Rosemount RAMAN Process Analyzer-Rev 1.0 Manuals & Guides

Download

RAMAN PROCESS ANALYZER

Instruction Bulletin IB-103-300 Rev 1.0

HIGHLIGHTS OF CHANGES

Effective May, 2001 Rev. 1.0

PAGE SUMMARY

Throughout Added information as needed to meet CE mark certification.

5-1 through 5-5 Added Analog Output section to manual.

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.

IB-103-300

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.

Highlights an essential operating procedure, condition, or statement.

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

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.

IB-103-300

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.

IB-103-300

iii

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.

IB-103-300

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

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-

tative for clarification. Refer to the technical support hotline on page ix.

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

product.

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

nance of the product.

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

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

• This product must only be used in the manner prescribed by Rosemount. To ensure

proper performance, use qualified personnel to install, operate, update, program, and maintain this product.

• The environmental conditions in which this equipment is designed to operate is

within an ambient operating temperature of 32° to 122°F (0° to 50°C) at 20 to 100% relative humidity.

• There are no operator-replaceable parts.When replacement parts are required, en-

sure that the qualified people use replacement 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.

• To prevent electrical shock and personal injury, ensure that all equipment doors are

closed and protective covers are in place. Only qualified persons are authorized to open equipment doors and remove protective covers for equipment service or maintenance.

IB-103-300

WHAT YOU NEED TO KNOW

BEFORE INSTALLING AND WIRING A ROSEMOUNT

RAMAN PROCESS ANALYZER

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

Write the line voltage here __________ .

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

3. 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....

1. You are familiar with the Raman Process Analyzer installation requirements.

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

3. A configuration set exists for the process to be analyzed.

4. 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.

IB-103-300

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.

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

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

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

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

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

II, paragraph 2-3.e.

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

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

to Section II, paragraphs 0 and 2-6.

8. Turn power on to the analyzer cabinet.

9. 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, para-

graph 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.

IB-103-300

vii

QUICK REFERENCE GUIDE

RAMAN PROCESS ANALYZER SOFTWARE

Select a configuration set

1. Close the MAIN program.

2. Start the MAINCFG program.

3. Select SYSTEM CONFIGURATION.

4. Select ENABLE A CONFIGURATION.

5. Select the configuration file to be used.

Calibrate the analyzer

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

to be monitored.

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

foreign material.

3. Mount the probe in the SURE calibration kit.

4. Select PHOTOMETRIC CALIBRATION from the MAIN Setup Menu screen.

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

Click the CONTINUE button.

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

click CONTINUE.

7. 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.

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

Press RE-SAMPLE, then press CONTINUE.

9. 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.

IB-103-300

viii

Technical Support Hotline:

For assistance with technical problems, please call the Customer Support Center (CSC).

Phone: 1-800-433-6076

In addition to the CSC, you may also contact Emerson Process Management North American Response Center (NARC). North American Response Center 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@emersonprocess.com

World Wide Web: www.processanalytic.com

Manufacturer’s Address

Rosemount Analytical Inc. 1201 N. Main Street Orrville, Ohio 44667

IB-103-300

ix/x

TABLE OF CONTENTS

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. Communication 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. ANALOG OUTPUT .............................................................................................................5-1

5-1. Introduction ..................................................................................................................... 5-1

5-2. Analog Output Scaling Setup ....................................................................................... 5-1

5-3. Access The Scaling Setup Screen................................................................................5-1

5-4. Save (or Replace) Configuration..................................................................................5-3

5-5. How Scaling is Applied................................................................................................... 5-3

5-6. Analog Output Diagnostic Screen................................................................................ 5-4

5-7. Accessing the Diagnostic Screen..................................................................................5-4

5-8. Concentration Values ......................................................................................................5-5

5-9. Outputs ............................................................................................................................5-5

Section VI. Preventive Maintenance .....................................................................................................6-1

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

6-2. Cleaning ..........................................................................................................................6-1

Section VII. Troubleshooting.................................................................................................................. 7-1

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

7-2. Alarm Messages .............................................................................................................7-1

7-3. Troubleshooting ..............................................................................................................7-1

Section VIII. Service ................................................................................................................................8-1

8-1. General ............................................................................................................................8-1

8-2. Analyzer Component Replacement............................................................................... 8-1

8-3. Analyzer Calibration ......................................................................................................8-6

IB-103-300

xi/xiv

TABLE OF CONTENTS (Continued)

Section Page

Section IX. Replacement Parts...............................................................................................................9-1

Section X. Returning Equipment to the Factory .............................................................................10-1

10-1. Returning Equipment....................................................................................................10-1

Glossary..........................................................................................................................................................1

Index............................................................................................................................................................... 1

LIST OF ILLUSTRATIONS

Figure Page

Figure 1-1. Typical Raman Process Analyzer 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

IB-103-300

xii

LIST OF ILLUSTRATIONS (Continued)

Figure Page

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

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 5-1. RAMAN PROCESS ANALYZER Screen ........................................................................5-1

Figure 5-2. PASSWORD VERIFICATION Screen ..............................................................................5-2

Figure 5-3. OPERATOR MENUS Screen.............................................................................................5-2

Figure 5-4. SETUP MENUS Screen...................................................................................................... 5-2

Figure 5-5. ANALOG OUTPUT SCALING SETUP Screen ............................................................... 5-2

Figure 5-6. SAVE Prompt ......................................................................................................................5-3

Figure 5-7. DIAGNOSTIC MENUS Screen..........................................................................................5-4

Figure 5-8. ANALOG OUTPUT DIAGNOSTIC Screen ..................................................................... 5-4

Figure 7-1. Raman Troubleshooting Flowchart #1.................................................................................7-2

Figure 7-2. Raman Troubleshooting Flowchart #2.................................................................................7-3

Figure 7-3. Raman Troubleshooting Flowchart #3.................................................................................7-4

Figure 8-1. Fuse Locations .....................................................................................................................8-2

Figure 8-2. CCD Camera Thermocouple Removal.................................................................................8-2

Figure 8-3. Laser Cooling Fan Removal.................................................................................................8-3

Figure 8-4. Laser Removal .....................................................................................................................8-4

LIST OF TABLES

Table Page

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

Table 9-1. Replacement Parts for the Raman Process Analyzer ...........................................................9-1

IB-103-300

xiii/xiv

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

IB-103-300

1-1

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

IB-103-300

1-2

SPLITTER

27320024

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.

b. 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.

c. 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.

d. 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.

e. 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.

f. 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.

g. Analyzer Outputs. The available analyzer out-

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

h. 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.

