Michell Instruments TDL600 Operating Manual

OptiPEAK TDL600

Process Moisture Analyzer

User’s Manual

97319 Issue 4.2
November 2018

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OptiPEAK TDL600

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© 2018 Michell Instruments

This document is the property of Michell Instruments Ltd. and may not be copied or

otherwise reproduced, communicated in any way to third parties, nor stored in any Data

Processing System without the express written authorization of Michell Instruments Ltd.

OptiPEAK TDL600 User’s Manual

Contents

Safety ...............................................................................................................................vii

Electrical Safety ..........................................................................................................vii

Pressure Safety ........................................................................................................... vii

Toxic Materials ............................................................................................................vii

Repair and Maintenance ..............................................................................................vii

Calibration (Factory Validation) ..................................................................................... vii

Safety Conformity .......................................................................................................vii

Abbreviations .................................................................................................................... viii

1 INTRODUCTION ................................................................................................1

1.1 Application ......................................................................................................... 1

1.2 Features ............................................................................................................ 1

1.3 Theory of Operation ........................................................................................... 2

1.3.1 Measurement Using a Laser ........................................................................... 4

2 INSTALLATION ..................................................................................................6

2.1 Unpacking the Instrument ................................................................................... 6

2.2 Lifting and Handling ........................................................................................... 7

2.3 Laser Safety ....................................................................................................... 7

2.4 Hazardous Area Safety ........................................................................................ 8

2.5 Electrical Safety .................................................................................................. 9

2.5.1 Equipment Ratings and Installation Details ...................................................... 9

2.6 Pressure Safety ................................................................................................ 11

2.7 Basic Installation Guidelines .............................................................................. 11

2.8 Electrical Connections ....................................................................................... 15

2.8.1 Power Connection ....................................................................................... 15

2.8.2 Analog Outputs ........................................................................................... 16

2.8.3 Analog Inputs ............................................................................................. 16

2.8.4 Alarm Relays............................................................................................... 16

2.8.5 Modbus RTU / RS485 Connection ................................................................. 17

2.9 Environmental Requirements ............................................................................. 17

2.10 Sample Conditioning Requirements .................................................................... 18

2.10.1 Gas Connections ......................................................................................... 18

2.10.2 Sample Flow Gas Handling Components ....................................................... 18

2.11 Options ............................................................................................................ 21

2.11.1 Enclosure Heater Temperature Control (Outdoor systems ONLY) ..................... 21

2.11.2 Vortex Cooling (Outdoor systems ONLY) ....................................................... 21

2.11.3 Trace Heated Sample Line ........................................................................... 21

3 OPERATION ....................................................................................................22

3.1 Start-Up Procedure ........................................................................................... 22

3.2 Shut Down Procedure ....................................................................................... 23

3.3 User Interface .................................................................................................. 24

3.3.1 Interface Controls ....................................................................................... 24

3.3.2 ‘Up/Down Arrow’ Keys ................................................................................. 24

3.3.3 ‘ENTER’ Key ................................................................................................ 25

3.3.4 ‘ESC’ Key .................................................................................................... 25

3.4 Description of Measured Parameters .................................................................. 25

3.5 Default Settings ................................................................................................ 26

3.5.1 Advanced Menu default settings ................................................................... 26

3.6 Menu Structure ................................................................................................ 27

3.7 Main Menu Screen ............................................................................................ 28

3.7.1 Parameters Screen ...................................................................................... 29

3.7.2 Display Screen ............................................................................................ 30

3.7.3 Log Menu Screen ........................................................................................ 31

3.7.4 About Screen .............................................................................................. 32

3.7.5 Graph Screen .............................................................................................. 32

iv 97319 Issue 4.2, November 2018

OptiPEAK TDL600 User’s Manual

3.7.6 Advanced Settings Screen ............................................................................ 33

3.7.6.1 Outputs Screen ..................................................................................... 34

3.7.6.2 Alarms Screen ...................................................................................... 35

3.7.6.3 Inputs Screen ....................................................................................... 38

3.7.6.4 Clock Screen ......................................................................................... 41

3.7.6.5 Modbus Screen ..................................................................................... 42

3.7.6.6 Region Defaults Screen.......................................................................... 43

3.7.6.7 N2-Mode (Measurement Mode) Screen ................................................... 44

3.7.6.8 Safe Mode (Laser Disabled) Screen ........................................................ 44

3.8 Enclosure Cover and User Interface ................................................................... 45

4 MAINTENANCE ................................................................................................46

4.1 Inspection of the Enclosure Cover ...................................................................... 47

4.2 Replacement of the Micro SD Data Logging Card ................................................ 49

4.3 Membrane and Particulate Filter Element Replacement ........................................ 51

4.3.1 Service Intervals ......................................................................................... 51

4.3.2 Installing the Filter Element and Membrane .................................................. 51

4.3.3 Field measurement verifi cation ..................................................................... 53

4.3.4 Long-term maintenance – Laser replacement ................................................ 54

Figures

Figure 1 Beer Lambert Law ......................................................................................3

Figure 2 Laser Scan .................................................................................................4

Figure 3 System Block Schematic ..............................................................................5

Figure 4 Unpacking the TDL600 ................................................................................6

Figure 5 Earthing Stud And Nut Washer Assembly ...................................................10

