Rosemount RAMAN Process Analyzer-Orig. Issue Manuals & Guides

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RAMAN PROCESS ANALYZER

Instruction Bulletin IB-103-300 Original Issue

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ROSEMOUNT WARRANTY

The Raman Process Analyzer is designed for industrial applications. Treat with care to avoid physical damage. THE WARRANTY DOES NOT COVER DAMAGE FROM MISHANDLING.

Rosemount warrants that the equipment manufactured and sold by it will, upon shipment, be free of defects in workmanship or material. Should any failure to conform to this warranty become apparent during a period of one year after the date of shipment, Rosemount shall, upon prompt written notice from the purchaser, correct such nonconformity by repair or replacement, F.O.B. factory of the defective part or parts. Correction in the manner provided above shall constitute a fulfillment of all liabilities of Rosemount with respect to the quality of the equipment.

THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES OF QUALITY WHETHER WRITTEN, ORAL, OR IMPLIED (INCLUDING ANY WARRANTY OF MERCHANTABILITY OF FITNESS FOR PURPOSE).

The remedy(ies) provided above shall be purchaser’s sole remedy(ies) for any failure of Rosemount to comply with the warranty provisions, whether claims by the purchaser are based in contract or in tort (including negligence).

Rosemount does not warrant equipment against normal deterioration due to environment. Factors such as corrosive gases and solid particulates can be detrimental and can create the need for repair or replacement as part of normal wear and tear during the warranty period.

Equipment supplied by Rosemount Analytical Inc. but not manufactured by it will be subject to the same warranty as is extended to Rosemount by the original manufacturer.

At the time of installation it is important that the required services are supplied to the system. This will ensure, that should there be a delay between installation and full commissioning that the analyzer being supplied with ac power will not be subjected to component deterioration.

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PURPOSE

The purpose of this manual is to provide a comprehensive understanding of the Raman Process Analyzer

components, functions, installation, and maintenance.

This manual is designed to provide information about the Raman Process Analyzer. We recommend that you thoroughly familiarize yourself with the Description and Installation sections before installing your analyzer.

The description presents the basic principles of the analyzer along with its performance characteristics and components. The remaining sections contain detailed procedures and information necessary to install and service the analyzer.

Before contacting Rosemount concerning any questions, first consult this manual. It describes most situations encountered in your equipment’s operation and details necessary action.

DEFINITIONS

The following definitions apply to WARNINGS, CAUTIONS, and NOTES found throughout this publication.

Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not strictly observed, could result in injury, death, or long-term health hazards of personnel.

NOTE

Highlights an essential operating procedure, condition, or statement.

: EARTH (GROUND) TERMINAL

: PROTECTIVE CONDUCTOR TERMINAL

: RISK OF ELECTRICAL SHOCK

: WARNING: REFER TO INSTRUCTION BULLETIN

Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not strictly observed, could result in damage to or destruction of equipment, or loss of effectiveness

NOTE TO USERS

The number in the lower right corner of each illustration in this publication is a manual illustration number. It is not a part number, and is not related to the illustration in any technical manner.

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IMPORTANT

LASER SAFETY INSTRUCTIONS

The Raman Process Analyzer uses a Class IV Diode Laser with a maximum output of 1 Watt at a wavelength of 810 nm (invisible, near-infrared light). The light is transmitted through fiber optic cables to and from the probe. The Raman Process Analyzer contains a Laser Safety Device that detects the return intensity of the laser light. If the return light diminishes below a certain level, the device reduces the laser power to Class I. This safety feature reduces the chance of personnel injury from contact with the laser. Take the following precautions when working around the Raman Process Analyzer:

Invisible laser light — avoid exposure to operating laser. A Class IV laser is used in this analyzer. The laser has a maximum output of 1 Watt at a wavelength of 810 nm.

1. Only service this product if you have completed formal training in laser safety and safe servicing techniques on this unit.

2. Never look at the probe tip when the probe is connected to the analyzer. Disconnect the fiber optic cables before examining the probe.

3. Always clean the probe tip when removed from process. It may be possible for liquid droplets or particles to attach to the tip of the probe, allowing light “reflection” to return to the Laser Safety Device. Use only appropriate material that will not scratch or otherwise damage the probe tip.

4. Do not bring the probe tip in contact with any surfaces when removed from the process. Any “scattered” light returned by the probe may trigger the laser back to Class IV.

5. All personnel working in the area of the laser must wear laser safety goggles (fullgoggle type with side shields). Goggles must have a minimum attenuation factor of 100,000 (optical density 5) for an 810 nm wavelength.

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IMPORTANT

SAFETY INSTRUCTIONS FOR THE WIRING AND

INSTALLATION OF THE LASER

The following safety instructions apply specifically to all EU member states. They should be strictly adhered to in order to assure compliance with the Low Voltage Directive. Non-EU states should also comply with the following unless superseded by local or National Standards.

1. Adequate earth connections should be made to all earthing points, internal and external, where provided.

2. After installation or troubleshooting, all safety covers and safety grounds must be replaced. The integrity of all earth terminals must be maintained at all times.

3. Mains supply cords should comply with the requirements of IEC227 or IEC245.

4. All wiring shall be suitable for use in an ambient temperature of greater than 75°C.

5. All cable glands used should be of such internal dimensions as to provide adequate cable anchorage.

6. To ensure safe operation of this equipment, connection to the mains supply should only be made through a circuit breaker which will disconnect all circuits carrying conductors during a fault situation. The circuit breaker may also include a mechanically operated isolating switch. If not, then another means of disconnecting the equipment from the supply must be provided and clearly marked as such. Circuit breakers or switches must comply with a recognized standard such as IEC947 (properly grounded three wire source of electrical power). All wiring must conform with any local standards.

7. Warning - Electrical Shock Hazard. Where equipment or covers are marked with the symbol to the right, hazardous voltages are likely to be present beneath. These covers should only be removed when power is removed from the equipment — and then only by trained service personnel.

8. Caution - Hot Surface Hazard. Where equipment or covers are marked with the symbol to the right, there is a danger from hot surfaces beneath. These covers should only be removed by trained service personnel when power is removed from the equipment. Certain surfaces may remain hot to the touch.