IB-103-300

1-3

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

IB-103-300

1-4

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 VAC, 60 Hz or 230 VAC, 50 Hz

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

Electrical Classification ................................................................... General Purpose or Class I, Div II, Type “Z” Purge

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

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

1-5. CERTIFICATIONS

Emerson Process Management has satisfied all obligations coming from the European legislation to harmonize the product requirements in Europe.

IB-103-300

1-5/1-6

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

IB-103-300

2-1

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.

2. 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.

4. If compatible with the process, apply a suit-

able sealant around the seal diameter of the probe.

5. 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

IB-103-300

Figure 2-3. Raman Probe

2-2

ENDPLATE

4. 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 conduit; 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

IB-103-300

2-3

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

IB-103-300

2-4

2. 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.

2-4. ELECTRICAL INSTALLATION

Use the following procedures to supply electrical power to the analyzer. Input power to the module can be either 115 VAC, 60 Hz or 230 VAC, 50 Hz, single phase. A 15 amp, 115 VAC or 220 VAC electrical circuit breaker is required.

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.

3. Repeat step 2 for each probe connector and

mating filter and/or cable connector.

4. 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.

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.

a. Input Voltage Selector. The input voltage se-

lection 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. The minimum requirement for the electrical supply line is a 3-wire, 10 amp, 220 VAC conductor. Refer to Figure 2-8 for the location of the conduit ports.

AIR

SUPPLY

60 PSI

(414 kPa)

PRESSURE

REGULATOR

WATER

FILTER

PRESSURE

GAGE

OIL

FILTER

Figure 2-7. Air Supply Hookup

ANALYZER

CABINET

27320026

Figure 2-8. Conduit Ports

IB-103-300

2-5

c. Cabinet Power.

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

Lock out the cabinet power source at the main disconnect. Connect cabinet electrical power at the input power terminal (Figure 2-9). A green and yellow protective earth ground conductor equal in size to the in-coming main supply conductors must be connected at the ground terminal.

NOTE

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

To ensure safe operation, connection to the main electrical power supply must be made through a 115 or 220 VAC, 15 amp circuit breaker that will disconnect all current-carrying conductors during a fault situation. The power circuit should also include a mechanically operated isolating switch or other means of disconnecting the supply near the analyzer cabinet. Circuit breakers and switches must comply with recognized standards.

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

IB-103-300

2-6

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.

1. Verify that the analyzer cabinet is securely

mounted out of the path of direct sunlight.

2. 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.

3. Verify the Raman probes are properly in-

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

4. 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.

2. 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.

IB-103-300

2-7/2-8

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:

a. Select NETSUPPORT LOCAL CONTROL

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

b. 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.

c. 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

27320033

Figure 3-2. KNOWN CLIENTS Screen

d. 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.

e. The program will display a message informing

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

27320032

Figure 3-1. NETSUPPORT CONTROL Screen

f. 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 commu-

nicate with multiple Raman Analyzers along a network. When provided, pc ANYWHERE also supports modem communication.

IB-103-300

3-1

Figure 3-3. MAINCFG Program Structure

IB-103-300

3-2

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. Before

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

(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

IB-103-300

3-3

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.

2 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

IB-103-300

3-4

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.

5 ACCEPT. Clicking on the AC-

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

IB-103-300

3-5

6 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.

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.

(d) QUIT. Clicking on the QUIT button

returns you to the MAIN screen.

27320014

Figure 3-11. SYSTEM CONFIGURATION

MENU Screen

3. 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.

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

IB-103-300

3-6

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.

4. 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.

5. ABOUT . Clicking the ABOUT button

displays the program information, such as version and date.

6. END. Clicking on the END button exits the

MAINCFG program.

IB-103-300

3-7

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:

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.

• 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

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

IB-103-300

3-8

27320019

b. Calibration. Calibrate the analyzer according to

the following procedure:

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

1. 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.

2. 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.

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

6. The analyzer will display a graph of the

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

7. 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.

8. 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.

9. 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 photo-

metric calibration scan for use in the configuration file. The selected channel photometrics are now calibrated.

11. Remove the probe from the SURE calibra-

tion 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.

IB-103-300

3-9/3-10

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. Use the mouse to

move 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. To change an

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.

This button zooms the image to include 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)

This button allows the op-

erator to select any area to zoom.

This button allows the operator to zoom on a specified x-axis area.

This button allows the operator to zoom on a specific y-axis area.

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

c. Screen Options. The following buttons are

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

This button zooms the image to include the extents of the x-axis. The switch displayed beside the button locks and unlocks this zoom selection.

IB-103-300

4-1

(d)

(e)

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

scroll the display.

This button allows the op-

erator to zoom in.

This button allows the op-

erator to zoom out.

This button sets the cursor to its de-

This button allows the operator to

Figure 4-1. MAIN Program Structure

IB-103-300

4-2

Figure 4-2. RAMAN PROCESS ANALYZER Screen

27320003

4-3. MAIN PROGRAM STARTUP

You can start the software by selecting the MAIN program from the Windows™ START menu. The program structure is illustrated in Figure 4-1.

a. Main Screen. The RAMAN PROCESS

ANALYZER screen (Figure 4-2) displays process information and a histogram chart for the specified process components. Up to eight process components can be displayed at one time.

Clicking on the OPERATOR MENUS button displays the PASSWORD VERIFICATION screen (Figure 4-3). Enter a valid password and

click on the ACCEPT button. Clicking on the QUIT button returns you to the RAMAN PROCESS ANALYZER screen.

27320004

Figure 4-3. PASSWORD VERIFICATION Screen

IB-103-300

4-3

27320069

Figure 4-4. OPERATOR MENUS Screen

When a valid password has been entered, the OPERATOR MENUS screen (Figure 4-4) displays with the following menu options:

1. SETUP. Clicking on the SETUP button

displays the SETUP MENUS screen (Figure 4-5). From this screen, you can select from the following menu items:

trum for each scan requested. The Logging Period box indicates how often the analyzer saves a scan. To save every other scan, enter 2.

the OUTPUT SCALING button allows you to set up the range and scale of the analog outputs. For more information on using the OUTPUT SCALING option, refer to section 5 of this manual.

(d) BACK. Clicking on the BACK but-

ton returns you to the OPERATOR MENUS screen.

(a) ZERO CLIP. This button displays

the screen in Figure 4-6. This screen allows you to configure the display on the MAIN screen to either include or exclude negative numbers. When disabled, the MAIN screen will display negative numbers. Click on the OK button to return to the SETUP MENUS screen.

(b) DATA LOGGING. Clicking on this

button displays the RAMAN ANALYZER DATALOG UTILITY screen (Figure 4-7). This screen allows you to save compositional and spectral data. The concentration log saves the concentration levels of the monitored process as a .DAT file for further analysis. One file will contain all the concentration data.