Figure 6 OptiPEAK Sampling System - Typical Indoor Version ....................................12

Figure 7 OptiPEAK Sampling System - Typical Intdoor Version ...................................12

Figure 8 OptiPEAK Sampling System - Typical Outdoor Version .................................13

Figure 9 OptiPEAK Sampling System - Typical Outdoor Version .................................14

Figure 10 User Interface ..........................................................................................24

Figure 11 Up/Down Arrow Keys ................................................................................24

Figure 12 'ENTER’ Key .............................................................................................25

Figure 13 ‘ESC’ Key .................................................................................................25

Figure 14 Menu Structure ........................................................................................27

Figure 15 Main Menu Screen ....................................................................................28

Figure 16 Parameters Screen ...................................................................................29

Figure 17 Display Setup Screen ................................................................................30

Figure 18 Data Logging Screen ................................................................................31

Figure 19 Contact/About Screen ...............................................................................32

Figure 20 Graph Screen ...........................................................................................32

Figure 21 Advanced Settings Screen .........................................................................33

Figure 22 Output Screens ........................................................................................34

Figure 23 Alarm Screens ..........................................................................................35

Figure 24 Typical Alarm Status Indication on the Run-Mode Screen .............................37

Figure 25 Input Screen ............................................................................................38

Figure 26 Line Pressure Setup Screen .......................................................................39

Figure 27 Spare Input Setup Screen .........................................................................40

Figure 28 Set Date/Time Screen ............................................................................... 41

Figure 29 Modbus Settings Screen ............................................................................42

Figure 30 Region Defaults Screen ............................................................................. 43

Figure 31 N2-Mode (Measurement Mode) Screen ......................................................44

Figure 32 Safe Mode (Laser Disabled) Screen ............................................................45

Figure 33 Dimensional Drawing - Indoor System Enclosure ........................................58

Figure 34 Dimensional Drawing - Outdoor System Enclosure ......................................59

Figure 35 Wiring Diagram Indoor System ..................................................................61

Figure 36 Wiring Diagram Outdoor System ................................................................63

Michell Instruments v

OptiPEAK TDL600 User’s Manual

Tables

Table 1 Parameters Screen Parameters ................................................................... 29

Table 2 Display Setup Screen Parameters ................................................................ 30

Table 3 Data Logging Screen Parameters ................................................................ 31

Table 4 Output Screen Parameters .........................................................................34

Table 5 Line Pressure Setup Screen Parameters ....................................................... 39

Table 6 Spare Input Setup Screen Parameters ......................................................... 40

Table 7 Set Date/Time Screen Parameters ..............................................................41

Table 8 Modbus Screen Parameters ........................................................................ 42

Table 9 Region Default Parameters .........................................................................43

Table 10 N2-Mode Parameters ................................................................................. 44

Appendices

Appendix A Technical Specifi cation ...............................................................................55

A.1 Dimensional Drawings .................................................................. 56

A.2 Dimensional Drawings .................................................................. 57

Appendix B Indoor Sampling System Wiring Diagram ....................................................59

Appendix C Outdoor Sampling System Wiring Diagram ..................................................61

Appendix D Flow Diagram ............................................................................................ 63

Appendix E Modbus Holding Register Map ....................................................................65

Appendix F Quality, Recycling, Compliance & Warranty Information ................................ 70

Appendix G Hazardous Area Certifi cation ...................................................................... 71

G.1 Product Standards ....................................................................... 72

G.2 Product Certifi cation ....................................................................72

G.3 Global Certifi cates/Approvals ........................................................72

G.4 Special Conditions of Use .............................................................72

G.5 Maintenance and Installation ........................................................ 73

Appendix H Return Document & Decontamination Declaration ........................................ 75

vi 97319 Issue 4.2, November 2018

OptiPEAK TDL600 User’s Manual

!

Safety

This manual contains all the required information to install, operate and maintain the OptiPEAK
TDL600 Process Moisture Analyzer. Prior to installation and use of this product, this entire manual
should be read and understood. Installation and operation of this product should be carried out by
suitably competent personnel only. The operation of this product must be in accordance with the
terms of this manual and associated safety certifi cates. Incorrect installation and use of this product
for other than its intended purpose will render all warranties void.

This product is intended for use in a Hazardous Area and is awarded an ATEX, IECEx and cQPSus
Certifi cate. These certifi cates should be fully examined prior to installation or use of this product.

Where this hazard warning symbol appears in the following sections,

it is used to indicate areas where potentially hazardous operations

need to be carried out and where particular attention to personal and

personnel safety must be observed.

Electrical Safety

The instrument is designed to be completely safe when used with options and accessories
supplied by the manufacturer for use with the instrument. The input power supply voltage limits
are 90 to 264 V AC, 50/60Hz (dependent on chosen options).

Pressure Safety

DO NOT permit pressures greater than the safe working pressure to be applied directly to the
instrument's sample cell. The specifi ed working pressure is 0.7 to 1.4 bara (10 to 20.3 psia). Refer
to the Technical Specifi cations in Appendix A.

Toxic Materials

The use of hazardous materials in the construction of this instrument has been minimized. During
normal operation it is not possible for the user to come into contact with any hazardous substance
which might be employed in the construction of the instrument. Care should, however, be exercised
during maintenance and the disposal of certain parts.

