50ºC, 5.
<3. GENERAL SPECIFICATIONS> 3-4 3.
<4. ANALYZER COMPONENTS> 4-1 4 Analyzer Components Launch Unit: • • • • Launch Unit: Detect Unit: TDLS200 TDL Analyzer Instruction Manual V2.1 • Analyzer detachable from process • Detect Electronics interface for Off-Line calibration / service. Housing • Flanged O-Ring Alignment • Detector Assembly • Flanged Metal Bellows Seal Alignment • Flow Cell 2.
<4. ANALYZER COMPONENTS> 4-2 4.1 Launch Unit Main Electronics Housing • Back Plane circuit board • Single Board Computer (SBC) • FPGA signal Processing board • Analog I/O circuit board • Field electrical terminals are located on Back Plane (and optional Analog I/O board).
<4. ANALYZER COMPONENTS> 4-3 4.2 Main Electronics Housing Enclosure Die cast copper free aluminum grade AL Si 12 alloy (A413.0) with a powder coat exterior finish. The copper free aluminum alloy is particularly resistant to salt atmospheres, sulfur gases and galvanic corrosion. An externally hinged door opening to the left incorporates a weather tight gasket seal and four captive fastening screws (stainless steel). The external dimensions are approx 16” W x 12” H x 7” D (400mm x 300mm x 180mm).
<4. ANALYZER COMPONENTS> 4-4 Watchdog Power Interrupts The power output channels for microprocessors have control logic lines (TTL activated). These allow for watchdog interrupt/reset functionality. Alarm Relays There are three alarm relay circuits on the board. These are capable of actuating Form C Single Pole Double Throw (SPDT) relays. The three connections of each relay (Common, Normally Open and Normally Closed) are routed through the board to field terminals.
<4. ANALYZER COMPONENTS> 4-5 Connections of each relay (Common and Normally Open) are routed through the board to field terminals. The contacts are rated for a maximum of 1A @ 24VDC (or 0.5A @ 125VAC). The pluggable field terminals are mounted on the lower edge of the board, just to the left side of the DC power input terminals. The appropriate relay(s) is actuated when a calibration gas check valve is to be initiated.
<4. ANALYZER COMPONENTS> 4-6 Optional Mini Display (4x20 VFD) mounts on the analyzer enclosure door. The display itself is an industrial grade 4 line 20 character vacuum fluorescence display (VFD) that is self illuminating (i.e. no back light required). Optional 6.5” Display is an industrial grade 6.5” VGA color TFT LCD Module that has a built-in CCFL backlight. Both the display and interface board are mounted to a cover plate that attaches to the inside of the enclosure door.
<4. ANALYZER COMPONENTS> 4-7 Laser Diode is either a Vertical Cavity Surface-Emitting Laser (VCSEL) or Distributed Feedback (DFB) that outputs at wavelengths in the 750nm to 2400nm range (invisible) depending on the target gas being measured. The primary output wavelength of the laser is controlled by a thermoelectric cooling module (Peltier Element). The laser diode is permanently attached to the module. Collimating Lens is an optical Window Body component that collimates the diverging light source. 4.
<4. ANALYZER COMPONENTS> 4-8 4.5 Detect Unit Detect unit Detect Electronics Housing • Detector Circuit Board Detect Electronic Housing Process Interface Detect Assembly Detector Housing and Detector Module • Detector and focusing lens assembly • Detector module designed to be field replaceable and purged to prevent ambient air ingress. • Housed in a stainless steel body with O-rings seals, attached to the detect electronics housing.
the maximum temperature reading is monitored. The board is medium size (approx. 4” H x 6” W) printed circuit board that mounts inside the enclosure. The field terminations are located along<4. the lower edge of the board via pluggable ANALYZER COMPONENTS> terminal block. All components and devices on the board are designed for extended temperature and low drift operation. 4-9 4.6 Process 2.3.7 Interface Process Interface An appropriate Process Interface is selected to suit the process/stack installation.
<4. ANALYZER COMPONENTS> 4-10 4.7 Analyzer Connections Launch – Detect Interconnect The two units are connected to each other via a four, twisted pair cable suitable for tray installation outdoors. Pluggable terminals strips are provided at both units to enable field termination of the cable. The cable pairs are individually shielded as well as an overall shield. The cable specifications are as below.
<4. ANALYZER COMPONENTS> 4-11 4.8 Communications Stand Alone Options The analyzer is capable of fully independent operation with no external computer or interface required. A number of options are available for a built in user interface (mounted on Launch Unit): • Blind with no display or keypad. Access to the analyzer through; Ethernet connection (local or remote computer), Remote Interface Unit (RIU), Universal Remote Display (remote display only - no keypad) with menu access via external computer.
TDLS200 TDL Analyzer Instruction Manual V2.1 <4. ANALYZER COMPONENTS> 4-12 The unit acts as a remote interface for the analyzer. Should the physical location of the actual analyzer(s) be inconvenient for easy then the RIU canfor bethe used. The unit actsaccess, as a remote interface analyzer. Should the physical location of the actual analyzer(s) be inconvenient for easy access, then the RIU can be used.