The process log saves the process spectra. The analyzer will create a new file containing the process spec

Figure 4-5. SETUP MENUS Screen

27320022

Figure 4-6. ZERO CLIP OPTION Screen

IB-103-300

4-4

Figure 4-7. RAMAN ANALYZER DATALOG UTILITY Screen

27320005

2. GRAB SCAN. Clicking the GRAB

SCAN button (Figure 4-8) displays the GRAB SCAN MENUS screen in Figure 4-9. The GRAB SCAN MENUS screen provides the following functions:

27320070

Figure 4-8. OPERATOR MENUS Screen

(a) GRAB SCAN. Clicking on the

GRAB SCAN button displays the GRAB SCAN screen shown in Figure 4-10. The GRAB SCAN screen allows you to capture and save scans.

27320006

Figure 4-9. GRAB SCAN MENUS Screen

IB-103-300

4-5

(b) <<<. This button returns you to the

OPERATOR MENUS screen.

Clicking on the ACQUIRE button displays the SAVE AS screen shown in Figure 4-11. Use the Folders box to select the desired drive and file folder for scan data storage. In the File Name box, enter a name to identify the scan. Use the Save file as type box to select the file delimiter. When the file is properly named, click on the OK button. When OK is selected, the analyzer begins the grab and save process. The analyzer grabs the number of scans entered in the Replicates box. Clicking on the QUIT button returns you to the GRAB SCAN MENUS screen.

Figure 4-10. GRAB SCAN Screen

27320007

Note

The program will not allow you to Quit while the analyzer is collecting spectral data.

Figure 4-11. SAVE AS Screen

IB-103-300

4-6

27320008

shown in Figure 4-14. The VIEW CALCULATIONS screen displays the calculations performed on the process and diamond data.

The Process spectrum is blue in color and the diamond spectrum is red in color.

Figure 4-12. OPERATOR MENUS Screen

27320071

3. DIAGNOSTICS. Clicking on the DIAG-

NOSTICS button (Figure 4-12) brings up the DIAGNOSTIC MENUS screen shown in (Figure 4-13). The following menu items are displayed:

(a) VIEW CALCULATIONS. Clicking

on the VIEW CALCULATIONS button displays the screen

27320067

Figure 4-13. DIAGNOSTIC MENUS Screen

Figure 4-14. VIEW CALCULATIONS Screen

IB-103-300

4-7

27320010

The following items are displayed in the VIEW CALCULATIONS screen:

1 Raw Data. Displays the raw Ra-

man spectrum and the raw diamond spectrum.

2 Dark Corrected. Shows the proc-

ess and diamond spectra after dark current correction.

3 Diamond De-fluoresced. Shows

the process and diamond spectra without the fluorescence effects.

11 Camera Comms Failures. Shows

how many times the analyzer’s computer lost communication with the CCD camera.

Click on the QUIT button (Figure 4-14) to return to the DIAGNOSTIC MENUS screen.

(b) VIEW ANALOG SIGNALS. This

button (Figure 4-15) displays the ANALOG INPUT MEASUREMENTS screen in Figure 4-16. This screen displays the following items:

4 X-Axis Corrected. Displays the

process and diamond spectra after the x-axis calibration correction.

5 Photometrically Compensated.

Displays the process and diamond spectra after radiometric calibration corrections.

Wavenumbers. Displays the process and diamond spectra after converting the x-axis values from wavelength to wavenumbers.

7 Standardized Spectrum. Shows

the convolution-corrected process spectrum. The diamond spectrum is compared to a theoretical diamond spectrum in the Fourier domain to compute a transfer formula. The process spectrum is then convolved with the transfer formula.

8 SNV Standard Spectrum. Shows

the process spectrum with a standard normal variant correction.

1 Laser Current (Amps). Displays

the laser drive current usage.

2 Laser Power (Watts). Displays

the output of the laser.

3 Laser Thermistor (Ohms). Shows

the laser diode temperature.

4 Instrument Temperature (°C).

Displays the cabinet temperature.

5 QUIT. Returns you to the

DIAGNOSTIC MENUS screen.

Diamond Ref (nm). Displays the peak of the diamond spectrum.

10 Laser Position (nm). Shows the

calculated peak position of the Raman laser.

IB-103-300

27320068

Figure 4-15. DIAGNOSTIC MENUS Screen

4-8

Figure 4-16. ANALOG INPUT MEASUREMENTS Screen

27320011

Clicking the VIEW DIGITAL I/O STATE button on the DIAGNOSTIC MENUS screen (Figure 4-15) displays the DIGITAL I/O STATE screen (Figure 4-17).

Figure 4-17. DIGITAL I/O STATE Screen

This screen displays the current status of the digital I/O ports. You can turn the I/O ports on and off by clicking on the designated port button. Click on the QUIT button to return to the DIAGNOSTICS MENUS screen.

27320012

IB-103-300

4-9

(d) SMART DIAGNOSTICS. Clicking

on the SMART DIAGNOSTICS button on the DIAGNOSTIC MENUS screen displays the SMART DIAGNOSTICS MENUS screen (Figure 4-18). The following menu items are displayed:

1 Analyzer Software Status. This

button displays the ANALYZER SOFTWARE STATUS screen in (Figure 4-19).

The ANALYZER SOFTWARE STATUS screen displays the software functions and the status of each function.

Clicking on the OK button displays the SMART DIAGNOSTICS MENUS screen.

27320044

Figure 4-18. SMART DIAGNOSTICS MENU Screen

Figure 4-19. ANALYZER SOFTWARE STATUS Screen

IB-103-300

4-10

27320039

2 Analyzer Alarms Status. Clicking

on the ANALYZER ALARMS STATUS button (Figure 4-18) displays the status screen shown in Figure 4-20.

The following functions are monitored:

Laser Power (Watt). Monitors the power consumption during laser operation. The upper and lower alarm limits can be set.

Laser Current (Amp). Monitors the laser amperage use during operation. The upper and lower alarm limits can be set.

Laser Thermistor (Ohm). Monitors the laser temperature. The upper and lower limits can be set.

Residual Limit. Monitors the calculated residual distance of the spectrum. The upper alarm limit can be set.

Mahalanobis Distance. Monitors the calculated Mahalanobis distance of the spectrum. The upper alarm limit can be set.

Cabinet Temperature (degrees C). Monitors the temperature in the cabinet. The upper alarm limit can be set.

Alarm Limits / Alarm Status: This screen displays the alarm settings for each monitor function (red is the upper limit and blue is the lower limit). To change a setting, use an authorized password.