9. Where equipment or covers are marked with the symbol to the right, refer to the Operator Manual for instructions.

10. Warning - Laser Light Warning. Where equipment or covers are marked with the symbol to the right, high powered laser light is beneath. These covers should only be removed by trained service personnel when power is removed from the equipment.

11. All graphical symbols used in this product are from one or more of the following standards: EN61010-1, IEC417, and ISO3864.

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ESSENTIAL INSTRUCTIONS

READ THIS PAGE BEFORE PROCEEDING

Rosemount Analytical designs, manufactures, and tests all its products to meet many national and international standards. Because these instruments are sophisticated technical products, you must properly install, use, and maintain them to ensure they continue to operate within their normal specifications. The following instructions must be adhered to and integrated into your safety program when installing, using, and maintaining Rosemount Analytical products. Failure to follow the proper instructions may cause any one of the following situations to occur: loss of life, personal injury, property damage, damage to the instrument, and warranty invalidation.

Read all instructions prior to installing, operating, and servicing the product. If this

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Instruction Bulletin is not the correct manual, telephone 1-800-654-7768 and the required manual will be provided. Save this instruction manual for future reference.

If you do not understand any of the instructions, contact your Rosemount represen-

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tative for clarification.

Follow all warnings, cautions, and instructions marked on and supplied with the

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product.

Inform and educate your personnel in the proper installation, operation, and mainte-

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nance of the product.

Install your equipment as specified in the installation instructions of the appropriate

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Instruction Bulletin and per applicable local and national codes. Connect all products to the proper electrical and pressure sources.

To ensure proper performance, use qualified personnel to install, operate, update,

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program, and maintain this product.

When replacement parts are required, ensure that the qualified people use replace-

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ment parts specified by Rosemount. Unauthorized parts and procedures can affect the product’s performance and place the safe operation of your process at risk. Look alike substitutions may result in fire, electrical hazards, or improper operation.

Ensure that all equipment doors are closed and protective covers are in place, except

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when maintenance is being performed by qualified persons, to prevent electrical shock and personal injury.

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WHAT YOU NEED TO KNOW

BEFORE INSTALLING AND WIRING A ROSEMOUNT

RAMAN PROCESS ANALYZER

What is the line voltage being supplied to the Raman Process Analyzer?

Write the line voltage here __________ .

Is the analyzer being controlled at the analyzer cabinet or by network connection?

Is the conduit set-up and all wiring for the analyzer run?

CAN YOU USE THE FOLLOWING

QUICK START GUIDE?

Use the Quick Start Guide if....

You are familiar with the Raman Process Analyzer installation requirements.

All wiring and conduit are in place for installation of the analyzer.

A configuration set exists for the process to be analyzed.

You are familiar with the SURE calibration procedures.

If you cannot use the Quick Start Guide, turn to Section II, Installation, in this Instruction Bulletin.

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QUICK START GUIDE

RAMAN PROCESS ANALYZER

Before using the Quick Start Guide, please read “WHAT YOU NEED TO KNOW BEFORE INSTALLING AND WIRING A ROSEMOUNT RAMAN PROCESS ANALYZER” on the preceding page.

Mount the analyzer cabinet. Refer to Section II, paragraph 2-3.a.

Install the Raman probes. Refer to Section II, paragraph 0.

Install the fiber optic cable conduits. Refer to Section II, paragraph 0.

Connect the fiber optic cables. Refer to Section II, paragraph 1-1.a.

Connect the cooling air supply and filters to the analyzer cabinet. Refer to Section

II, paragraph 2-3.e.

Connect line voltage to the analyzer cabinet. Refer to Section II, paragraph 2-4.

Connect the network cable or computer peripherals to the analyzer cabinet. Refer

to Section II, paragraphs 0 and 2-6.

Turn power on to the analyzer cabinet.

If using a network connection to control the analyzer, use the NetSupport software

to enable communication with the analyzer. Refer to Section III, paragraph 3-1.

10. Use MAINCFG to select the desired configuration set. Refer to Section III, paragraph 3-3.a.

11. Perform a dark scan and photometric calibration procedure. Refer to Section III, paragraph 3-3.b.

12. Select the QUIT option to start the MAIN program and monitor the process.

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QUICK REFERENCE GUIDE

RAMAN PROCESS ANALYZER SOFTWARE

Select a configuration set

Close the MAIN program.

Start the MAINCFG program.

Select SYSTEM CONFIGURATION.

Select ENABLE A CONFIGURATION.

Select the configuration file to be used.

Calibrate the analyzer

Use the MAINCFG program and load the correct configuration set for the process

to be monitored.

Remove the probe from the process and ensure the probe is clean of any liquid or

foreign material.

Mount the probe in the SURE calibration kit.

Select PHOTOMETRIC CALIBRATION from the MAIN Setup Menu screen.

A prompt to verify that the probe is connected to the calibration kit is displayed.

Click the CONTINUE button.

Select the appropriate channel to be calibrated. Set the number of scans to 1 and

click CONTINUE.

The system auto-ranges and acquires the dark scan current, then displays the pho-

tometric curve. Make sure the curve is not saturated (have a flat region). If flat regions appear in the scan, back out the calibration kit two or three turns and press RE-SAMPLE. Repeat the calibration kit adjustments and re-sampling until a smooth photometric curve is measured.

Make sure the appropriate channel is selected and set the number of scans to 10.

Press RE-SAMPLE, then press CONTINUE.

Press STORE to save this scan for future use. The selected channel photometrics

are calibrated.

10. To calibrate the photometrics of another channel, repeat steps 1 through 9.

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Technical Support Hotline:

For assistance with technical problems, please call the Customer Support Center (CSC). The CSC is staffed 24 hours a day, 7 days a week.

Phone: 1-800-433-6076

In addition to the CSC, you may also contact Field Watch. Field Watch coordinates Rosemount’s field service throughout the US and abroad.