Repair and Maintenance

The instrument must be maintained either by the manufacturer or an accredited service agent. Refer
to www.michell.com for details of Michell Instruments’ worldwide offi ces contact information.

Calibration (Factory Validation)

Prior to shipment, the analyzer undergoes stringent factory calibration to traceable standards. Due to
the inherent stability of the instrument, regular fi eld calibration is not required under normal operating
conditions. The analyzer should perform reliably for many years with just basic maintenance and
housekeeping. Michell can provide a fully traceable factory calibration service for the instrument
when required. Please contact your local Michell offi ce or representative for further details (www.
michell.com).

Safety Conformity

This product meets the essential protection requirements of the relevant EU directives. Further
details of applied standards may be found in the product specifi cation.

Michell Instruments vii

Abbreviations

The following abbreviations are used in this manual:

A ampere

AC alternating current

bara pressure unit (=100 kPa or 0.987 atm)

barg pressure unit (=100 kPa or 0.987 atm) gauge

°C degrees Celsius

°F degrees Fahrenheit

EU European Union

ft feet

hr hour

kg kilogram(s)

lbs pound(s)

OptiPEAK TDL600 User’s Manual

lb/MMscf pounds per million standard cubic feet

LCD liquid-crystal display

Nl/min normal liters per minute

m meters

mA milliampere

max maximum

*mg/m3 milligrams per cubic meter

mm millimeters

nm nanometers

NPT(F) National pipe thread (female)

PCB printed circuit board

parts per million by volume

ppm

V

psia pounds per square inch absolute

psig pounds per square inch gauge

RH relative humidity

RS485 serial data transmission standard

scfh standard cubic feet per hour

sec seconds

TDL Tuneable Diode Laser

V Volt

W Watts

% percentage

“ inch(es)

ø diameter

3

* mg/m

refers to standard sm3 (i.e. 15°C at atmospheric pressure)

viii 97319 Issue 4.2, November 2018

OptiPEAK TDL600 User’s Manual

1 INTRODUCTION

The OptiPEAK TDL600 Tunable Diode Laser Analyzer employs the latest techniques in laser
absorption spectroscopy and signal processing power to offer a robust high performance
analyzer, designed specifi cally for the measurement of moisture in natural gas. The analyzer is
fully hazardous area certifi ed and delivers class-leading measurement performance, stability
and detection sensitivity.

The complete OptiPEAK TDL600 Analyzer Sampling System can be located close to the gas
sample take-off point in a potentially explosive environment - designated Zone 1 and Zone 2
hazardous area.

The indoor version Sampling System gas handling components are assembled on a 316 Stainless
Steel plate suitable for wall mounting within a temperature controlled analyzer house.

The outdoor version Sampling System is housed within a stainless steel enclosure (304
or 316), with optional thermostatically controlled heating and cooling, for direct fi eld
installation in a 100% shaded location next to the process line (with overall environmental
protection to IP66).

INTRODUCTION

All sample gas wetted metallic parts are in AISI 316L stainless steel with Viton
comply with the NACE standard MR-01-75 (latest edition). Tube fi ttings are type 316 Stainless
Steel. All gas and cable entries are located in the base of the enclosure.

1.1 Application

The measurement of moisture in natural gas streams is an essential and highly critical
analysis for the natural gas industry. Gas companies need to meet specifi c quality
standards for transmission, custody transfer and delivery. High levels of water in the gas
increase the cost of transportation and lower the calorifi c value of the gas. In addition,
excessive moisture content in the gas stream can lead to internal pipe corrosion and
hydrate formation, requiring expensive pipe cleaning or 'pigging'. In severe cases,
pipeline blockage can occur.

Although the analyzer is designed for the measurement of water in transmission quality
natural gas backgrounds it has been confi gured for use with almost any natural gas
stream. This provides full fl exibility if, for example, the analyzer is later re-deployed to
a different application. (See Section 3, Operation, for further details.)

1.2 Features

• High Measurement Sensitivity

®

soft parts that

The OptiPEAK TDL600 features a lower detection limit (LDL) of 1 ppm

water content. This

V

high sensitivity, coupled with the inherent fast response of the TDL optical measurement,
provides an extremely fast, accurate and reliable non-contact gas measurement.

• D-MET – Dynamic Methane Compensation. BioGas Ready

Moisture measurement is virtually independent* of changes in the methane composition
of the natural gas feed and accuracy is not reliant on manual software correction factors
being applied.

The analyzer can be used with a wide range of background gas compositions. With
increasing statutory requirements in many regions for Biomethane to be added to
natural gas streams, the analyzer has been future proofed by being Biomethane ready.

* Over a methane concentration range of 40 - 100% CH

4

Michell Instruments 1

INTRODUCTION

• Laser Lock System

Tunable diode lasers can drift. This means that the laser wavelength may slowly change
with time and, eventually, may not precisely match the absorption peak of the water.
This can lead to a reduction in sensitivity and analyzer drift. This inherent property of
diode lasers is overcome in the OptiPEAK TDL600 by the built-in Laser lock system.
This system monitors the optical profi le of the gas absorption peaks to ensure the
laser remains locked to the correct water absorption peak, maintaining a high integrity
measurement at all times.