<4. ANALYZER 4-13 TDLS200COMPONENTS> TDL Analyzer Instruction Manual V2.1 RIU Optional Ethernet Switch RIU Optional Ethernet Switch If there is one more than one analyzer the are RIU, then via they routedEthernet via an industrial If there is more than analyzer connected to connected the RIU, thentothey routed anare industrial switch. Up to four Ethernet analyzers switch. can be routed through one RIUcan switch. The switch is powered by switch.
TDLS200 TDL Analyzer Instruction Manual V2.1 <4. ANALYZER COMPONENTS> 4-14 TDLS200 TDL Analyzer Instruction Manual V2.1 Purging Analyzer for Safe Area. The block diagram below sections of the analyzer that require nitrogen purging. The purging should Purging Analyzer forshows Safe the Area for Safeas Area bePurging carried inAnalyzer sequence typically shown below. The block diagram below shows the sections of the analyzer that require nitrogen purging.
<5. INSTALLATION AND WIRING> 5-1 5 Installation and Wiring Detailed Installation, Wiring, Utility Drawings are included on a Project Basis. Please contact Yokogawa for any project specific documentation to ensure correct installation. Drawings provided herein are considered for standard installation use only 5.
TDLS200 TDL Analyzer Instruction Manual V2.1 <5. INSTALLATION AND WIRING> 5-2 Position of Process Flanges forDetect Launch and 5.2 3.2 Position of Process Flanges for Launch and Units: Detect Units: Process flanges should be located on the process such that the Launch and Detect Units can be Process flanges should be located in onathe process such that the Launch and Detect Units can be installed, installed, accessed removed safe and convenient manner.
TDLS200 TDL Analyzer Instruction Manual V2.1 2 <5. INSTALLATION AND WIRING> 5-3 The following safety symbols are used on the product as well as in this manual. Operating and Maintenance Manual 1. Introduction ...................................................................................................4 DANGER 1.1 Features ................................................................................................
<5. INSTALLATION AND WIRING> 5-4 5.3 Process Flange Welding Alignment and Line-Up 21 - Reinforcing Plate mechanisms for Launch orthat Detect Unit The Launch and Detect units Figure are provided with alignment allow forFlanges some manual adjustment of the laser beam direction in both planes. It is however recommended that the following angular tolerances be adhered to as closely3.3 as possible.
WARNING This symbol indicates that an operator must refer to the instructions in this manual in order to prevent the instrument (hardware) or software from being damaged, or a system failure from occurring. 5.4 Process Flange Clear Aperture 3.4 Heat Exchanger Section ...............................................................6-7 3.5 Outlet Temperature Section .............................................................7 3.6 Self Temperature Controller ................................................
<5. INSTALLATION AND WIRING> 5-6 5.5.1 Process Window Purge Gas Connection In order to keep the process windows clean (prevent fouling by process gas) it is necessary to purge the windows with a clean dry gas of sufficiently low dew point. When measuring Oxygen, Nitrogen should be used for purging the windows. The purge gas or nitrogen should be clean (<0.5 μ particulate), dry (-40˚C dew point), oil free. The process flanges are provided with two diagonally opposed inlet ports (typically ¼” OD tube).
<5. INSTALLATION AND WIRING> 5-7 5.7 Typical Purge Gas Configuration, In-Situ Please refer to project specific details, the following is a typical standard in-situ configuration: Figure 30 5.
<5. INSTALLATION AND WIRING> 5-8 Typical Purge Large Aperture Optics (LAO) combustion O2, CO/CH4 Figure 32 5.
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<5. INSTALLATION AND WIRING> 5-15 5.10 Wiring 5.10.
<5. INSTALLATION AND WIRING> 5-16 5.10.2 Launch and Detect Unit Wiring – Standard for CE/ATEX SPECIAL NOTE: Noise sources magnetically coupled to the 4-pair launch to detect cable can cause errors to the measurement if the frequency and applied total voltage meet or exceed the following; Frequency range of 0.1 to 7.5 MHz and Total induced voltage of 3Vrms. A combination of these parameters will cause measurement error outside of the analyzer performance specification.
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<5. INSTALLATION AND WIRING> 5-18 5.10.
<5. INSTALLATION AND WIRING> 5-19 2 The following safety symbols are used on the product as well as in this manual. Operating and Maintenance Manual 1. Introduction ...................................................................................................4 DANGER This symbol indicates that an operator must follow the instructions laid out in this manual in order to avoid the risks, for the human body, of injury, electric shock or fatalities.
The Purge Systems are not manufactured by Yokogawa Laser Analysis Division. <5. INSTALLATION AND WIRING> 5-20 3.9.1 Analyzer Purgingfor Analyzer for Hazardous Areas (with On-Line 5.11.
<5. INSTALLATION AND WIRING> 5-21 5.11.3 Purging Analyzer Universal Power Supply and/or forvalidation Hazardous Figure 28and - Purge Flow Diagram when not usingURD on line Areas (with On-Line Validation) 3.9.
<5. INSTALLATION AND WIRING> 5-22 5.12 Cyclops Division 2/Zone 2 Purge Indictor, with switch Type Z purging reduces the classification within a protected electronics enclosures from Division 2 or Zone 2 to nonhazardous. Failure to maintain pressure within the protected enclosure shall be detected by an alarm or indicator at the electronics enclosure.