Phone: 1-800-654-RSMT (1-800-654-7768)

Rosemount may also be reached via the Internet through e-mail and the World Wide Web:

E-mail: GAS.CSC@frco.com

World Wide Web: www.processanalytic.com

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Section Page

Rosemount Warranty................................................................................................................................... i

Section I. System Overview.................................................................................................................... 1-1

1-1. Scope of Manual .............................................................................................................1-1

1-2. Components Checklist (Package Contents)...................................................................1-1

1-3. Functional Equipment Description................................................................................ 1-1

1-4. Equipment Specifications............................................................................................... 1-5

Section II. Installation ............................................................................................................................. 2-1

2-1. Overview......................................................................................................................... 2-1

2-2. Typical Installation.......................................................................................................... 2-1

2-3. Mechanical Installation .................................................................................................. 2-2

2-4. Electrical Installation ..................................................................................................... 2-5

2-5. Computer Network.......................................................................................................... 2-6

2-6. Computer Peripherals..................................................................................................... 2-6

2-7. Installation Inspections...................................................................................................2-7

Section III. Setup ..................................................................................................................................... 3-1

3-1. Networking Software ..................................................................................................... 3-1

3-2. MAINCFG Program....................................................................................................... 3-3

3-3. Setup ............................................................................................................................... 3-8

Section IV. Operation.............................................................................................................................. 4-1

4-1. Overview......................................................................................................................... 4-1

4-2. Software Usage Conventions ........................................................................................ 4-1

4-3. MAIN Program Startup................................................................................................. 4-3

Section V. Preventive Maintenance....................................................................................................... 5-1

5-1. General............................................................................................................................ 5-1

5-2. Cleaning ..........................................................................................................................5-1

Section VI. Troubleshooting ...................................................................................................................6-1

6-1. General............................................................................................................................ 6-1

6-2. Alarm Messages.............................................................................................................6-1

6-3. Troubleshooting .............................................................................................................. 6-1

Section VII. Service ................................................................................................................................. 7-1

7-1. General............................................................................................................................ 7-1

7-2. Analyzer Component Replacement............................................................................... 7-1

7-3. Analyzer Calibration ...................................................................................................... 7-6

Section VIII. Replacement Parts ........................................................................................................... 8-1

Section IX. Returning Equipment to the Factory .............................................................................9-1

9-1. Returning Equipment ..................................................................................................... 9-1

Glossary ..................................................................................................................................................... G-1

Index ............................................................................................................................................................I-1

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LIST OF ILLUSTRATIONS

Figure Page

Figure 1-1. Typical Raman Process Analyer System Package...........................................................1-1

Figure 1-2. Functional Equipment Diagram.......................................................................................1-2

Figure 1-3. Analyzer Cabinet.............................................................................................................1-4

Figure 2-1. Typical Installation.......................................................................................................... 2-1

Figure 2-2. Analyzer Cabinet Installation.......................................................................................... 2-2

Figure 2-3. Raman Probe ...................................................................................................................2-2

Figure 2-4. Cable Pull Box.................................................................................................................2-3

Figure 2-5. Cable to Pull Tape Connection........................................................................................ 2-3

Figure 2-6. Probe Connections...........................................................................................................2-4

Figure 2-7. Air Supply Hookup .........................................................................................................2-5

Figure 2-8. Conduit Ports................................................................................................................... 2-5

Figure 2-9. Input Power Terminal......................................................................................................2-6

Figure 2-10. Computer Connections....................................................................................................2-6

Figure 3-1. NETSUPPORT CONTROL Screen ..............................................................................3-1

Figure 3-2. KNOWN CLIENTS Screen ..........................................................................................3-1

Figure 3-3. MAINCFG Program Structure ........................................................................................3-2

Figure 3-4. SETUP MENUS Screen ................................................................................................ 3-3

Figure 3-5. SYSTEM CONFIGURATION MENU Screen ........................................................... 3-3

Figure 3-6. SYSTEM CONFIGURATION Screen.......................................................................... 3-3

Figure 3-7. PLS SETUP Screen ....................................................................................................... 3-4

Figure 3-8. SYSTEM CONFIGURATION Screen.......................................................................... 3-4

Figure 3-9. CCD MAP Screen ..........................................................................................................3-5

Figure 3-10. CONFIGURE MODBUS Screen ...................................................................................3-5

Figure 3-11. SYSTEM CONFIGURATION MENU Screen ............................................................ 3-6

Figure 3-12. SETUP MENUS Screen ................................................................................................. 3-6

Figure 3-13. Calibration Message ........................................................................................................ 3-6

Figure 3-14. PHOTOMETRIC CALIBRATION Screen...................................................................3-7

Figure 3-15. DARK CURRENT CALIBRATION Screen ...............................................................3-8

Figure 4-1. MAIN Program Structure................................................................................................4-2

Figure 4-2. RAMAN PROCESS ANALYZER Screen...................................................................4-3

Figure 4-3. PASSWORD VERIFICATION Screen.........................................................................4-3

Figure 4-4. OPERATOR MENUS Screen .......................................................................................4-4

Figure 4-5. SETUP MENUS Screen ................................................................................................ 4-4

Figure 4-6. ZERO CLIP OPTION Screen ......................................................................................4-4

Figure 4-7. RAMAN ANALYZER DATALOG UTILITY Screen ............................................... 4-5

Figure 4-8. OPERATOR MENUS Screen .......................................................................................4-5

Figure 4-9. GRAB SCAN MENUS Screen.....................................................................................4-5

Figure 4-10. GRAB SCAN Screen .....................................................................................................4-6

Figure 4-11. SAVE AS Screen...........................................................................................................4-6

Figure 4-12. OPERATOR MENUS Screen ........................................................................................4-7

Figure 4-13. DIAGNOSTIC MENUS Screen.....................................................................................4-7

Figure 4-14. VIEW CALCULATIONS Screen ..................................................................................4-7

Figure 4-15. DIAGNOSTIC MENUS Screen.....................................................................................4-8

Figure 4-16. ANALOG INPUT MEASUREMENTS Screen ............................................................4-9

Figure 4-17. DIGITAL I/O STATE Screen .......................................................................................4-9

Figure 4-18. SMART DIAGNOSTICS MENU Screen ...................................................................4-10

Figure 4-19. ANALYZER SOFTWARE STATUS Screen .............................................................4-10

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LIST OF ILLUSTRATIONS (Continued)

Figure Page

Figure 4-20. ANALYZER ALARMS STATUS Screen.................................................................. 4-11