• Fast Response

Being a non-contact optical measurement, the analyzer offers fast response times,
meaning no long wet-up or dry-down times in contrast to traditional moisture sensors.
None of the sensing components are exposed to the gas stream, protecting them from
any aggressive components or harmful contamination.

OptiPEAK TDL600 User’s Manual

• HMI system

Provides a highly intuitive menu driven interface, utilizing a capacitive touch screen
system, offering stylus-free setup and operation without the need for a 'hot work' permit
to adjust settings or to perform validation checks.

1.3 Theory of Operation

The OptiPEAK TDL600 uses the technique of absorption spectroscopy to measure the
concentration of water vapor in the gas stream. Many gas molecules exhibit very specifi c
resonant vibrations in the infrared region of the electromagnetic spectrum. If infrared
energy, at the same resonant wavelength, is passed through these molecules, some of
this energy will be absorbed. If a suitable detector is used to measure the amount of
received energy, and the gas is contained within a cell of a known path length, then the
gas concentration can be calculated. This can be expressed mathematically and is often
referred to as the Beer-Lambert Law.

A

c =

ε

l

where:

A

= absorbance

ε

= extinction coeffi cient (absorption strength of gas at a specifi c wavelength)

l

= sample cell path length

c

= gas concentration

(l)

This law states that, if the sample cell path length
coeffi cient of the water molecule (
gas absorbs light at a specifi c wavelength) is known, then, if the absorbance of laser
energy by the water molecules is measured (A), the water concentration (c) of the
sample stream can be calculated. This gas law is the basis of all photometric gas
absorption measurement.

ε

- a constant that describes how strongly a particular

is known, and the extinction

2 97319 Issue 4.2, November 2018

OptiPEAK TDL600 User’s Manual

Beer Lambert law

concentration (c)

INTRODUCTION

Absorbent

I

O

I

X

Path length (l)

Figure 1

The Michell OptiPEAK TDL600 uses a tunable diode laser source to generate a narrow
and coherent beam of near infrared (NIR) energy at the precise resonant wavelength
of water vapor. Traditionally, infrared analyzers use broadband sources which generate
a wide gamut of wavelengths. To make these analyzers as selective as possible to
moisture only, optical fi lters have to be deployed to 'narrow' the range of wavelengths
that are fi nally passed through the sample. These fi lters do not offer very high selectivity

- they are quite broadband, which can lead to signifi cant spectral interference, as other
gas peaks close to the water absorption peaks are also detected, leading to cross
interference, drift and general degradation in measurement performance.

In contrast, the laser has a bandwidth of less than 0.0001 nanometers. This means the
laser is very selective in detecting only the water and not any other gases present in
the gas stream.

Beer Lambert Law

This optical technique also has the advantage that the analyzer uses a non-contact
method of measurement, i.e. there is no sensing element in contact with the gas
stream. This offers a highly robust and reliable measurement, as only photons of light
pass through the gas. This provides very fast response and no long wet-up or dry-down
times.

Michell Instruments 3

INTRODUCTION

1.3.1 Measurement Using a Laser

The diagram below illustrates the advantages of using a laser source, compared to a
traditional broadband source.

The water absorption peak is shown in the center of the diagram (red area). The width
of the laser beam is very narrow and is represented by the yellow line.

The laser wavelength is varied in order to scan across the water absorption peak (yellow
area). By scanning the peak in this way, important information can be extracted, such
as changes to the absorption peak caused by variation in the sample gas. This very
precise scan range minimizes any overlap with nearby absorption bands, as would be
the case with conventional broadband infrared sources and optical fi lters (blue area).

Typical broadband source bandwidth

OptiPEAK TDL600 User’s Manual

Scan range

5 Hz ‘sawtooth’

laser scan

Conventional IR

source gives

very broad

transmission

Potential interferant gases Potential interferant gases

Gas absorption

(peak of interest)

Bandwith

approximately 0.05nm

Figure 2

Laser Scan

4 97319 Issue 4.2, November 2018

OptiPEAK TDL600 User’s Manual

INTRODUCTION

The schematic of the laser measurement system is shown in

Figure 3

below. This
highlights the major control and signal processing sections of the analyzer. The analyzer
uses the WMS (Wavelength Modulation Spectroscopy) technique, in combination with
proprietary signal processing algorithms to provide a selective response and high
sensitivity to moisture.

Here, a single frequency, distributed feedback (DFB) laser diode is tuned by applying
a current ramp to the laser. A further sinusoidal modulation is then applied. Lock-in
detection is applied to the photo-detector signal obtained by passing the tuned laser
radiation through the gas cell. The second harmonic signal from the lock-in detection is
measured to recover the spectroscopic peak of interest. WMS offers a practical method
of recovering weak signal changes from a dilute trace gas sample. WMS is becoming
wide spread within the sector of natural gas monitoring and represents current state­of-the-art technology.

Temperature

controlled

diode laser

Diode

current

Diode

laser

power

Launch head

Detector

Ramp

current

High

frequency

‘carrier’

modulation

Second harmonic

Mixer

Filter

Direct signal

Laser scanning

Signal

processing

Fiber Optic cable

Figure 3

Det. current

System Block Schematic

Michell Instruments 5

INSTALLATION

!

2 INSTALLATION

2.1 Unpacking the Instrument

Open the crate and unpack carefully as follows:

The instrument is heavy and should not be lifted alone.