Figure 4-20. ANALYZER ALARMS STATUS Screen

IB-103-300

4-11

27320040

27320052

Figure 4-21. PASSWORD VERIFICATION Screen

When a valid password is entered, the ALARM LIMITS SET/ FREEZE or ALARM STATUS ENABLED/DISABLED switch can be used. To change a switch position, select the switch image.

The ALARM LIMITS switch must be in the SET position to modify the alarm settings and in the FREEZE position to exit the status screen.

Clicking on the PASSWORD AUTHORIZATION button displays the screen in Figure 4-21.

Enter a valid password and click the ACCEPT button to enter the password.

Clicking on the QUIT button returns you to the ANALYZER ALARMS STATUS screen.

Analyzer alarm monitoring can be disabled by positioning the ALARM STATUS switch to the DISABLED position.

Clicking on the TRENDS button displays the TRENDS screen (Figure 4-22), a graphical history of the monitored functions.

Clicking BACK TO ALARMS PANEL returns you to the ANALYZER ALARMS STATUS screen.

Figure 4-22. TRENDS Screen

IB-103-300

4-12

27320053

27320044

Figure 4-23. SMART DIAGNOSTICS MENU Screen

3 Analyzer Performance Measures.

Clicking ANALYZER PERFORMANCE MEASURES (Figure 4-23) displays the screen shown in Figure 4-24. Predicted averages for the following functions are displayed:

Residual. This display is a calculated difference of the process spectrum and the “reference” spectrum. The calculation is performed and the resulting difference is displayed.

Mahalanobis Distance. This display is a calculated difference of the process spectrum and the “reference” spectrum. The calculation is performed and the resulting difference is displayed.

Residual Spectrum. The display is the residual spectrum after the calculation process is completed.

The display can be used to troubleshoot spectrum calculations.

The hardware performance portion displays the average Laser Wavelength (nm) and the number of comm failures the analyzer has detected.

Clicking on the BACK button will return you to the SMART DIAGNOSTICS MENUS screen.

Figure 4-24. PERFORMANCE MEASURES Screen

IB-103-300

4-13

27320041

Figure 4-25. DARK CURRENT & PHOTOMETRIC CORRECTION Screen

27320054

Figure 4-26. CALIBRATION PATH & MODEL Screen

IB-103-300

4-14

27320055

4 Dark Current & Photometric Cor-

rection. Clicking on the DARK CURRENT & PHOTOMETRIC CORRECTION button (Figure 4-23) displays the screen in Figure 4-25. The upper screen display shows the dark current reference and process spectrums.

The lower screen display shows the photometric response to standard material.

Clicking on the OK button returns you to the SMART DIAGNOSTICS MENU screen.

Calibration Path & Model. Clicking this menu button on the SMART DIAGNOSTICS MENU screen displays the CALIBRATION PATH & MODEL screen in Figure 4-26. This screen

displays the calibration set in use and the partial least squares (PLS) iteration number being used in the calculations.

Clicking the BACK button on the CALIBRATION PATH & MODEL screen returns you to the SMART DIAGNOSTICS MENU screen (Figure 4-23).

Cancel. Clicking the CANCEL button of the SMART DIAGNOSTICS MENUS screen returns you to the DIAGNOSTIC MENUS screen (Figure 4-27).

(e) Back. Clicking the Back button in the

DIAGNOSTIC MENUS screen (Figure 4-27) returns you to the OPERATOR MENUS screen (Figure 4-28).

Figure 4-27. DIAGNOSTICS MENUS Screen

27320068

27320020

Figure 4-28. OPERATOR MENUS Screen

IB-103-300

4-15

Figure 4-31 GRAB DARK SCAN Screen

6. GRAB DARK SCAN. Clicking on the

GRAB DARK SCAN button on the OPERATOR MENUS brings up the GRAB DARK SCAN Screen (Figure 4-31).

27320023

27320045

Figure 4-29. SET SECURITY Screen

4. SET SECURITY. Clicking the SET SE-

CURITY button on the OPERATOR MENUS screen (Figure 4-28), displays the SET SECURITY screen (Figure 4-29). This screen allows you to set the screen availability for the password levels. If the screen box is checked, the screen is accessible using the current password level.

SET PASSWORDS. Clicking the SET PASSWORDS button on the OPERATOR MENUS screen (Figure 4-28), displays the SET PASSWORDS screen (Figure 4-30). This screen allows you to set the passwords for the specific access levels. You must enter the old password prior to entering the new password.

This screen allows you to grab a new dark scan without having to exit the program and start the MAINCFG program. The analyzer will continuously grab and display a new dark scan every 1 to 2 minutes. To save a dark scan, click on the STORE button. To return to the OPERATOR MENUS screen, click on the QUIT button.

ABOUT. Clicking on the ABOUT button on the OPERATOR MENUS screen displays the program ABOUT screen (Figure 4-32). This screen identifies the name, date, and version of the program.

8. QUIT. Clicking on the QUIT button on the

OPERATOR MENUS screen returns you to the RAMAN PROCESS ANALYZER screen.

Figure 4-30. SET PASSWORDS Screen

27320046

IB-103-300

27320047

Figure 4-32. ABOUT Screen

4-16

SECTION V. ANALOG OUTPUT

5-1. INTRODUCTION

The goal of this manual is to provide the reader with the necessary information to operate the ANALOG SCALING SETUP screen and give a description of the ANALOG OUTPUT DIAGNOSTIC screen. These features were added to the existing LabVIEW program for the Raman Analyzer at Rosemount Analytical in Orrville, Ohio.

5-2. ANALOG OUTPUT SCALING SETUP

The ANALOG OUTPUT SCALING SETUP screen is used to define the numerical range that will represent linearly 4 to 20 mA at the output terminals of the National Instruments AT-AO-6/10 analog output card. The Range is defined as

Range = Span – Zero

where Zero is either zero or another positive value chosen to represent 4 mA and Span is a positive value chosen to represent 20 mA. The screen also provides for entering a Correction Factor, which is an arbitrary positive value multiplied to the incoming raw data value before scaling and being sent to an output terminal. Likewise an Offset value can be entered, positive or negative, and is added or subtracted to the incoming raw data value before scaling and being sent to an output terminal. The Range, Cor- rection Factor, and Offset can be configured inde- pendently for each of the analog output card’s output terminals.

5-3. ACCESS THE SCALING SETUP SCREEN

In order to access the ANALOG OUTPUT SCALING SETUP screen, first click on the OPERATOR MENUS button found at the bottom of the RAMAN PROCESS ANALYZER screen, Figure 5-1.