Figure 4-21. PASSWORD VERIFICATION Screen .......................................................................4-12

Figure 4-22. TRENDS Screen ...........................................................................................................4-12

Figure 4-23. SMART DIAGNOSTICS MENU Screen.................................................................. 4-13

Figure 4-24. PERFORMANCE MEASURES Screen ...................................................................... 4-13

Figure 4-25. DARK CURRENT & PHOTOMETRIC CORRECTION Screen ............................ 4-14

Figure 4-26. CALIBRATION PATH & MODEL Screen ............................................................. 4-14

Figure 4-27. DIAGNOSTICS MENUS Screen ............................................................................... 4-15

Figure 4-28. OPERATOR MENUS Screen...................................................................................... 4-15

Figure 4-29. SET SECURITY Screen ..............................................................................................4-16

Figure 4-30. SET PASSWORDS Screen.......................................................................................... 4-16

Figure 4-31 GRAB DARK SCAN Screen..................................................................................... 4-16

Figure 4-32. ABOUT Screen ............................................................................................................. 4-16

Figure 6-1. Raman Troubleshooting Flowchart #1............................................................................ 6-2

Figure 6-2. Raman Troubleshooting Flowchart #2............................................................................ 6-3

Figure 6-3. Raman Troubleshooting Flowchart #3............................................................................ 6-4

Figure 7-1. Fuse Locations ................................................................................................................7-2

Figure 7-2. CCD Camera Thermocouple Removal............................................................................ 7-2

Figure 7-3. Laser Cooling Fan Removal............................................................................................ 7-3

Figure 7-4. Laser Removal ................................................................................................................ 7-4

LIST OF TABLES

Table Page

Table 1-1. Raman Process Equipment Specifications (Analyzer)*................................................. 1-5

Table 8-1. Replacement Parts for the Raman Process Analyzer.......................................................8-1

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SECTION I. SYSTEM OVERVIEW

1-1. SCOPE OF MANUAL

This instruction bulletin covers installation, setup, operation, troubleshooting, and maintenance of the Raman Process Analyzer manufactured by Rosemount Analytical. The troubleshooting and service procedures in this manual are limited to those that can be performed by most equipment operators.

1-2. COMPONENTS CHECKLIST

(PACKAGE CONTENTS)

The Raman Process Analyzer system includes the items listed in Figure 1-1. The SURE Calibration Kit contains all the necessary components for quickly calibrating the analyzer.

1-3. FUNCTIONAL EQUIPMENT DESCRIPTION

When properly configured, the analyzer detects and measures the concentration of sample components that inelastically scatter light. Access for the detection of the process components is accomplished with one to four analyzer probes installed in or around the process flow.

Functional components of the analyzer are shown in the electronic diagram of Figure 1-2. The important components of the diagram include the process probes, the diode lasers, the laser safety device, spectrograph, vortex cooler, CCD camera, and the industrial computer. Brief descriptions of the analyzer component functions are provided in the following paragraphs.

1. Analyzer

2. Analyzer Test Records

3. Instruction Bulletin

4. Backup Software

5. SURE Calibration Kit

6. Oil Filter

7. Water Filter

8. In Situ Probe (1 per channel)

9. Fiber Optic Cables (3 per probe)

Figure 1-1. Typical Raman Process Analyzer System Package

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PRESSURE

REGULATOR

AIR

SUPPLY

OIL

FILTER

VORTEX

COOLING

CHAMBER

AIR

VALV E

HOT

AIR

USER

INTERFACE

ANALYZER CABINET

INDUSTRIAL

COMPUTER

LASER

CONTROL

MODULE

WATER FILTER

CONTROLLER

PROCESS PROBES

LASER

SAFETY

BOARD

DIAMOND

REFERENCE 1

FILTER

CCD

CAMERA

OPTIC

SPECTROGRAPH

DIODE

LASER 1

SPLITTER

OPTIC

FILTER

DIODE

LASER 2

DIAMOND

REFERENCE 2

CCD

CAMERA

HEAD

SPLITTER

Figure 1-2. Functional Equipment Diagram

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SPLITTER

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The following are brief descriptions of analyzer component functions. A listing of components in the analyzer cabinet is provided in Figure 1-3.

a. Diode Lasers and Probes.

The analyzer uses one or two diode lasers and up to four process probes. Each diode laser generates a light beam. The light beam is split in a 10/90 optic splitter. Fiber optic cables transmit ten percent of the beam to a diamond reference circuit and the remaining ninety percent to a 50/50 optic splitter. A fiber optic cable from the diamond reference transmits the reference beam to the spectrograph.

The ninety percent portion of the beam is evenly split to provide excitation energy for two process probes. Each beam is filtered at the probe to eliminate stray radiation. The probe emits the filtered laser beam into the process flow.

The process components inelastically scatter distinct wavelengths. Two return cables transmit scattered light from the probe to the analyzer. The unfiltered S cable transmits all scattered light to the Laser Safety Device. The filtered R cable transmits only a specific range of nearinfrared wavelengths to the spectrograph.

Laser Safety Device.

To minimize operator hazards, the laser safety device monitors the intensity of the scattered laser light from the process flow. If the safety device receives less than an acceptably large part of the scattered light, it reduces the laser power output from Class IV to Class I.

The laser safety device continues to regulate the output of the diode lasers at pulsed Class I power levels until the device detects an acceptable amount of scattered light from the process.

Low light scatter may indicate a broken fiber optic cable, a bad cable connection, or removal of the probe from the process. Refer to the “Laser Safety Instructions” in the front of this manual for more information.

b. Vortex Cooler.

The vortex cooler helps control the temperature of the CCD (charge coupled device) camera and the cabinet interior. The main function of the vortex cooler is to maintain the ambient temperature near the camera at 30°C so that the internal CCD chip temperature will remain at –30°C.

Incoming instrument air is dried, filtered, and routed through a temperature-controlled air valve to the vortex cooler. The vortex effect separates the forced air into warm and cold air flows. The chilled air is routed to the CCD camera.

As the cabinet air gets warmer, the air valve opens a larger flow of forced air to the vortex chamber, providing more cooling air to the camera. As the cabinet air cools, a proportional air valve partly closes to slow the flow of cooling air.

c. Spectrograph and CCD Camera.