Mechanical lifting aids may be required for larger systems.

OptiPEAK TDL600 User’s Manual

WARNING:

3

2

1

Figure 4

1. Remove the accessories box (1).

2. Remove the spacer foam (2).

2

Unpacking the TDL600

3. Remove the instrument enclosure (3) and set it down at the site of

installation.

It is recommended to save all the packing materials for the purpose of returning the
instrument for warranty claims.

The accessories box should contain the following items:

• Calibration Certifi cate

• Application Software CD

• User Manual

• CD containing System Documentation

6 97319 Issue 4.2, November 2018

OptiPEAK TDL600 User’s Manual

!

!

2.2 Lifting and Handling

This product is in excess of 75kg (165lbs).

Personnel must observe suitable lifting and handling

The TDL600 is not designed as portable or transportable equipment. The product should
be rigidly fi xed in position as per the full installation instructions.

Appropriate lifting and handling techniques should be used during the installation process.
Before commencing any lifting or handling ensure that its intended location is suitable
and appropriately prepared. Make sure that mounting point design considerations have
employed locally approved safety factors.

INSTALLATION

WARNING:

precautions.

When handling and installing this instrument (particularly after removal from its
packaging) ensure that it is not dropped, impacted or subjected to high levels of
vibration or environmental conditions that may impair its operation.

2.3 Laser Safety

This product contains a Diode Laser with an invisible beam, operating in the near
infrared range. The laser as used in this product classifi es it as a CLASS 1 product.

For the purposes of CDRH and FDA Registration the OptiPEAK TDL600 complies with
21CFR1040 with deviations pursuant to Laser Notice 50 and with IEC/EN 60825-1:2007.

WARNING:

This product is a CLASS 1 LASER PRODUCT.

Beware of Laser radiation.

Do not access the Laser.

Do not view the Laser directly.

WARNING:

Use of controls or adjustments, or performance of

procedures other than those specifi ed herein, may result in

hazardous radiation exposure.

Michell Instruments 7

INSTALLATION

!

2.4 Hazardous Area Safety

Refer to Appendix G for the Hazardous Area Certifi cation of this product.

This product is fi tted with a marking label that contains Hazardous Area information
pertinent to the suitable location and installation.

During all installation and operation activities, local regulations and permitted working
routines must be observed. Installation should only be performed by competent
personnel and in accordance with IEC 60079-14:2007 and EN 60079-14:2008 or local
equivalent.

Cable glands / conduit seals shall be installed in accordance with the manufacturer’s
instructions.

Conduit seals used should be suitable for a reference pressure of 6.1 bar (89 psi).

Repair and servicing of this equipment must only be carried out by the manufacturer.

OptiPEAK TDL600 User’s Manual

WARNING:

This product is certifi ed safe for use in a Zone 1 and Zone 2

area only. This product must not be installed or used within

a Zone 0 area.

WARNING:

This product must not be operated within an explosive

atmosphere greater than 1.1 bara (16 psia).

WARNING:

This product must not be operated within an enriched

oxygen atmosphere (more than 21% oxygen content).

WARNING:

This product must not be operated outside of the

temperature range of -20 to +55°C (-4 to +131°F)

WARNING:

The analyzer enclosure of this product provides Exd
protection, partly through the threads used for mounting
the lid, stopping plugs and cable gland. At all times effort

should be made to ensure these threads are suitably

protected from damage and that only appropriately rated

mating parts are applied to them, in accordance with the

certifying requirements.

8 97319 Issue 4.2, November 2018

OptiPEAK TDL600 User’s Manual

DANGER

Electric

Shock Risk

2.5 Electrical Safety

During the installation of this product, ensure that all

applicable national and local electrical safety regulations are

Always ensure that power is switched off prior to accessing

the product for any purpose other than normal operation, or

prior to disconnecting any cables.

INSTALLATION

WARNING:

observed.

WARNING:

2.5.1 Equipment Ratings and Installation Details

The following mandatory statements refer to the Ex certified TDL600 Analyzer and
sampling system.

This equipment must be supplied with a voltage in the range of 90 to 264 V AC, 50/60
Hz. Maximum power rating depends on chosen standard options, 80W to 250W.

All electrical connections to the analyzer are made through junction boxes, mounted on
the panel of the sample system in accordance with Section 2.8.

Any power cable should be 3 core over sleeved, with minimum 0.5mm insulation
and rated at 300 V. Cables should have Live (L), Neutral (N) and Earth [Ground] (E)
conductors. Ensure suitably rated power supply cables and glands are used to ensure
that electrical safety is maintained. Ensure the power supply can deliver suffi cient power
to meet the consumption requirements.

Any power supply terminals and voltages must be suitably separated from the other I/O
requirements to this product.

Before applying power, perform a continuity test to ensure that the power supply cable
and the TDL600 are effectively connected to the protective Earth.

Michell Instruments 9

INSTALLATION

The protective Earth terminal is mounted internally and the Earth wire connected to it
should never be disconnected. The analyzer enclosure is supplied with an external earth
stud at the lower right hand side. This earth stud is connected to the sampling system
earth using 4mm2 minimum earthing bonding.

OptiPEAK TDL600 User’s Manual

Figure 5

Fuse: A replacement fuse can be obtained by contacting Michell Instruments' technical
support. Fuse rating = 5 x 20mm 2.5 A anti-surge to IEC 60127-2.