<5. INSTALLATION AND WIRING> 5-23 Normal Operating Conditions Power Certified for installation and use in ATEX and IECEx for Type Z – Purge, II 3 G Ex nA nL [pz] IIC T6 For Zone 2 gas hazardous areas Manual Dilution Cycle Time To Typically, dilution cycle time is to ensure that at least five (5) Energizing Electrical Equipment times the volume of free space in the enclosure of protective gas supply is exchanged before power is applied to the electrical equipment.
<6. BASIC OPERATION> 6-1 6 Basic Operation 6.1 Menu Structure Map Online Menu Level 1 Menu Level 2 Menu Level 3 Menu Level 4 Menu Basic MENU Select A/O Mode -Block (mA value) -Track -Hold Configure Process Path Length Old New Level 5 Menu Pressure* Temperature* *(Similar to Process Path) IP Address Serial No.
<6. BASIC OPERATION> 6-2 Online Menu Level 1 Menu Level 2 Menu Level 3 Menu Level 4 Menu Level 5 Menu Advanced * Password Protected Configure System I/O Analog Output Channel 1 Conc1/Conc2/Tran/Temp/Pres/ None 4 mA- 20 mA Channel 2* (Always uses track mode) Channel 3* *(similar to Channel 1) Warning Mode Fault Mode* *(similar to Warning) Block Mode Field Loop Check AO CH Calibration System I/O System Digital Output Block Mode (mA value) Track mode Hold Mode (mA value) High (20 mA) Low (3.
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<6. BASIC OPERATION> 6-4 Online Menu Level 1 Menu Level 2 Menu Level 3 Menu Level 4 Menu Trends Refresh Refresh Current Trend screen Gas 1 Concentration Min Max Minutes STDEV of Gas 1 Concentration* Gas 2 Concentration* STEV of Gas 2 Concentration* Transmission* Laser Temp Setpoint* Laser Temp in DegC* Peak Center Position* Gas Temperature* Gas Pressure* *(Similar to Gas 1 Concentration) Line 1 - Measurement Level 5 Menu Display Text Description O2 xx.
<6. BASIC OPERATION> 6-5 6.2 Software Guide NOTE: At any time in the Main Menu, press the F5 key (only on Screen & Keypad versions) to toggle the LCD backlight on/off. If there is no keypad (or VNC) activity for 30 minutes then the LCD backlight will automatically switch off, press any key to restore backlight.
<6. BASIC OPERATION> 6-6 BASIC CONFIGURE PATH LENGTH – allows adjustment of the optical path (distance the laser is exposed to the process gas). PRESSURE – allows adjustment of the gas pressure value if using fixed pressure. If the analyzer is using active pressure compensation (live signal fed from pressure transducer) no changes are allowed. Active pressure compensation settings are found in Advanced Menu. TEMPERATURE – allows adjustment of the gas pressure value if using fixed pressure.
<6. BASIC OPERATION> 6-7 The BASIC DATA MENU allows the user to select: ALARM HISTORY – displays the last 17 alarms and faults with brief description, date and time CALIBRATION HISTORY - displays the last 17 calibration events with adjustment amount, date and time The TREND SCREEN is identical for BASIC or ADVANCED MENUS.
<6. BASIC OPERATION> 6-8 ADVANCED CONFIGURE MENU PROCESS PATH LENGTH – allows user to enter in a new optical path length (distance laser is exposed to process gas) PRESSURE – allows selection of ACTIVE (analyzer fed pressure value from external transducer) or FIXED (value entered into software) process gas pressure. In Active mode, a BackUp value can be entered, in case of active input failure. CONTROLLED is not applicable for TDLS-200.
<6. BASIC OPERATION> 6-9 PROCESS PRESSURE FIXED is used when the process gas pressure will not vary under normal operating conditions when the measurement is required. If there is any process pressure variation, then the results are typically affected proportionally according to gas law. Fixed is most suited to ~atmospheric conditions, such as vent lines and combustion.
<6. BASIC OPERATION> 6-10 UNITS Path Length, select the appropriate units of measure for Path Length: in/ft/cm/m Pressure, select the appropriate units of measure for Pressure: psiA, barA, kPa, torr, atm Temperature, select the appropriate units of measure for Temperature: F, C, K SYSTEM I/O - ANALOG OUTPUT CHANNEL 1 to 3 – configuring each 4 to 20mA channel to output Concentration, Transmission, Gas Temperature, Gas Pressure or None.
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<6. BASIC OPERATION> 6-12 CHANNEL 2 FAULTS Menu allows setting of various analyzer FAULT conditions. FAULT is an event that will eliminate the measurement integrity, it is an indication that maintenance is require and the analyzer is not operational.
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<6. BASIC OPERATION> 6-14 SYSTEM Some settings are not adjustable by user, user adjustment is possible for: PASSWORD – changes password for ADVANCED menu access DATE & TIME – changes analyzer date and time TCP/IP – the analyzers real IP address used for Ethernet communications can be changed via this menu option. External keyboard with Windows key no longer required as in older software versions.
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<6. BASIC OPERATION> 6-16 OFFLINE CALIBRATIONS ZERO CALIBRATION – manual or automatic calibration of Zero - ensure there is no absorption peak feature before performing a zero calibration, failure to do so can result is false low readings later when the un-desired target gas has been removed.