Filtered light from the diamond reference and the R probe is transmitted by fiber optic cable to the spectrograph. The spectrograph separates incoming light into distinct wavelengths. Each wavelength of light is sent to the CCD camera head where the spectral image is decoded and electronically transferred to the CCD camera controller. The controller processes the spectral image into numerical data. The data is sent to the industrial computer for interpretation and display.

d. Industrial Computer.

The industrial computer converts data points into light intensity with respect to frequency. The histogram of each predicted component is displayed on the CRT. The spectra are processed by the prediction’s algorithm in accordance with the calibration file. Each application requires its own calibration file. The output data is stored for further analysis.

e. User Interface.

An interface device is required to set up and operate the analyzer using the MAIN and MAINCFG software programs. The user interface device can be a remote computer connected through a network modem, Ethernet, RF antenna and laptop computer, or a monitor, keyboard, and mouse connected at the analyzer cabinet.

f. Analyzer Outputs.

The available analyzer out-

puts are MODBUS and/or analog, 4 to 20 mA.

g. SURE Calibration Kit.

The SURE calibration kit is a light proof housing that secures the probe tip above a fluorescent glass. The kit uses no external light source or power source. When the fluorescent glass and probe are properly assembled in the light-proof housing, the analyzer can be calibrated using the MAINCFG software program.

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1. Hoffman Enclosure 10. Temperature Controller

2. Computer Power Supply 11. Enclosure Backplate

3. Computer 12. CCD Camera Controller

4. Disk Drives 13. Spectrograph Assembly

5. Optics Assembly Tray 14. Laser Pedestal Assembly

6. CCD Camera 15. Laser Safety Device

7. CCD Camera Hood 16. Proportional Air Valve

8. Termination Board 17. Raman Power Supply

9. Peripheral Device Connector 18. Vortex Cooler Assembly

Figure 1-3. Analyzer Cabinet

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1-4. EQUIPMENT SPECIFICATIONS

Table 1-1. Raman Process Equipment Specifications (Analyzer)*

Spectral Range .......................................................................................................... 500 cm

-1

to 2000 cm-1 Raman Shift

Spectral Resolution ..................................................................................................................................................∼2 nm

Typical Error ...................................................................................... Less than 1% of full-scale, application dependent

Operating Temperature ............................................................................................................ 32° to 122°F (0° to 50°C)

Storage Temperature ................................................................................................................ 32° to 122°F (0° to 50°C)

Relative Humidity .......................................................................................................................................... 20 to 100%

Warm-up Time ................................................................................................................................................ 60 minutes

Input Power ....................................................................................................................... 115 or 230 VAC, 50 or 60 Hz

Power Rating .......................................................................................................................................... 250 VA (250 W)

Electrical Classification ............................................................................................... General Purpose or Class I, Div II

Environmental Classification .......................................................................................................................... NEMA-4X

Dimensions (H x W x D) .................................................................................. 48 x 24 x 12 in. (1219 x 610 x 305 mm)

Weight ....................................................................................................................................................... 165 lbs (75 kg)

Certification ......................................................................................................................................... CE Mark Pending

*Probe specifications may vary from probe to probe. Refer to the material supplied with probe for specifications.

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SECTION II. INSTALLATION

2-2. TYPICAL INSTALLATION

Before starting to install this equipment, read the “Safety instructions for the wiring and installation of the laser” at the front of this Instruction Bulletin. Failure to follow the safety instructions could result in serious injury, death, or substantial property damage.

2-1. OVERVIEW

This section covers installation of the Rosemount Raman Process Analyzer. Included are a typical installation, common requirements, what you need to have on hand to start an installation, and the mechanical and electrical installation instructions. An authorized Rosemount service representative must complete the analyzer installation. You must complete the mechanical installation before calling the service representative for final check-out and installation commissioning.

A typical system installation is shown in Figure 2-1. When properly installed, the analyzer cabinet is securely mounted to a wall in the process control area. The cabinet should not be mounted in the path of direct sunlight.

Process probes are installed in the process flow (usually a sampling flow). Up to four process probes may be installed for each analyzer. The installed probes should be adequately shielded from accidental impact, rainfall, and direct sunlight. Ready access for probe removal, cleaning, and replacement is recommended.

Fiber optic cable lengths are per customer specification. Make sure the correct cables are selected for each run. One inch or larger diameter conduits or cable troughs are recommended for shielding the fiber optic cables. Pull boxes are needed when successive cable bend angles exceed 180 degrees. Conduit ends should point down to protect against water accumulation. Sharp conduit edges must be avoided and the cables should be lubricated before pulling.

Figure 2-1. Typical Installation

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2-3. MECHANICAL INSTALLATION

a. Analyzer Cabinet.

Lift the cabinet with the upper brackets. Avoid contact with the vortex cooler. Position and securely mount the cabinet using appropriate screws and flat washers.

b. Raman Probe.

Never rest the cabinet standing up. Damage to conduit fittings can occur.

The analyzer is housed in a NEMA-4X cabinet. The NEMA-4X cabinet is suitable for wall mounting in a Class I, Division II environment when equipped with an ISA Type Z-Purge.

When lifting, the cabinet door must be closed and latched. Make sure the mounting brackets are installed and tight.

The analyzer cabinet weighs approximately 165 lbs (75 kg). Analyzer cabinet mounting dimensions are provided in Figure 2-2. Mark the position for cabinet hanger mounting on center with wall studs or a securely mounted plywood backplate.

24.0

(609.6)

12.0 (304.8)

Each analyzer system includes up to four process probes designed for mounting in a flow line or tank. Install each process probe according to the following instructions:

Remove the protective covers from the probe tip, Figure 2-3.

Install a bored through compression fitting of compatible metallurgy in the process line, tee, or process tank wall.

Insert the probe to the desired depth in the compression fitting.

If compatible with the process, apply a suitable sealant around the seal diameter of the probe.

Tighten the compression fitting to secure the probe. Do not over-tighten the fitting.

48.0

(1219.2)

NOTE:

DIMENSIONS ARE IN INCHES WITH MILLIMETERS IN PARENTHESIS.