This measuring product is designed, where applicable and possible, to be in compliance
with EN/BS/IEC61010 safety requirements or electrical equipment or measurement,
control, and laboratory use. This product is designed to be safe at least under the
following conditions: between a temperature range of -40 to +60°C (-40 to +148°F),
in maximum 80% relative humidity for temperatures up to +31°C (+88°F) decreasing
linearly to 50% RH at +50°C (+122°F). Supply voltages of ±10% and transient over
voltages up to Overvoltage Category II. Pollution Degree 2. Altitudes up to 2000m.
Outdoor mounting is permitted using suitably rated glands equivalent to NEMA 4 / IP66.

See Appendix A, Technical Specifi cation, for full operating parameters.

NOTE: Do not remove or exchange any of the cables or electrical components
supplied with this product. Doing so will invalidate all warranties.

There are no additional or special electrical safety requirements other than those
referred to in this manual.

For location and mounting arrangements please refer to the relevant sections of this
manual.

Earthing Stud And Nut Washer Assembly

Installation of this equipment must include the provision of a suitable and locally
positioned power isolation switch or circuit breaker. Indication of the purpose of the
switch or circuit breaker is strongly recommended. An over-current protection device
should be rated to a maximum of 3 A.

This equipment and all power isolation devices must be installed in a location and
position that allows safe and easy access to their operation and is able to rigidly support
the equipment.

10 97319 Issue 4.2, November 2018

OptiPEAK TDL600 User’s Manual

!

Do not install this equipment in a location that would expose it to impact or high levels
of vibration.

Operation of this equipment, other than in a manner specifi ed by the manufacturer, may
impair the safety protections provided.

The safe installation of this equipment and any system incorporating this equipment is
the responsibility of the installer. Ensure local regulations and requirements are referred
to prior to any installation commencing.

2.6 Pressure Safety

This product is used in conjunction with pressurized gases.

Pressurized gas should only be handled by suitably trained

Observe pressurized gas handling precautions.

INSTALLATION

WARNING:

personnel.

The TDL600 measurement chamber requires pressurized gas to be connected to it.
Observe pressurized gas handling regulations. Only suitably trained personnel should
carry out tasks that include the use of pressurized gas media.

The TDL600 measurement cell accepts a maximum sample pressure of 1.4 bara (20.3 psia).

2.7 Basic Installation Guidelines

The OptiPEAK TDL600 Moisture Analyzer Sampling System gas handling components
are assembled onto a stainless steel mounting plate suitable for wall mounting.

The outdoor version Sampling System provides environmental ingress protection to IP66
and should be mounted vertically, free of any appreciable vibration, in a permanently
shaded position to prevent heating effects through sun radiation. The Sampling System
enclosure can be specifi ed with optional thermostatically controlled heating (fi xed set
point). Optional enclosure cooling, using a compressed-air-driven vortex tube and
fi xed set point thermostat, is recommended for installation in hot climates (>+45°C
(>+113°F)).

NOTE: Any TDL being installed within a plant where it cannot vent to open
atmosphere needs a fl are line connection that runs to the highest point and
enters the fl are system from a topside connection. This is to prevent liquids
present in the fl are stack from draining back into the analyzer system.

NOTE: The actual detailed confi guration will be shown in the as-built drawings
provided with the shipped analyzer.

For start-up instructions refer to Section 3.

Michell Instruments 11

INSTALLATION

1 BV1 Ball Valve

2 F2 Particulate Filter

3 PR1 Pressure Regulator

4 PG1 Pressure Gauge

5 PR2 Pressure Gauge

6 F2 Coalescing & Membrane Filter

7 PR2 Pressure Regulator

8 PG3 Pressure Gauge

9 PRV1 Pressure Relief Valve

10 FM1 Flowmeter

11 AN1 Moisture Analyzer

12 MV1 Metering Valve

13 NV1 Needle Valve

14 FM2 Flowmeter

TP1 Sample Gas Inlet 1/4” NPT (F)

TP2 Sample Gas Outlet 1/4” NPT (F)

TP3 Bypass Flow Gas Outlet 1/4” NPT (F)

TP4 Letdown Gas Vent/Drain 1/4” NPT (F)

TP Connections

OptiPEAK TDL600 User’s Manual

10

11

9

8

7

5

6

12

13

TP2TP4

TP1

TP3

4

3

2

14

1

Figure 6

25.0 700.0 CRS 25.0

12.0 726.0 CRS 12.0

970.0

463.0 CRS 463.0 CRS

475.0 CRS 475.0 CRS

OptiPEAK Sampling System - Typical Indoor Version

750.0

250.0

MIN. CLEARANCE

MOUNTING HOLES
(10x



MODEL: OPTIPEAK TD L600
TYPE: PROCESS MOISTURE ANALYZER
SERIAL NUMBER : nnnn nn /2017
WO NUMBER : BC4556 5

www.michell.com

11mm)

316SS NAMEPLATE

316SS MOUNTING
PLATE

POWER INLET
CABLE ENTRY
(M20)

SIGNAL OUTPUTS
CABLE ENTRIES
(2 x M20)