<6. BASIC OPERATION> 6-17 ONLINE VALIDATIONS CHECK GAS 1 – allows user to select and configure the on-line validations for check gas #1. The configuration options include Manual or Automatic. Automatic has selections for Local Initiate, Remote Initiate, Time Initiate as well as Settings for these options CHECK GAS 2 – allows user to select and configure the on-line validations for check gas #2. The configuration options include Manual or Automatic.
<6. BASIC OPERATION> 6-18 6.3 Non-Process Parameters Non-Process Parameters is the Yokogawa Laser Analysis Division term used to define regions of the optical path that may be purged with a gas containing the actual target (measured) gas. The most common application of this is to use Instrument Air (~20.9% O2) as the purge gas for analyzers measuring Oxygen in the process.
<6. BASIC OPERATION> 6-19 If measuring CO in the process gas and the purge gas is Instrument Air, then these parameters are not applicable because the CO concentrations typically found in Instrument Air are below practical detection limits. In order for the analyzer to measure correctly under these purge conditions, the analyzer must know the correct parameters such that the measured output value has been compensated i.e.
<6. BASIC OPERATION> 6-20 ADVANCED CONFIGURE MENU (UPDATED) The Advanced Configure Menu has been updated with a subsection titled Non-Process Parameters. NON-PROCESS PARAMETERS These non-process parameters are for the measured gas in the optical path but outside of the process path length.
<6. BASIC OPERATION> 6-21 NON-PROCESS TEMPERATURE This is the temperature of the non-process gas with two modes of input: FIXED – manual input of fixed temperature value ACTIVE AMBIENT - ambient gas temperature derived from integral sensor on detector circuit with offset adjustment (typically -5 deg C) and an adjustable coefficient value (1.0 shown left). To derive the optimum coefficient value, please contact Yokogawa with installation and application details.
absorption peak near the measured absorption peak as the reference. This is used when the measured gas concentration is normally zero or very low such that its absorption peak is not large enough for the wavelength locking function. The adjacent absorption peak level, however, is <6. BASIC typically always high and therefore provides a large enough absorption peakOPERATION> for the wavelength6-22 locking function. 6.
Following pages are the various “Laser Spectra & Control”<6.
On-Line Nitrogen: On-Line Process Process Conditions Conditions – – Analyzer Analyzer Purged Purged with with Nitrogen: TDLS200 TDL Analyzer Instruction Manual <6. BASIC OPERATION> 6-24V2.
<6. BASIC OPERATION> 6-25 On-Line Process Conditions – Analyzer Purged with Nitrogen: When purging with Instrument Air (as opposed to ambient air), the H2O levels are much smaller (due to it having been dried and having a dew point typically in the order of -40˚C) and therefore the H2O concentration is not large enough to produce an absorption peak that can be seen.
TDLS200 TDL Analyzer Instruction Manual V2.1 <6. BASIC OPERATION> 6-26 4.6 Large Aperture Optics 6.5 Large Aperture Optics For in-situ application (typically large scale combustion systems) the optical path lengths are very long(typically (7-30m large for large combustion andthe ethylene furnaces).
<6. BASIC OPERATION> 6-27 6.5.1 Large Aperture Optics Installation, Alignment & Detector Gain The alignment of the Large Aperture Optics (or LAO) is quite similar to the alignment method of a standard TDLS200. To prepare for the alignment you will need some form of screen at the analyzer this can be a launch unit with a screen and keypad, a mini display, or a laptop PC connected through VNC/Ethernet. Go into “Laser Spectra & Control” observe the “Trans. (%)”.
<6. BASIC OPERATION> 6-28 6.5.2 Adjustment of Detector Gain for Large Aperture Optics This section of the User’s Guide gives the guidance and procedures to adjust the detector board gain after the analyzer is installed and powered up. This operation should be done by qualified personnel. Read instructions fully before starting this operation. Any doubts or questions, please contact Yokogawa.
<6. BASIC OPERATION> 6-29 4. [Optional] For a high-process-temperature application and if the current process temperature is higher than 600°C, apply a multi-meter to measure the voltage across R21. If the measured voltage absolute value is greater than 5V, change R21 to the 100Ω resistor from the resistor bag. Keep the original R21 in the resistor bag as it can be used for future offline calibration. 5.
<6. BASIC OPERATION> 6-30 9. Close the detector enclosure. Write down the final values of R21, R22 and R23 below for record. R21 = ____________; R22 = ____________; R23 = ____________. 10. Keep the resistor bag and this procedure document by customer. DO NOT leave them in the detector box or throw them away. 11. Enter these new resistor values into the analyzer configuration under Advanced Menu, Configure, System, Adjustable Resistors Detect – R22, Detect R23 and Detect R-23.
<6. BASIC OPERATION> 6-31 TIME SEQUENCE • It can happen only when there is no active auto calibration or validation. • When time counting is up, o Turn off the current valve. o Turn on the next valve. o Start the new time counting. o Multiple valve time sequences are allowed. When configure the parameters, please pay attention. Time sequence is not recommended to use with remote control at the same time to avoid valve chaos.