Figure 5-1. RAMAN PROCESS ANALYZER Screen

IB-103-300

5-1

The PASSWORD VERIFICATION window, Figure 5-2 will open and prompt the user for a password.

Figure 5-2. PASSWORD VERIFICATION Screen

Depending on how password security is set for the program, the user may or may not need an appropriate password to access the ANALOG OUTPUT SCALING SETUP screen. Setting password security is beyond the scope of this manual and will not be discussed here.

After entering a password, the OPERATOR MENUS window, Figure 5-3, will open. Select SETUP from the menu to display the SETUP MENUS screen.

From the SETUP MENUS window, Figure 5-4, select OUTPUT SCALING to bring up the ANALOG OUTPUT SCALING SETUP screen shown in Figure 5-5.

Figure 5-3. OPERATOR MENUS Screen

Figure 5-4. SETUP MENUS Screen

Figure 5-5. ANALOG OUTPUT SCALING SETUP Screen

IB-103-300

5-2

Each set of output terminals for the output card is represented on the ANALOG OUTPUT SCALING SETUP screen and the current configuration values will be displayed. The default values will be displayed as shown in figure 2-5 until they are changed. If the user wishes to change a value, simply double click on the value with the mouse cursor, type in the new value and press Enter. When the values are changed they will remain in memory as long as the program is running. If the program is stopped, the values are lost and will revert to their default values the next time the program is started. To avoid losing a configuration, the values can be stored to a file, which is described in Section 2.2. When finished viewing the ANALOG OUTPUT SCALING SETUP screen, click on the BACK button to go back to the SETUP MENUS screen.

5-4. SAVE (OR REPLACE) CONFIGURATION

This feature is useful if the user wishes to store a configuration so that the values are not lost on a power outage or some other situation that causes the program to stop running. After entering the desired setup values, click on SAVE CONFIGURATION to save the current values to a configuration file. A prompt window will pop up asking the user to verify saving the configuration as shown in Figure 5-6.

5-5. HOW SCALING IS APPLIED

Using Output 1 with the default values shown in Figure 5-5 as an example, the raw data input value is taken from the prediction model where it will first be multiplied by the CORRECTION FACTOR, in this case a factor of 1. Next, the OFFSET value is added, in this case zero. Finally, the adjusted value is linearly scaled between 0 and 100 where 0 represents 4 mA and 100 represents 20 mA respectively. A general formula for the scaling is:

Equation 2-1:

Y = ((X(Correction Factor) + Offset) – Zero)10

Span - Zero

Where:

Y = Scaled output value (0-10 volts) X = Raw data input value from the

prediction model

So for the example:

Y= ((X(1) + 0) – 0)10

100 – 0

when X = 50, then:

Figure 5-6. SAVE Prompt

Clicking OK will save the current configuration. The next time the program is started, the configuration will be read from the file and the values will be loaded into memory. To replace a configuration, enter the desired values and click on SAVE CONFIGURATION to save the new values.

Y = ((50(1) + 0) – 0)10 = 5

100-0

The National Instruments AT-AO-6/10 analog output card will only interpret values for output in terms of volts from 0-10. The analog card then performs the conversion from voltage to milliamps. For this example the value 5 will be converted to 12 mA at the output card’s terminals.

See the AT-AO-6/10 User Manual for more information about the analog output card. If the scaled output value is outside of the defined range, the output will be raised to either 4 or 20 mA depending on whether the value is less than the zero or greater than the span.

IB-103-300

5-3

5-6. ANALOG OUTPUT DIAGNOSTIC SCREEN

The ANALOG OUTPUT DIAGNOSTIC screen is used to monitor the raw data input values from the prediction model and the values being sent to the output terminals after scaling is applied. No data can be entered on this screen; it can only be used to view what data is coming in, what the scaling setup is, and what values are being sent to the output card for each output.

5-7. ACCESSING THE DIAGNOSTIC SCREEN

To access the ANALOG OUTPUT DIAGNOSTIC screen, click on the OPERATOR MENUS button at the bottom of the RAMAN PROCESS ANALYZER screen, Figure 5-1.

The PASSWORD VERIFICATION window, Figure 5-2, will open and prompt for a password. After entering a password, the OPERATOR MENUS window, Figure 5-3, will open.

Select DIAGNOSTICS. The DIAGNOSTIC MENUS screen, Figure 5-7, will open. Select VIEW ANALOG OUTPUTS. The ANALOG OUTPUT DIAGNOSTIC screen, Figure 5-8, will open.

Figure 5-7. DIAGNOSTIC MENUS Screen

Figure 5-8. ANALOG OUTPUT DIAGNOSTIC Screen

IB-103-300

5-4

5-8. CONCENTRATION VALUES

The four channels displayed on the left half of the screen represent the corresponding measuring probes. The column of numbers under the label channel displays the incoming raw data values from the prediction model for each probe. The column of numbers under the label adjusted dis- plays the value directly to its left after scaling has been applied.

5-9. OUTPUTS

The output section located on the right half of the screen displays information about each output of the analog output card. The AT-AO-6/10 has a maximum of 10 outputs, which are labeled 1 thru 10 on the screen. For each output, a row of numbers displays the following information about an output:

• Volts Scaled voltage (0-10) sent to the

analog output card to be converted to milliamps.

• mA Equivalent current at the physical

output terminals of the analog output card.

• Zero Number chosen to represent 4

mA in the scaling range.

• Span Number chosen to represent 20

mA in the scaling range.

• CF Correction factor multiplied by

the raw data input value

• Offset Offset added to the raw data in-

put value

The Zero, Span, CF, and Offset values are read from the analog setup configuration.

When finished viewing the ANALOG OUTPUT DIAGNOSTIC screen, click the OK button to return to the DIAGNOSTIC MENUS screen.

IB-103-300

5-5/5-6

SECTION VI. PREVENTIVE MAINTENANCE

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

6-1. GENERAL

This section covers the routine preventive maintenance procedures for the Raman Process

Analyzer under normal operating conditions. In most applications, the maintenance required for the analyzer is minimal.

6-2. CLEANING

In most applications, cleaning of the analyzer is not required. In facilities where accumulations of dust and/or chemical corrosives may impair equipment life, remove loose particulates with a soft-bristle brush. To remove soil deposits, clean the outer surfaces of the analyzer with a lint-free cleaning cloth dampened with mild soap and warm water.

IB-103-300

6-1/6-2

SECTION VII. TROUBLESHOOTING

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

7-1. GENERAL

This section describes how to identify and isolate equipment failures that may occur during operation of the Raman Process Analyzer. These troubleshooting procedures are designed for use by persons trained to operate the Raman Process Analyzer.