12.0

22.0 22.0

10.0 10.0

TP04

TP02

TP01 TP03

Figure 7

12 97319 Issue 4.2, November 2018

OptiPEAK Sampling System - Typical Indoor Version

OptiPEAK TDL600 User’s Manual

1 BV1 Ball Valve

2 F2 Particulate Filter

3 PR1 Pressure Regulator

4 PG1 Pressure Gauge

5 PG2 Pressure Gauge

6 F2 Coalescing & Membrane Filter

7 PR2 Pressure Regulator

8 AN1 Pressure Gauge

9 FM1 Pressure Relief Valve

10 PRV1 Flowmeter

TS1

11

12 MV1 Metering Valve

13 FM2 Needle Valve

14 NV1 Flowmeter

15

16

SOV1

17

18

Moisture Analyzer

HT

Enclosure Heater

TS1

Thermostat

Solenoid Valve

TH

Trace Heating

INSTALLATION

10

11

9

8

7

5

6

12

13

TP4 TP3

TP2

TP1

16

4

3

2

14

1

15

17

18

TP5

TP Connections

TP1 Sample Gas Inlet 1/4” NPT (F)

TP2 Sample Gas Outlet 1/4” NPT (F)

TP3 Bypass Flow Gas Outlet 1/4” NPT (F)

TP4 Letdown Gas Vent/Drain 1/4” NPT (F)

TP5 Vortex Cooler Inlet 1/4" NPT (F)

Figure 8

OptiPEAK Sampling System - Typical Outdoor Version

Michell Instruments 13

INSTALLATION

1045

1000

800
758

OptiPEAK TDL600 User’s Manual

300.0

MOUNTING HOLES



10mm)

(4x

316SS NAMEPLATE

ENCLOSURE (NOTE 1)

TP05

SIGNAL OUTPUTS
CABLE ENTRIES
(2 x M20)

POWER INLET
CABLE ENTRY
(M20)

TP04

TP02

TP01

TP03

BREATHER/DRAIN

EARTH STUD

TP1 Sample Gas Inlet 1/4” NPT (F)

TP2 Sample Gas Outlet 1/4” NPT (F)

TP3 Bypass Flow Gas Outlet 1/4” NPT (F)

TP4 Letdown Gas Vent/Drain 1/4” NPT (F)

TP5 Vortex Cooler Inlet 1/4" NPT (F)

Figure 9

OptiPEAK Sampling System - Typical Outdoor Version

14 97319 Issue 4.2, November 2018

OptiPEAK TDL600 User’s Manual

!

2.8 Electrical Connections

All electrical connections to the TDL600 are made through junction boxes JB1 & JB2

(ATEX, IECEx and NEC500 Class I, Division 2 versions only).

INSTALLATION

WARNING:

Once the mains power connections are made to JB1 the

heaters and vortex cooling solenoid (if fi tted) will be

energized.

This includes:

• Power Connection

• Analog Outputs

• Analog Inputs (line pressure transmitter)

• Alarm Relays

• Modbus RTU / RS485 Connection

For the wiring diagram, consult the appropriate Appendix, depending on whether the
TDL600 was supplied with the indoor sample system, or the outdoor sample system:

Indoor Sample System Appendix B
Outdoor Sample System Appendix C

2.8.1 Power Connection

A single-phase AC mains power supply is required to operate the Analyzer and Sampling
System. The analyzer power supply can accommodate voltages from 90 to 264 V AC, 50/60
Hz. If enclosure heating or cooling options are selected, these will have defi ned voltage and
wattage requirements.

The factory-set power supply voltage is indicated on a yellow label located on the rear panel.

NOTE: The user cannot change the specifi ed power supply voltage.

Cable connections are made onto terminals within the Power Circuits junction box. Cable
entry into the junction box is provide via M20 threaded holes (fi tted with certifi ed stopping
plugs). Suitably certifi ed cable glands should be used (not supplied).

The power connection is made through JB1 (ATEX, IECEx and NEC500 Class I, Division
2 versions only) – refer to the appropriate Appendix.

Michell Instruments 15

INSTALLATION

Terminals are marked:

NOTE: An earth stud is provided in the base of the enclosure. This must be
used to earth bond the Sampling System.

A power isolator switch is provided on the Power Circuits junction box for local power
isolation of the OptiPEAK TDL600 Moisture Analyzer (Main Unit only) for maintenance or
servicing. NOTE: This switch isolates the analyzer but does not isolate power

from ancillaries such as the heating/cooling circuits where fi tted.

2.8.2 Analog Outputs

OptiPEAK TDL600 User’s Manual

Terminal No. Power Supply

1 Live
5 Neutral

Earth

Three 2-wire analog outputs are provided that can be confi gured to represent any of
the directly measured or calculated output parameters. These outputs are active, self­powered from the analyzer and can be set as either 0-20mA or 4-20mA.

For an overview of the analog output menu, refer to Section 3.7.6.1.

The analog output connections are made through JB2 (ATEX, IECEx and NEC500

Class I, Division 2 versions only) – refer to the appropriate Appendix.

2.8.3 Analog Inputs

Connection for process line pressure transmitter (optional).
Enables dynamic pressure compensation for calculation of moisture content
units.

Input 1

Input 2 No function

12 V DC excitation power provision for loop powered 4-20mA, 2-wire
transmitter. Transmitter must be able to function from 12 V DC excitation,
such as typical devices requiring 8 - 30 V DC.
Internal sensing resistor 100 Ω.