<6. BASIC OPERATION> 6-32 AUTO ONLINE VALIDATION – see separate section of User Guide for details 1. Remember the current valve status. 2. Turn on the assigned valve(s), turn off other valves. Two valves could be open for auto online validation with blocked line lock gas in validation cell. 3. If only one valve is used, turn off the assigned valve. If two valves are used, turn off the first valve. 4. If two valves are used, turn off the second valve. 6.
<6. BASIC OPERATION> 6-33 Normal Operation – TDLS200 TruePeak Software Main Menu The analyzer is configured to measure not only H2O ppm but it will also indicate the CH4 % concentration value, as shown on the Main Menu display below: Note that the flow cell gas temperature is also shown as Active (based on flow cell sensor active input) and pressure is input as a Fixed value (shown in psiA units, based on the external sample system regulator fixed setting).
<6. BASIC OPERATION> 6-34 The following graph illustrates an example. At 800 degC, there are two oxygen absorption peaks, and their ratio is 8.6. At 1500 degC, the left oxygen absorption peak increases while the right peak drops significantly. The peak ration is 2.2. So by calculating the peak ratio of these two oxygen peaks, the gas temperature can be predicted.
<6. BASIC OPERATION> 6-35 6.9.1 Instructions for Connecting an External Computer to the Analyzer Requires Windows 98SE or later (on computer to be connected to the analyzer) and crossover Ethernet cable. The analyzer is provided with a CD that includes the VNCviewer program. Windows 7 will support the UltraVNC software and associated functionality. Contact your local Yokogawa agent for a free copy of the necessary “VNCviewer.exe” file that will enable the VNC connection with the analyzer. This VNCviewer.
<6. BASIC OPERATION> 6-36 TDLS200 TDL Analyzer Instruction Manual V2.1 6.9.2 Using Ultra-VNC Software 4.8.2 Using Ultra-VNC Software TDLS200 TDL Analyzer Instruction Manual V2.1 the Ultra-VNC software double-clickingon onthe the “vncviewer.exe” “vncviewer.exe” ICON shown below): StartStart the Ultra-VNC software byby double-clicking ICON(as (as shown below): TDLS200 TDL Analyzer Instruction Manual V2.1 4.8.2 Using Ultra-VNC Software Start the Ultra-VNC software by double-clicking on the “vncviewer.
<6. BASIC OPERATION> 6-37 6.9.3 OPTIONAL Remote Interface Unit (RIU) The OPTIONAL RIU runs the Virtual Analyzer Controller (VAC) software described below. 6.9.
<6. BASIC OPERATION> 6-38 6.9.5 OPTIONAL Virtual Analyzer Controller (VAC) Operating Software Guide ALWAYS “END VNC SESSION” TO ANALYZER WHEN DONE – THIS WILL PREVENT THE ANALYZER AND/ OR RIU FROM ‘HANGING’. DO NOT LEAVE THE RIU PERMANENTLY CONNECTED TO ANALYZER – CONNECT ONLY WHEN IN USE 6.9.6 Virtual Analyzer Controller (VAC) Operating Software Guide The RIU VAC software is designed to allow communication between an analyzer and an appropriate interface.
<6. BASIC OPERATION> 6-39 After selecting “Configuration – F4” you will be asked to Enter Password – the default password is 1234, then press F2 to proceed and then you will be allowed to select the analyzer (with description and IP address) you wish to configure.
<6. BASIC OPERATION> 6-40 To shut down the RIU, press the Esc key and the screen will appear as shown. Press 9 to continue with the shut-down process and when the RIU screen turns white, the power can be switched off. Note, there is no watch-dog in the RIU so un-like the TDLS-200, it will not automatically re-start after a period of time if power is not switched off.
<7. ROUTINE MAINTENANCE> 7-1 7 Routine Maintenance The TDLS200 TDL analyzer requires little routine maintenance if it has been installed, set-up and calibrated correctly. This section will outline the routine maintenance procedures. 7.1 Maintaining Good Transmission The % Transmission of the laser light through the process is the most important variable to consider for routine maintenance and troubleshooting.
• • If the window does not appear to clean up well, then replace the window assembly with a new one. If the window appears to have an etched surface then it has probably been contaminated <7. ROUTINE MAINTENANCE> 7-2 with HF or other similar corrosive gas. Window surface to be cleaned Figure 32 - Window Cleaning Figure 56 - Window Replacement TDLS200 TDL Analyzer Instruction Manual V2.
<7. ROUTINE MAINTENANCE> 7-3 7.1.2 Replacing Windows If the windows are contaminated they may be cleaned using the following procedure: • • • • • • • • • • If the analyzer has not yet been shut down, then please shut-down the analyzer properly and remove power to ensure the laser if OFF Remove Launch or Detect (as appropriate) from the process interface by removing the one fixed hole fastener (5/32” Allen Wrench), loosening the remaining three fasteners and then twisting and pull off the unit.
TDLS200 TDL Analyzer Instruction Manual V2.1 <7. ROUTINE MAINTENANCE> 7-4 8-4 7.2 Alignment 5.2 Alignment Alignment Nuts (x8) Alignment Studs (x4) Alignment Studs Analyzer Mounting Flange (x4) AnalyzerProcess Flange Mounting Flange Alignment Nuts Window Purge Port (x8)(x2) Process Flange Analyzer Quick Connect Analyzer Quick Connect Alignment Bellows Window Purge Port (x2) Alignment Bellows Figure 34 - Alignment Mechanism Figure 58 - Alignment Mechanism 7.