Operator level corrective actions are limited to adjusting the laser amperage and replacement of the items listed below. If equipment repair involves more than replacement of these components or laser current adjustment, notify your Rosemount Service Representative.

descriptive explanation of each alarm, refer to Section 4-3, Main Program Startup.

a. Laser Power (Watt). Monitors the watt usage

of the laser. This alarm may indicate a problem with the laser or fiber optic cables.

b. Laser Current (Amp). Monitors the amp usage

of the laser. This alarm may indicate a problem with the laser.

c. Laser Thermistor (Ohm). Monitors the tem-

perature of the laser (displayed in ohms). The upper alarm indicates a cooling failure within the system. The lower limit indicates the laser is not up to operating temperature.

d. Residual Limit. Monitors the residual calcu-

lated spectrum. The displayed number indicates the distance from the “reference” spectrum. The high limit indicates a calculated spectrum outside the set range.

• fuses

•

fiber optic cables

• CCD camera thermocouple

• 12 VDC cooling fans

• laser

7-2. ALARM MESSAGES

An alarm acknowledgement message is displayed in the control software whenever an alarm condition is detected. The message is only to tell the operator an alarm condition exists, it is the operator’s responsibility to access the ALARM STATUS screen to determine what the cause of the alarm is.

The ALARM SCREEN will indicate the alarm by flashing the specific alarm display with red.

The following is a list of the processes monitored by the Raman Process software. A brief description of the alarm and possible causes for its occurrence is provided for each alarm. For a more

e. Mahalanobis Distance. Monitors the Mahala-

nobis calculated spectrum. The displayed number indicates the distance from the “reference” spectrum. The high limit indicates a calculated spectrum outside the set range.

f. Cabinet Temperature (deg C). Monitors the

operating temperature of the cabinet enclosure. The upper alarm indicates a cooling failure and overheating of the cabinet. The lower limit indicates the cabinet is not at operating temperature.

7-3. TROUBLESHOOTING

Figure 7-1, Figure 7-2, and Figure 7-3 provide additional troubleshooting guides for detecting the source of equipment faults in the Raman Process Analyzer system. The fault conditions are general. The faults may not be determined by an alarm condition, or reported by an alarm message. If any fault should occur, the condition will be apparent while monitoring or operating the Raman Process Analyzer.

IB-103-300

7-1

NO MAIN SCREEN IS

DISPLAYED WHEN POWER

IS TURNED ON

ALL

COMPONENTS

TURNED

ON?

YES

TURN ANALYZER

COMPONENTS ON

COMPONENT

FUSES

OK?

YES

CORRECT

POWER AT

POWER

INPUT?

YES

CALL A CERTIFIED

ROSEMOUNT FIELD

SERVICE REPRESENTATIVE

REPLACE FUSES

CORRECT POWER

INPUT PROBLEM

Figure 7-1. Raman Troubleshooting Flowchart #1

IB-103-300

7-2

NO PROCESS

SPECTRUM DISPLAYED

ALARMS

PRESENT?

YES

CORRECT ALARM

CONDITION

IS DIAMOND

REFERENCE DISPLAYED?

IS DIODE

LASER POWER

ON?

TURN POWER TO DIODE

LASER ON

IS DIAMOND

REFERENCE DISPLAYED?

YES

YES YES

PERFORM LASER CURRENT

ADJUSTMENT PROCEDURE

REPLACE DIODE LASER

IS PROCESS

SPECTRUM

DISPLAYED?

TROUBLESHOOTING

COMPLETE

NO NO

CALL A CERTIFIED

ROSEMOUNT FIELD

SERVICE REPRESENTATIVE

Figure 7-2. Raman Troubleshooting Flowchart #2

IB-103-300

7-3

27320062

IS CCD

CAMERA POWER

ON?

IS CCD

CAMERA FUSE

BLOWN?

CALL A CERTIFIED

ROSEMOUNT FIELD

SERVICE REPRESENTATIVE

YES

CALL ROSEMOUNT FOR

IS CCD

CAMERA SHUTTER

OPERATING?

NONO

A REPLACEMENT CCD

CAMERA HEAD.

REPLACE CCD CAMERA

FUSE

Figure 7-3. Raman Troubleshooting Flowchart #3

YESYES

CALL A CERTIFIED

ROSEMOUNT FIELD

SERVICE REPRESENTATIVE

27320063

IB-103-300

7-4

SECTION VIII. SERVICE

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

8-1. GENERAL

This section covers customer level service for the Raman Process Analyzer. Only persons fully trained and qualified to repair electronic equipment and laser devices are authorized to maintain and service the Raman Process Analyzer. Customer level service is limited to the following:

• adjusting laser amperage

• replacing burned out fuses

•

replacing damaged fiber optic cables

• replacing CCD camera thermocouple

•

replacing 12 VDC cooling fans

• replacing the laser

8-2. ANALYZER COMPONENT REPLACEMENT

Turn off electrical power at the main disconnect box before servicing or replacing electronic assemblies or electrical components. Failure to turn off electrical power may result in serious injury or death.

a. Fuse Replacement

1. Turn the analyzer power OFF at the main

disconnect box.

2. Verify that the analyzer cabinet is properly

grounded.

3. Open the analyzer cabinet door.

If analyzer repair involves more than adjusting the laser amperage or replacing one or more of the listed components, notify an authorized Rosemount Service Representative.

The service instructions included here cover the replacement of the above items with the exception of fiber optic cables. Refer to Section III, Installation, for replacement of a fiber optic cable. Refer to the replacement parts listing in Section VII for applicable part numbers.

Install only properly rated fuses in analyzers. Failure to install properly rated fuses may result in severe equipment damage.

Always wear a static band when working inside the analyzer cabinet. Failure to wear a static band could result in severe equipment damage.

IB-103-300

8-1

Always wear a static band when working inside the analyzer cabinet. Failure to wear a static band could result in severe equipment damage.

4. Remove the screws attaching the CCD

camera cooling cover to the CCD camera bracket. See Figure 8-2.

Figure 8-1. Fuse Locations

4. See Figure 8-1 for fuse locations. Remove

the “blown” fuse and replace with a new fuse. Fuse specifications can be found on page 9-1. Install only properly rated fuses.

5. Close and secure the cabinet door.

6. Turn the analyzer power ON at the main

disconnect box.

b. CCD Camera Thermocouple

Turn the analyzer power OFF at the main disconnect box.

2. Verify the cabinet is properly grounded.

Open the analyzer cabinet door.

Figure 8-2. CCD Camera Thermocouple Removal

IB-103-300

8-2

5. Disconnect the thermocouple wire from the

analyzer.

6. Remove the thermocouple retaining screw

from the bottom of the CCD camera.