Figure 2-2. Analyzer Cabinet Installation

27320025

Figure 2-3. Raman Probe

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ENDPLATE

Overlay 3 ft (91.4 cm) of the fiber optic ca-

ble onto the pull tape and wrap with nylon string to hold in place. Wrap and tape the fiber optic cable to the pull tape as shown in Figure 2-5.

CABLE PULL

BOX (90 TURN

CONDUIT

FIBER OPTIC

CABLE

Figure 2-4. Cable Pull Box

c. Fiber Optic Cable Conduits.

Fiber optic cables are precision optics devices. Careless handling or installation of a fiber optic cable can result in permanent cable damage.

Install a 3/4 in. (19 mm) diameter minimum

conduit from the analyzer cabinet to each process probe. The minimum radius for all conduit bends is 10 in. (254 mm). For fiber optic cable runs, it is not required to connect the conduit to the analyzer cabinet.

FITTING)

27320060

NYLON STRING

(WRAP TIGHTLY)

PULL TAPE

Carefully pull the cable through the con-

duit; pull enough cable to allow for cable slack when connecting at the analyzer cabinet or probe.

When using cable pull boxes, turn the

coiled cable over. Feed the pull tape to the opposite side of the pull box. Wrap and tape the cable to the pull tape and pull the free end through the next section of conduit. Repeat the cable pulling instructions as needed to install all fiber optic cables.

FIBER OPTIC

CABLE

FEED STRING

THROUGH PULL

TAPE EYELET

3FT

(91.4 CM)

WRAP WITH ELECTRICAL

TAPE

Install a cable pull box following a series of

conduit bends totaling 180 degrees. A 90 degree turn fitting (Figure 2-4) is recommended for use as a cable pull box.

When using pull boxes, coil the fiber optic

cable into a figure eight below the pull box. Feed a cable pull tape from one conduit end to the pull box.

27320031

Figure 2-5. Cable to Pull Tape Connection

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d. Connecting Fiber Optic Cables.

Each process probe has four SMA connectors. The probe connectors are marked “S” for the laser safety, “L” for laser excitation light, and “R” for Raman light collection. The L and R connectors have mating, in-line optic filters. The unmarked connector is a spare S or R connector. Install the Raman probes according to the following instructions:

Remove the protective caps from the S, L,

and R probe connectors (Figure 2-6).

Carefully handle fiber optic cables. Avoid bending, pulling, or compressing the cables. Excess stress on the cables or connectors can cause permanent cable damage.

The Raman probe is a delicate precision optics device. Careless handling or installation can result in permanent probe damage.

Figure 2-6. Probe Connections

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Remove a protective cap from one probe

terminal. Tilt the mating optic filter or cable connector and carefully align the fiber optic filament with the mating filter or connector orifice. Level both connectors, insert the filament, and install the connector finger tight.

NOTE

Save the protective caps and use them whenever the fiber optic cables are disconnected. For ready access, Rosemount recommends that you store the protective caps in a plastic bag taped to the inside of the analyzer cabinet door.

Repeat step 2 for each probe connector and

mating filter and/or cable connector.

2-4. ELECTRICAL INSTALLATION

Use the following procedures to supply electrical power to the analyzer. Input power to the module can be either 115 or 230 VAC, 50/60 Hz, single phase. A properly rated electrical breaker is required.

Rosemount recommends installing an ON/OFF switch outside the analyzer cabinet.

Install all protective equipment covers and safety ground leads after installation. Failure to install covers and ground leads could result in serious injury or death.

Using a procedure similar to step 2, care-

fully connect the fiber optic cables to their mating terminals at the analyzer cabinet.

e. Air Supply Connection.

The analyzer uses a vortex cooler system to maintain the analyzer cabinet temperature. Connect the supplied water and oil filters to the analyzer cabinet as shown in Figure 2-7.

Rosemount recommends mounting a pressure gage after the filters to monitor filter performance.

Connect the air supply and air pressure regulator to the water filter. The instrument air supply must be dry, filtered air at 60 psi (414 kPa) minimum, developing 15 SCFM, minimum.

PRESSURE

REGULATOR

PRESSURE

GAGE

a. Input Voltage Selector.

The input voltage selection is configured per customer request (115 or 230 VAC). If it becomes necessary to change the input voltage, contact an authorized Rosemount Service Representative.

b. Electrical Wiring and Conduits.

NOTE

It may be necessary to enlarge conduit ports to install the conduits.

All electrical wiring and conduits must conform to local codes. Refer to Figure 2-8 for the location of the conduit ports.

AIR

SUPPLY

60 PSI

(414 kPa)

WATER

FILTER

OIL

FILTER

Figure 2-7. Air Supply Hookup

ANALYZER

CABINET

27320026

Figure 2-8. Conduit Ports

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c. Cabinet Power.

Lock out the cabinet power source at the main disconnect. Connect cabinet electrical power at the input power terminal (Figure 2-9).

Disconnect and lock out power source before working on electrical components. Failure to lock out power may result in severe injury or death.

NOTE

All through cables and wiring should be routed through the conduit ports on the bottom of the cabinet.

2-5. COMPUTER NETWORK

If using the network function of the analyzer, connect an appropriate networking cable to the computer modem terminal shown in Figure 2-10.

2-6. COMPUTER PERIPHERALS

A monitor, keyboard, and mouse may be connected to the analyzer computer. Remove the computer terminal cover and connect the peripherals to the terminals shown in Figure 2-10.

Figure 2-9. Input Power Terminal

Figure 2-10. Computer Connections

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2-7. INSTALLATION INSPECTIONS

Perform the following equipment installation checks in the order provided.

Install all protective equipment covers and safety ground leads after installation. Failure to install covers and ground leads could result in serious injury or death.

a. Mechanical Checks.

Verify that the analyzer cabinet is securely

mounted out of the path of direct sunlight.

Verify that all the fiber optic cables are

connected to mating terminals on the analyzer termination board. Ensure that all fiber optic cable connections are finger-tight.

Verify the Raman probes are properly in-

stalled in the process stream. Verify that all probe shields are in place.

Verify that the fiber optic cables and optic

filters are connected to mating terminals on the probe. Ensure that all fiber optic cable connections are finger-tight.

b. Electrical Checks.