<8. VALIDATION AND CALIBRATION> 8-1 8 Validation and Calibration There are several methods that can be used to validate and/or calibrate the TDLS200 analyzer. Generally, we recommend routine validation of the analyzer either on-line (if appropriately set-up) or off-line. when the process gas can be isolated from the optical path (such as extractive enhanced flow cell).
<8. VALIDATION AND CALIBRATION> 8-2 Please note that you can select the block mA value for automatic Off-Line Zero Calibration, Off-Line Span Calibration, Off-Line Validations and On-Line Validations: 8 .1 Off-Line Manual/Automatic Checking and Off-Line Calibration To perform either “Offline Calibrations” or “Offline Validations”, the Launch unit and Detect unit need to be removed from their respective process interface and connected to an Off-Line Calibration Cell.
<8. VALIDATION AND CALIBRATION> 8-3 Moving the analyzer to the off-line calibration cell: 1 If the process gas is at a positive pressure, Isolate the analyzer from the process and shut-off the window purge gas flow to prevent excessive pressure building up on the window. 2 If the process is at or near negative pressure then be aware that ambient air will be drawn in to the process/stack when the analyzer is removed from its interface.
<8. VALIDATION AND CALIBRATION> 8-4 Procedure for Alignment Optimization on Calibration Cell 1. The launch unit should be adjusted so that the transmission is maximized for off-line calibration 2. Ensure launch unit alignment nuts are securely fastened so that the launch unit cannot move it’s alignment position 3. To optimize the detect unit alignment, make small adjustments in alignment nuts of detect alignment flange while increasing the transmission value 4.
<8. VALIDATION AND CALIBRATION> 8-5 12 With the appropriate user interface, go to either Basic Menu (to Check Zero or Span) or Advanced Menu (to Check Zero or Span and/or perform actual Calibration). 13 Follow the detailed on-screen instructions when check the analyzer zero and/or checking the span 14 We do not recommend calibrating the Zero unless some core spare parts have been replaced (such as laser module or FPGA board).
<8. VALIDATION AND CALIBRATION> 8-6 15 After Zero calibration is completed, double check the absorption spectrum to ensure there is no absorption peak present or that there is no negative absorption peak (indicating that the zero gas had not fully purged the optical path). Perform the zero calibration again in either case or check with your local Yokogawa representative.
<8. VALIDATION AND CALIBRATION> 8-7 After entering cell pressure, cell temperature and cell length (28.6” or 72.6cm) the following option will appear on the basis of two gas measurement option. Please toggle to either of the two gases configured within the analyzer or as in the example below, there is no second measured gas configured. Note, after entering the desired span gas value, the following display will prompt you to press 9 to actually perform the calibration or escape to cancel.
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<8. VALIDATION AND CALIBRATION> 8-10 MANUAL OFFLINE VALIDATIONS Enter into the Advanced Menu, Calibrate & Validate section, Off-Line Validations. Choose Check gas 1, 2 or two gas validation and select Manual Validation. Following the on screen directions, enter in the pressure, temperature, cell length, & concentration of the gas within the off-line line check gas flow cell. Press Enter to proceed.
<8. VALIDATION AND CALIBRATION> 8-11 MANUAL OFFLINE VALIDATIONS Enter into the Advanced Menu, Calibrate & Validate section, Off-Line Validations. Choose Check gas 1, 2 or 3 and select Manual Validation. AUTOMATIC OFFLINE VALIDATIONS The Validations may be for Gas 1, Gas 2 or Two Gas Validation (such as Zero & Span Check, or 20% & 80% FS checks as required by some regulatory applications). The Offline Validations can also be automatically configured. Refer to later section for details.
<8. VALIDATION AND CALIBRATION> 8-12 There are several critical parameters that must be preconfigured in the TDLS200 software when using the automatic validation sequence. These parameters MUST be correctly set otherwise the analyzer will report false/incorrect validation results. • Check Gas Concentration specifies the concentration (ppm or %) of the gas within the offline flow cell.
<8. VALIDATION AND CALIBRATION> 8-13 8.2 Off-Line Calibration for Reference Peak Locking Applications: Zero and Span calibrations MUST be performed as per normal off-line procedures, without using and Reference Line locking gases. Process/Calibration OPL: N2 Analyzer Purge: N2 This is how the absorption spectra will appear when there is neither NH3 nor H2O (or any other target gas for the given application) in the entire optical path (Process OPL and Analyzer Purge).
<8. VALIDATION AND CALIBRATION> 8-14 8.3 On-Line Validation The basic concept of on-line validation is to add a known gas concentration via an integral check gas flow cell while still measuring the process gas concentration under relatively controlled conditions.
<8. VALIDATION AND CALIBRATION> 8-15 A tunable diode laser emits light energy within a very narrow wavelength range which is controlled by the analyzer itself, typically no more than 0.1nm across the entire scan region. This therefore allows laser scanning across just one absorption peak and baseline (zero absorption) regions on either side. The analyzer scans this region approximately 1,000 times per second while accumulating the spectra in memory. The scanning (i.e.