2.8.4 Alarm Relays

Three alarm relays are provided that can be triggered by any of the directly measured
or calculated output parameters. Each alarm relay has Common (CO), Normally Open
(NO) and Normally Closed (NC) contacts.

For detailed information on the alarms refer to Section 3.7.6.2.

The alarm relay connections are made through JB2 (ATEX, IECEx and NEC500 Class
I, Division 2 versions only) – refer to the appropriate Appendix.

16 97319 Issue 4.2, November 2018

OptiPEAK TDL600 User’s Manual

2.8.5 Modbus RTU / RS485 Connection

The TDL600 features an RS485 port for digital communication, and uses a subset of the
Modbus RTU protocol. The RS485 connection should be confi gured with the following
parameters:

Parameter Value

Baud Rate 9600bps
Data Bits 8
Parity None
Stop Bits 2

A full list of Modbus registers can be found in Appendix E.

The RS485 connection is made through JB2 (ATEX, IECEx and NEC500 Class I,

Division 2 versions only) – refer to the appropriate Appendix.

INSTALLATION

2.9 Environmental Requirements

The environmental requirements of the analyzer (complete with sampling system) are
as follows:

Temperature

Indoor version +10 to +45°C (+50 to +113°F)

Outdoor version -20 to +45°C (-4 to +113°F)

Outdoor version with enclosure cooling option -20 to +55°C (-4 to +131°F)

Temperature (Storage) -30 to +60°C (-22 to +140°F)

Relative Humidity Less than 90% RH

If installed outside, the analyzer must be in a shaded position to prevent heating effects
through sun radiation.

Michell Instruments 17

INSTALLATION

2.10 Sample Conditioning Requirements

Sample extraction, handling and conditioning techniques are of critical importance to assure
optimal performance and reliability of all gas analyzers that accurately quantify specifi c
components within a process gas composition. Michell Instruments' recommendations
and requirements in relation to the OptiPEAK TDL600 are outlined below.

Michell Instruments offers a range of sample extraction probes and sample conditioning
systems that have been selected and designed to exceed these minimum requirements.
For further information and advice please contact your local Michell offi ce or distributor
– refer to contact details on www.michell.com.

2.10.1 Gas Connections

Ensure that the process sample gas supply line is well fl ushed

through to clear any liquids and debris present, prior to

connection to the Sampling System.

OptiPEAK TDL600 User’s Manual

Connections are as follows - refer to Flow Diagram in Appendix D:

• TP1 Sample Gas Inlet

• TP2 Sample Gas Outlet

• TP3 Bypass Outlet

• TP4 System Vent/Drain

TP1 to TP3 are 1/4” NPT(F), TP4 is 1/4" OD.

2.10.2 Sample Flow Gas Handling Components

The sample fl ow gas handling components are as follows:

• Gas Inlet Isolation Valve (BV1):

Allows user to manually isolate the system from the process sample gas
supply line for maintenance or servicing.

• Particulate Filter (F1):

Provides protection to regulator from particulates

• Line Pressure Gauge (PG1):

Indicates the sample gas line pressure.

• Pressure Regulator 0-35 Bar (PR1):

Allows the user to manually set the sample gas analysis pressure for moisture
measurement. 1st stage pressure regulation.

• Regulated Pressure Gauge (PG2)

Indicates pressure set on PR1.

18 97319 Issue 4.2, November 2018

OptiPEAK TDL600 User’s Manual

• Particulate/Coalescing Filter (F2):

Provides system protection from contamination of entrained liquids and
particulates using membrane fi ltration.

• Pressure Regulator 0-4 Bar (PR2):

2nd stage pressure regulation for moisture measurement.

• Input Pressure Gauge (PG3):

Indicates cell input pressure as set at PR2.

• Insert Pressure Relief Valve (PRV1)

Protects AN1 from over pressure

• Metering Valve (MV1):

Allows the user to manually set the sample gas fl owrate into the TDL gas
cell.

INSTALLATION

• Moisture Analyzer (AN1):

TDL600 Process Moisture Analyzer

• Flowmeter (FM1):

Provides indication of the sample gas fl ow rate through the TDL gas cell.

• System Drain Needle Valve (NV1):

Allows the user to manually letdown the sample gas pressure trapped in the
system for maintenance or servicing.

The bypass fl ow gas handling components are as follows:

• Bypass Flowmeter & Valve (FM2):

Allows the user to manually set and provide indication of the bypass gas fl ow
rate across the membrane fi lter.

Sample Extraction and Impulse Tubing

An insertion probe, with tip positioned within the central one-third of the cross­sectional area of the pipe, should be used to extract a sample with a composition that
is representative of the majority of gas fl owing within the pipeline. Attention should
be given to the installation of impulse tubing connecting from the sample probe to the
analyzer sample conditioning system. Analytical grade acid-etched stainless steel tubing
should be used, which has a low moisture sorption capacity. Tube size should be 1/8"
or 3mm diameter, or 1/4” or 6mm as a maximum, to ensure that sample transportation
delay time is kept to a minimum. Likewise, to ensure the best dynamic response of
the complete installed analyzer system, the positioning of the analyzer with sample
conditioning system should be as close to the sample extraction probe as possible.

Michell Instruments 19