Verify that analyzer input power is properly

connected per Figure 2-9.

Open the analyzer cabinet and verify that

the computer POWER ON/OFF switch is in the ON position.

Verify that the CCD camera controller

POWER ON/OFF switch is in the ON position and close the analyzer cabinet.

If using the remote networking, ensure the

network cables are attached to the analyzer per Figure 2-10.

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Page 31

3-1. COMMUNICATION SOFTWARE

When provided, the NetSupport Local Control program allows remote personal computers to communicate with the analyzer through a RF wireless network. The NetSupport software must be started each time the remote computer is turned on. If needed, refer to the software manual for more information. To initiate network access to the analyzer:

Select NETSUPPORT LOCAL CONTROL

from the Windows™ START menu. The NETSUPPORT CONTROL screen (Figure 3-1) is displayed.

From the NETSUPPORT CONTROL screen,

click on the menu CLIENTS and select CONNECT/DISCONNECT from the menu items. The KNOWN CLIENTS screen (Figure 3-2) is displayed.

In the KNOWN CLIENTS screen, click the

analyzer you wish to control and click the CONNECT button. The program will prompt you when the connection is made.

SECTION III. SETUP

Figure 3-2. KNOWN CLIENTS Screen

After the program prompts that the connection is

made, click the CLOSE button. You will be returned to the NETSUPPORT CONTROL screen. From the NETSUPPORT CONTROL screen, click on the menu SELECTED CLIENTS menu and select CONTROL from the menu items.

The program will display a message informing

you how to switch from the client computer to the local computer. Click on the OK button.

27320033

27320032

Figure 3-1. NETSUPPORT CONTROL Screen

The local computer will now display the RA-

MAN PROCESS ANALYZER screen of the MAIN program for the analyzer selected above.

Analyzers supplied with an Ethernet connection are equipped with pcANYWHERE software. The pcANYWHERE software provides TCP/IP protocol and allows a personal computer (PC) to communicate with multiple Raman Analyzers along a network. When provided, pc ANYWHERE also

supports modem communication.

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Figure 3-3. MAINCFG Program Structure

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3-2

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27320013

Figure 3-4. SETUP MENUS Screen

Figure 3-5. SYSTEM CONFIGURATION

MENU Screen

27320014

3-2. MAINCFG PROGRAM

This program is used for setting up and calibrating the Analyzer.

a. Starting the MAINCFG Program.

starting the MAINCFG program, close the MAIN program, if running. Select FILE ⇒

EXIT from the MAIN file menu. To start the MAINCFG program, select MAINCFG from the Windows START menu. Figure 3-3 shows the MAINCFG program structure.

b. SETUP MENUS.

The SETUP MENUS screen

(Figure 3-4) displays when the program starts.

The selections following are available from the SETUP MENUS screen:

SYSTEM CONFIGURATION. Clicking

on the SYSTEM CONFIGURATION button displays the SYSTEM CONFIGURATION MENU screen shown in Figure 3-5.

NOTE

Before

(a) CHANGE AN EXISTING CON-

FIGURATION. Selecting this button allows you to specify new settings for a configuration file used to process raw data. The program will prompt you for the configuration file to be modified. When the file is selected, the SYSTEM CONFIGURATION screen (Figure 3-6) displays the following menu selections:

CONFIGURE PLS. Clicking this

button prompts you to select a calibration file to use in the configuration. When a calibration file is selected, the PLS SETUP screen (Figure 3-7) displays.

When changing a configuration file, keep in mind that the file will be overwritten and the previous configuration will be lost.

27320015

Figure 3-6. SYSTEM CONFIGURATION

Screen

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Figure 3-7. PLS SETUP Screen

27320016

The PLS SETUP screen allows you to enable or disable the PLS predictions used to display the histogram on the RAMAN PROCESS ANALYZER screen. Click on the ACCEPT button to accept the new calibration file. Click on the QUIT button to exit without changing the calibration file.

CONFIGURE STRIPS. Clicking

on this button displays the CCD MAP screen (Figure 3-9). This screen allows you to select the regions of interest (ROI) on the CCD camera array. Use the GRAB AN IMAGE button to acquire an image. Click on and drag the lines on the image map to define the diamond reference channel and sample channel ROIs. Green lines define the ROI for the diamond reference channel. Black lines define the ROI

for the sample channel. Click on the APPLY STRIPS button to save the new strip configuration. Click on the QUIT button to exit the CCD MAP screen.

27320015

Figure 3-8. SYSTEM CONFIGURATION

Screen

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Figure 3-9. CCD MAP Screen

27320018

Figure 3-10. CONFIGURE MODBUS Screen

FACTORY PARAMETERS.

This screen is for use by authorized Rosemount Service Representatives only.

27320017

CONFIGURE MODBUS.

Click on this button to display the CONFIGURE MODBUS screen in Figure 3-10. This screen allows you to configure the RS-485 serial port parameters. This screen is typically used by authorized Rosemount Service Representatives only.

The ACCEPT button saves the displayed parameters and returns you to the SYSTEM CONFIGURATION screen.

The QUIT button will ignore parameter changes and return you to the SYSTEM CONFIGURATION screen.

ACCEPT. Clicking on the AC-

CEPT button saves the new system configuration set and returns you to the SYSTEM CONFIGURATION MENU screen.

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QUIT. Clicking on the QUIT

button will discard the configuration changes made and will return you to the SYSTEM CONFIGURATION MENU screen.

(b) CREATE A NEW CONFIGURA-

TION SET. This button (Figure 3-11) allows you to create a new configuration set using the same configuration menus as changing a configuration set. The program will prompt you for the file name before the SYSTEM CONFIGURATION screen displays.

This button allows you to select a configuration file. The program will prompt you for the configuration file to load.

(d) QUIT. Clicking on the QUIT button

returns you to the MAIN screen.

27320013

Figure 3-12. SETUP MENUS Screen

X-AXIS CALIBRATION. The X-AXIS

CALIBRATION option (Figure 3-12) should be used by authorized Rosemount Service Representatives only.

PHOTOMETRIC CALIBRATION.

Clicking this button displays a configuration message (Figure 3-13). When the probe is mounted in the SURE calibration kit, click the CONTINUE button.