<8. VALIDATION AND CALIBRATION> 8-16 Instrument Span Drift: The analyzer does not contain measurement components that can wear, decay and generally drift in one direction. These are items that are used in conventional analyzers that determine the requirement for routine span gas calibrations. With TDLS analyzers, the measurement drift is limited to essentially optical elements only and these effects are fixed values. The amount of drift does not change over time as the actual optical elements do not change.
<8. VALIDATION AND CALIBRATION> 8-17 A validation cycle consists of first capturing a process gas only spectra (1), then adding the validation gas to the validation cell and capturing a spectra (2) and then removing the validation gas and finally capturing a second process gas only spectra (3). Spectra (1) and (3) are then averaged spectra as they represent the process gas only before and after validation.
<8. VALIDATION AND CALIBRATION> 8-18 8.5 Performing Manual OnLine Validation This will require the appropriate valves, tubes and tubes fittings such that the integral on-line check gas flow cell can be purged with either normal purge gas (typically Nitrogen) or the check gas (instrument air is acceptable for Oxygen analyzers in most applications).
TDLS200 TDL Analyzer Instruction Manual V2.1 <8. VALIDATION AND CALIBRATION> 8-19 Enter in the temperature of the gas within the on-line lineon check gas flow Following the screen directions, enter in the pressure of the cell.gas within the on-line line check gas flow cell. Typically this Typically cell is the same cell isthis vented to atmosphere so an atmospheric pressure value temperature as ambient. Use a (14.7 psiA or 1.01barA) will work.
<8. VALIDATION AND CALIBRATION> 8-20 Wait for the reading to stabilize. Many processes are dynamic but judge for yourself when you believe the check gas has fully purged the integral check gas flow cell – typically at least one minute depending on the location of the switching valve. Press ENT to proceed. Re-apply the original purge gas (typically Nitrogen) and again wait for the reading to stabilize (as the check gas is being purged from the check gas flow cell). Press ENT to proceed.
<8. VALIDATION AND CALIBRATION> 8-21 If the validation fails, repeat the validation after checking the parameters are correct and ensuring there is sufficient purge gas time. If the failure is due to a known non-related event (such as incorrect validation gas value or non-functioning valve) then the validation alarm can be cleared as shown. 8.
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<8. VALIDATION AND CALIBRATION> 8-23 Types of Validation Reading: There are two different ways in which the validation reading can be presented. Validation Only: When this method is selected, the analyzer will calculate AND output the result as the actual gas value e.g. instrument air if validated correctly would show AND output 20.9% O2 as the validation result.
• Through board. RIU with VAC software – The TDLS200 software allows for the user throu running VAC software to initiate the Auto Validation sequence. The opera <8. VALIDATION AND CALIBRATION> 8-24 the RIU in this case. Selecting Automatic Validation Initiation Selecting Automatic Validation Initiation From Online Validations – Automatic menu, the following options may be selected From Online Validations – Automatic menu, the following options may be selected.
<8. VALIDATION AND CALIBRATION> 8-25 • • • • • • Check Gas Pressure specifies the pressure at which the gas within the online line check gas flow cell. Typically this cell is vented to atmosphere so an atmospheric pressure value (14.7 psiA or 1.01barA) will work. Valve Selection specifies which analyzer’s solenoid valve driver is used for the check gas. Check Gas Purge Time specifies how long the check gas will purge the check gas flow cell.
<9. TROUBLE SHOOTING> 9-1 9 Troubleshooting The TDLS200 Analyzer troubleshooting is fairly simple for a process analyzer. First, virtually all components used in the system have a long Mean Time Between Failures (MTBF) with rated life of components typically exceeding 15 years (when operating within their stated specifications). Second, most probable failures and problems are diagnosed by the system, generating internal warning and fault conditions.
<9. TROUBLE SHOOTING> 9-2 9.1 Common Troubleshooting Steps For most conditions the troubleshooting steps are common. In general, the most common issues with the analyzer revolve around ensuring an adequate amount of the laser light is received at the detector. • Check Status LEDs. This will ensure that power is routed properly to the system components.
<9. TROUBLE SHOOTING> 9-3 • • • • • Adjust Analyzer Alignment. Adjusting the alignment will ensure the analyzer has not physically changed to the point where the laser beam is off center (at detect unit). While monitoring transmission % adjust the alignment in all directions (by a small amount) until you see the transmission increase. Fine tune the adjustment to ensure maximum alignment. Initiate On-Line Validation (if fitted).
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<9. TROUBLE SHOOTING> 9-5 1. Alignment Adjustment 2. a. Sometimes the original mechanical alignment of the analyzer may change due to mechanical/ thermal properties of the installation or perhaps the alignment nuts not being fully tightened originally. In these situations the analyzer can simply be realigned. b. Adjust the mechanical alignment using small adjustments of typically one quarter turn per nut at a time and allowing for at least two measurement up-dates before making further adjustments. c.
<9. TROUBLE SHOOTING> 9-6 Figure 66- Insertion tubes, with insulation - materials, dimensions, etc. are specified to suit each different application lf possible to isolate the process flow through the measurement section of the process pipe/stack then proceed to shut it off accordingly to facilitate full, safe unrestricted access. c. If the process gas cannot be isolated (as is typically the case), then “Process Inspection Port” must be used (see below/next page).