NOTE Use care not to damage the thermocouple wire when installing the thermocouple retaining screw. Damage to the thermocouple wire could result in false thermocouple readings.

7. Replace the new thermocouple in the CCD

camera. Use care not to damage the thermocouple wire when installing the new thermocouple in the CCD camera.

8. Reconnect the thermocouple wire to the

analyzer.

Install the CCD camera cooling cover.

10. Close and secure the cabinet door.

11. Turn the analyzer power ON at the main

disconnect box.

c. Cooling Fans

The following procedure is for replacing the laser cooling fan. Refer to page 9-1 for fan replacement specifications.

1. Turn the analyzer power OFF at the main

disconnect box.

Verify the cabinet is properly grounded.

3. Open the analyzer cabinet door.

Always wear a static band when working inside the analyzer cabinet. Failure to wear a static band could result in severe equipment damage.

Disconnect the cooling fan power wires from the laser safety device. See Figure 8-3.

Figure 8-3. Laser Cooling Fan Removal

5. Remove the cooling fan from the laser heat

sink by removing the four retaining screws.

6. Install the new cooling fan to the laser heat

sink and secure in place with the four retaining screws.

IB-103-300

8-3

7. Connect the cooling fan power to the laser

safety device.

8. Close and secure the cabinet door.

9. Turn the analyzer power ON at the main

disconnect box.

d. Laser Replacement

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

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

1. Turn the analyzer power OFF at the main

disconnect box and lock out the power source.

Verify the cabinet is properly grounded.

Open the analyzer cabinet door.

Always wear a static band when working inside the analyzer cabinet. Failure to wear a static band could result in severe equipment damage.

4. Disconnect the MPT, MPL, and laser cool-

ing fan leads from the laser safety device. See Figure 8-4.

Figure 8-4. Laser Removal

5. Remove the four retaining nuts securing the

laser module assembly to the cabinet.

6. Disconnect the SMA termination at the la-

ser fiber optic connection.

7. Disconnect the SMA connection at the

laser.

IB-103-300

8-4

8. Carefully remove the laser module assem-

bly from the analyzer cabinet.

4. Turn the analyzer power ON at the main

disconnect box.

9. Remove the four retaining screws securing

the laser to the module assembly.

10. Carefully remove the laser from the module

assembly.

11. Apply a thin film of thermal grease to the mounting surface of the new laser.

12. Secure the laser to the module assembly with the four retaining screws.

13. Place the laser module assembly on the laser module mount in the analyzer cabinet.

14. Connect the laser fiber optics to the laser

and SMA termination.

15. Secure the laser module assembly to the

cabinet with four retaining nuts.

16. Immediately do the Laser Current Adjustment procedure before turning equipment power ON.

5. In the Raman control software, display the

View Analog Signal screen.

6. Adjust VR102 to the fully open position

(clockwise), allowing current to be supplied to the MPL. The screw is located on the Laser Safety Device.

7. Adjust the Laser Current Adjust screw to

the fully open position (clockwise).

8. While monitoring the Laser Current (Amps)

display on the Analog Input Measurements screen, adjust the Laser Current Limit screw clockwise slowly until the desired Laser Current (Amps) measurement +0.25 Amps is displayed.

9. While monitoring the Laser Current (Amps)

display, adjust VR102 screw counterclockwise until the laser current display changes slightly. Try to adjust VR102 to maintain the desired laser current +0.24 Amps displayed on the Laser Current (Amps).

e. Laser Current Adjustment

The laser current must be adjusted after a fiber optic cable change, laser replacement, or a new process is being analyzed.

1. Adjust VR102 on the laser safety device

counterclockwise, closing the current flow from the laser safety device.

Turn the Current Limit Adjust screw to the fully negative position (counterclockwise). The screw is located on the MPL.

Turn the Output Current Adjust screw to the fully negative position (counterclockwise). The screw is located on the MPL.

10. While monitoring the Laser Current (Amps)

display, turn the Laser Current Adjust screw counterclockwise slowly until the desired laser current is displayed on the Laser Current (Amps).

11. If required, allow the system to operate for

at least 15 minutes prior to adjusting the alarm thresholds according to the new laser power settings.

12. Turn the analyzer power OFF at the main disconnect box.

13. Close and secure the cabinet door.

14. Turn the analyzer power ON at the main

disconnect box.

IB-103-300

8-5

8-3. ANALYZER CALIBRATION

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

• Replacement of a fiber optic cable.

• Replacement of a diode laser.

• Adjustment of laser power.

• Change to the process chemistry or

to the configuration set.

If the probe is mounted in the SURE calibration block, click the CONTINUE button. Otherwise, click the QUIT button.

e. Using the PHOTOMETRIC CALIBRATION

screen (page 3-7) enter the number of scans you wish to average.

f. Click the CONTINUE button. The analyzer be-

gins the calibration process.

To calibrate the analyzer:

a. Verify the correct configuration set is loaded for

the process to be monitored.

1. Exit the MAIN program and start the

MAINCFG program.

2. Select the SYSTEM CONFIGURATION

button from the SETUP MENUS screen.

3. Select ENABLE A CONFIGURATION

from the SYSTEM CONFIGURATION screen.

4. Type the name of the configuration file you

will be using to monitor the process.

b. Remove the probe from the process stream.

Clean all liquid and foreign material from the probe.

c. Carefully insert the process probe into the SURE

calibration block. Tighten the nylon nut to secure the probe.

g. The analyzer will take and display a dark scan.

Inspect the scan for ambient light leaks.

h. The analyzer will then take, average, and display

the photometric calculation spectrum.

Inspect the spectrum for quick drops followed by flat spectrum. This indicates the detector is being saturated and the probe must be moved away from the fluorescent glass.

If no signal, or a weak signal is shown on the spectrum, the probe tip must be moved closer to the fluorescent glass.

If the spectrum is inadequate, adjust the probe position as needed.

i. Click the RESAMPLE button. The calibration

process will repeat.

j. When an adequate spectrum is displayed, click

the STORE button. This saves the photometric calibration spectrum for use in the configuration file.

d. From the SETUP MENUS screen, select PHO-

TOMETRIC CALIBRATION. The calibration message will display.

IB-103-300

k. Remove the probe from the calibration block and

mount the probe in the process stream. The analyzer is now calibrated.