27320014

Figure 3-11. SYSTEM CONFIGURATION

MENU Screen

If the probe is not mounted in the SURE calibration kit, click the QUIT button to return to the SETUP MENUS screen.

ENSURE THAT THE FLUORESCENT MATERIAL IS ATTACHED TO THE END OF THE PROBE FOR THE CHANNEL TO BE CALIBRATED

27320057

Figure 3-13. Calibration Message

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Figure 3-14. PHOTOMETRIC CALIBRATION Screen

27320058

The PHOTOMETRIC CALIBRATION screen (Figure 3-14) is used during the analyzer calibration procedure outlined in paragraph 3-3.b of this section. When the number of scans to average has been entered, click the continue button. The analyzer performs a series of scans and averages the scans to display a calibration spectrum. When the spectrum is displayed, the following buttons appear on the bottom of the screen:

(a) RE-SAMPLE. Clicking the RE-

SAMPLE button starts the calibration process over. The new averaged spectrum will display.

(b) STORE. Clicking the STORE button

will save the calibration spectrum for use in the configuration set as the photometric calculation spectrum.

exit without saving the spectrum and

return you to the SETUP MENUS screen.

DARK CURRENT CALIBRATION.

Clicking on the DARK CURRENT CALIBRATION button displays the DARK CURRENT CALIBRATION screen (Figure 3-15). This screen allows you to capture and save a dark scan used to cancel out the dark current background “noise” captured by the camera. To grab a dark scan, click on the RE-SAMPLE button. The scan will display on the CRT. To save the dark scan, click on the STORE button. To exit the DARK CURRENT CALIBRATION screen, click on the QUIT button.

ABOUT . Clicking the ABOUT button

displays the program information, such as version and date.

END. Clicking on the END button exits the

MAINCFG program.

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3-3. SETUP

The following procedures are for setup and calibration of the analyzer. If you are inexperienced, or do not understand the procedures, contact an authorized Rosemount service representative for help.

The analyzer must be calibrated after any of the following occurs:

• Replacement of fiber optic cable(s).

• Replacement of Diode Laser.

• Adjustment of laser power.

• Process or configuration set change.

a. Select A Configuration Set.

A configuration set must be selected prior to monitoring a process. After selecting a configuration set, the

analyzer must be calibrated according to step 3-3.b.

An existing configuration set can be modified using the MAINCFG program. See CHANGE AN EXISTING CONFIGURATION on page 3-3 for more information on modifying an existing configuration set.

A new configuration set may be created using the MAINCFG program. See CREATE A NEW CONFIGURATION SET on page 3-6 for more information on creating a new configuration set.

After modifying or creating a new configuration set, the set must then be enabled. See ENABLE A CONFIGURATION on page 3-6 for more information on enabling a configuration set.

Figure 3-15. DARK CURRENT CALIBRATION Screen

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27320019

Page 39

b. Calibration.

Calibrate the analyzer according to

the following procedure:

Verify that the correct configuration set is

loaded for the process to be monitored.

(a) Exit the MAIN program and start the

screen.

(b) Type the MAINCFG program.

TION button from the SETUP MENUS screen.

(d) Select ENABLE A CONFIGURA-

TION from the SYSTEM CONFIGURATION MENU screen and enter the name of the file you will be using to monitor the process.

Remove the probe from the process stream.

Clean all liquid and foreign material from the probe.

Carefully place the probe into the SURE

calibration block and secure the probe.

From the SETUP MENUS screen, select

PHOTOMETRIC CALIBRATION. The calibration message will display. If the probe is mounted in the SURE calibration kit, click the CONTINUE button. Otherwise click the QUIT button.

Using the PHOTOMETRIC CALIBRA-

TION screen as described on page 3-7, set the number of scans to average to 1 and

click the CONTINUE button. The analyzer begins the calibration process.

The analyzer will display a graph of the

dark scan current followed by a display of the photometric curve.

Inspect the photometric curve for a quick

rise or fall followed by a flat region. A flat region indicates that the detector is saturated; the probe must be backed away from the fluorescent glass. If no signal or a weak signal is shown on the spectrum, the probe must be moved toward the fluorescent glass.

If the spectral curve is not adequate, adjust

the probe position two or three turns and select the RE-SAMPLE button to repeat the calibration process.

Repeat steps 7 and 8 as needed to achieve a

smooth spectral curve. When an adequate spectral curve is displayed, set the number of scans to 10, select RE-SAMPLE, then select CONTINUE.

10. Press the STORE button to save the photometric calibration scan for use in the configuration file. The selected channel photometrics are now calibrated.

11. Remove the probe from the SURE calibration assembly and mount the probe in the process stream according to company guidelines.

12. Repeat steps 1 through 11 to calibrate the photometrics of another channel.

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Page 41

SECTION IV. OPERATION

4-1. OVERVIEW

This section covers analyzer operation. Before attempting to operate the analyzer, thoroughly read and understand the information provided in this Instruction Bulletin.

4-2. SOFTWARE USAGE CONVENTIONS

The following paragraphs describe how to select menu options and change operator-selected equipment parameters.

NOTE

“Display” and “window” refer to graphic and text overlays that appear on the CRT.

a. Selecting a Menu Item.

the pointer over the desired menu item, usually a button, and click once with the left mouse button to select the menu item.

b. Changing a Setup Variable.

equipment setup variable, highlight the existing data block and type in the new value or use the displayed arrow buttons to increase or decrease the value shown.

To toggle an on/off setting, click the on/off switch image once with the left mouse button.

c. Screen Options.

found on most histogram screens. Their functions are as follows:

This button zooms the image to in-

clude the extents of the x-axis. The switch displayed beside the button locks and unlocks this zoom selection.

Use the mouse to move

To change an

The following buttons are

This button zooms the image to in-

clude the extents of the y-axis. The switch displayed beside the button locks and unlocks this zoom selection.

This button allows the operator to

change the format and precision of the x-axis values displayed.

This button allows the operator to

change the format and precision of the y-axis values displayed.

This button allows the operator to

choose from the following zoom selections:

(a)

(b)

(c)

(d)

(e)

fault icon. The operator cannot zoom or scroll using this icon.

scroll the display.