<9. TROUBLE SHOOTING> 9-7 h. Use the same procedure for the detect side however use CAUTION because the launch unit laser diode source will now be visible (if the analyzer is still powered on) through the detect side window (laser source is inside launch unit body). i. Remove any obstructions in the nozzles in accordance with any local standards/procedures. If the obstructions are a re-occurring event, then please contact your local agent or Yokogawa for advice on how to prevent/reduce the events. j.
<9. TROUBLE SHOOTING> 9-8 2 Figure 68 The following safety symbols are used on the product as well as in this manual. TDLS200 TDL Analyzer Instruction Manual V2.1 Operating and Maintenance Manual Please consult Yokogawa with specific information about the dust loadings within the process such that 1. determined Introduction ...................................................................................................4 a proper evaluation can be made.
<9. TROUBLE SHOOTING> 9-9 If there is any sign of a transmission signal then try adjusting the angles very slightly to see if any stronger signal can be obtained. If, after adjusting the direct angle between the two units there is still no transmission then the laser diode (and or detector) has failed. Please contact Yokogawa Laser Analysis Division for further assistance and information pertaining to Laser Module replacement.
<9. TROUBLE SHOOTING> 9-10 Warning Action Steps Process Pressure out of range. The gas pressure range for the application is programmed into the analyzer. Check pressure transducer feed to analyzer Check to ensure software setting (Advanced Menu, Configure) is correct Process Temperature out of range. The gas temperature range for the application is programmed into the analyzer.
<10. Data Files and Format> 10-1 10 Data Files and Format The TDLS200 analyzer is capable of automatically storing many important pieces of information. We would recommend that the data files are downloaded periodically and stored at a local drive for future reference. Also, if there is any sign of potential trouble with the analyzer and/or the process, please download files as soon as possible to ensure potentially helpful data is stored/saved off-line.
<10. Data Files and Format> 10-2 alarms alarms .his .bak calibr .his calibr .bak Alarms History A historical log of analyzer alarm events Alarms History Back-Up A back-up of the historical log of analyzer alarm events Calibration History A historical log of analyzer calibrations Calibration History Back-Up A back-up of historical log of analyzer calibrations Alarm History - in the form of ASCII data files that can be opened with Microsoft “Notepad” as simple .txt file formats.
<10. Data Files and Format> 10-3 calibr .pik Calibration Pick List Factory Use Only FACTORY PERSONNEL ONLY S S1 S2 .dat Chemometric Model File Parent spectra for chemometric model used only for specialized applications that utilize the TruePeak CLS measurement capability. span00 .
<10. Data Files and Format> 10-4 system .bak System Configuration History - When the system.his file exceeds 100KB size the contents is saved to this .bak file and the .his file is emptied. This .bak file is in the form of ASCII data files that can be opened with Microsoft System History Back-Up “Notepad” as simple .txt file formats. The content can then be copied and pasted into Microsoft Excel spread.
<10. Data Files and Format> 10-5 10.1 Configuring Data Capture: Select Data To select the Spectrum capture, stay in Advanced Menu user mode and the Data sub section – select Spectrum Capture To store spectrum automatically, select Automatic. If you do not wish to store any spectrum file during normal analyzer operation, then select Manual mode.
<10. Data Files and Format> 10-6 analyzer to capture spectrum files and under what condition. The default condition is related to the number of measurement however, the user can select Relative or Absolute changes pending the site specific conditions/ requirements. Typical updates between capture value would be 300 The more frequently spectrum are stored then the larger the MMDDYY.spe files will become.
<10. 7.2 Downloading (Transferring/Exporting) theData Data: Files and Format> 10-7 All the files can be easily transferred from the analyzer to the supplied USB memory device. 10.2 Downloading (Transferring/Exporting) the Data: NOTES: Please use the supplied “Sandisk” USB memory device with when getting data theanalyzer. files can be easily transferred from thewith analyzer the supplied USB memory device.
Revision Record Manual Title: Model TDLS200 Tunable Diode Laser Spectroscopy Analyzer Manual Number: IM 11Y01B01-01E-A Edition 1st 2nd 3rd 4th 5th 6th Date April 2008 April 2009 April 2010 Remark (s) Newly Published Revisions: Formatting was corrected. Revisions: August 2011 General specifications, page 3, were added to the document, and dimensional drawings were added. Revisions: Feburary 2012 Dimensional drawings in section 5.9 were corrected and updated.
Yokogawa Corporation of America North America 2 Dart Road, Newnan, GA 30265-1094, USA Phone: 800-258-2552 Fax: 770-254-0928 12530 West Airport Blvd., Sugar Land, TX 77478 Phone: 281-340-3800 Fax: 281-340-3838 Yokogawa has an extensive sales and distribution network. Please refer to the website (www. yokogawa.com/us) to contact your nearest representative. Mexico Melchor Ocampo 193, Torre C, Oficina 3”B” Veronica Anzures D.F., C.P. 11300 Phone: (55) 5260-0019, (55) 5260-0042 Yokogawa Canada, Inc.