8-6

SECTION IX. REPLACEMENT PARTS

Table 9-1. Replacement Parts for the Raman Process Analyzer

FIGURE and INDEX NO. PART NUMBER DESCRIPTION QTY

Figure 1-1 1A99516H01 Oil Filter 2

Figure 1-1 1A99517H01 Water Filter 2

Figure 2-6 1M03533 Laser (L) Filter Assembly 1

Figure 2-6 1M03534 Raman (R) Filter Assembly 1

Figure 8-1 1A97913H02 Fuse, 0.5 Amp, 250 VAC 1

Figure 8-1 1A97913H04 Fuse, 1 Amp, 250 VAC 2

Figure 8-1 1A97913H08 Fuse, 2 Amp, 250 VAC 2

Figure 8-1 1A97913H12 Fuse, 0.1 Amp, 250 VAC 1

Figure 8-1 1A97913H17 Fuse, 0.05 Amp, 250 VAC 1

Figure 8-3 1L04441H01 Cooling Fan, Laser, 12 VDC 1

Figure 8-4 1L04453H01 Laser Module Assembly 1

IB-103-300

9-1/9-2

SECTION X. RETURNING EQUIPMENT TO THE FACTORY

10-1. RETURNING EQUIPMENT

If factory repair of defective equipment is required, proceed as follows:

Complete shipping instructions for return of equipment.

6. Reference the return authorization number.

a. Secure a return authorization number from a

Rosemount Analytical Sales Office or Representative before returning the equipment. Equipment must be returned with complete identification in accordance with Rosemount instructions or it will not be accepted.

In no event will Rosemount be responsible for equipment returned without proper authorization and identification.

b. Carefully pack defective unit in a sturdy box

with sufficient shock absorbing material to insure that no additional damage will occur during shipping.

c. In a cover letter, describe completely:

The symptoms from which it was determined that the equipment is faulty.

2. The environment in which the equipment

has been operating (housing, weather, vibration, dust, etc.).

Site from which the equipment was removed.

4. Whether warranty or nonwarranty service is

requested.

d. Enclose a cover letter and purchase order and

ship the defective equipment according to instructions provided in Rosemount Return Authorization, prepaid, to:

Rosemount Analytical Inc. RMR Department 1201 N. Main Street Orrville, Ohio 44667 330/684-4436

If warranty service is requested, the defective unit will be carefully inspected and tested at the factory. If failure was due to conditions listed in the standard Rosemount warranty, the defective unit will be replaced at Rosemount’s option, and an operating unit will be returned to the customer in accordance with shipping instructions furnished in the cover letter.

For equipment no longer under warranty, the equipment will be repaired at the factory and returned as directed by the purchase order and shipping instructions.

Contact Rosemount Analytical Customer Service at 1-800-433-6076.

IB-103-300

10-1/10-2

GLOSSARY

Calibration The process of tuning the analyzer to monitor specific process elements.

CCD Camera Thermocouple Equipment used to monitor the CCD camera head temperature.

Configuration Set The collection of calibration information used to monitor a process for specific sub-

stances.

Dark Current Calibration The process of calibrating the analyzer to eliminate ambient light from the monitored

process spectrum.

Diamond De-fluoresced The process of adjusting the diamond reference spectrum to remove ambient light.

Fiber Optic Cable Thin transparent fibers of glass or plastic enclosed in light-proof material used to transmit

light signals.

Histogram A graphical representation of a spectrum frequency.

In Situ A method of analyzing process gases without removing them from the process stream.

MPL Laser diode driver module which provides the interface, control, and drive for the laser

module.

MPT Laser temperature controller module which provides the interface and drive for the

thermoelectric cooler in the laser module.

Photometric Calibration The process of calibrating the analyzer using known parameters to eliminate equipment

variables from the photometric calculation.

Raman Spectroscopy The analysis of spectral composition of scattered light (process spectrum) as compared to

the original incident light (diamond reference).

Spectrograph The equipment used to separate the wavelengths of light and direct the desired wave-

lengths to the CCD camera.

Spectrum The image formed from dispersed wavelengths that are focused and arranged in a specific

order.

SURE Calibration The process of calibrating the analyzer using a photometric response standard (included

in the SURE calibration kit) to measure the photometric response of the analyzer and adjust the photometric calculation accordingly.

Wavelength The distance of a line from any one point of a wave to the same point on the next corre-

sponding waveform.

IB-103-300

G-1/G-2

INDEX

The index is an alphabetized listing of parts, terms, and procedures related to the Raman Process Analyzer. Every item listed in the index refers to a location in the manual by page number or numbers.

Diamond De-fluoresced, 4-8

Air Supply

Connection, 2-5

Alarms

Cabinet Temperature, 4-11, 7-1 Laser Current (Amp), 4-11, 7-1 Laser Power (Watt), 4-11, 7-1 Laser Thermistor (Ohm), 4-11, 7-1 Mahalanobis Distance, 4-11, 7-1 Messages, 7-1 Residual Limit, 4-11, 7-1

Analog Output, 5-1

Concentration Values, 5-5 Diagnostics, 5-4 Outputs, 5-5 Scaling Setup, 5-1

Saving Configuration, 5-2 Analyzer Alarms Status, 4-11 Analyzer Cabinet, 2-1

Mounting, 2-1 Analyzer Performance Measures, 4-13

Average Laser Wavelength, 4-13

Comm Failures, 4-13

Mahalanobis Distance, 4-13

Residual, 4-13

Residual Spectrum, 4-13 Analyzer Software Status, 4-10

Calibration, 3-6, 3-7, 8-6 Camera Comms Failures, 4-8 CCD Camera, 1-3 CCD Camera Thermocouple Replacement, 8-2 Cleaning, 6-1 Component Replacement, 8-1 Computer Peripherals

Connection, 2-6 Configuration Set

Changing, 3-3

Creating, 3-6

Enabling, 3-6

Selecting, 3-8 Cooling Fans Replacement, 8-3

Dark Corrected, 4-8 Dark Current Calibration, 3-7 Dark Current Reference, 4-15 Data Logging, 4-4 Diagnostics, 4-7

Diamond Reference, 1-3, 4-8 Diode Laser, 1-3

Electrical Checks, 2-7 Electrical Installation, 2-5 Equipment Description, 1-1 Equipment Diagram, 1-2 Equipment Specifications, 1-5

Fiber Optic Cables, 2-3 Filters, 2-3 Fuse Replacement, 8-1

Grab Dark Scan, 4-16 Grab Scan, 4-6

Industrial computer, 1-3 Input Power Connections, 2-5 Input Voltage Selector, 2-5 Installation, 2-1

Electrical, 2-5 Mechanical, 2-2

Instrument Temperature, 4-8

Laser Current (Amps), 4-8 Laser Current Adjustment, 8-5 Laser Power (Watts), 4-8 Laser Replacement, 8-4 Laser Safety Device, 1-3 Laser Thermistor (Ohms), 4-8

MAIN

Program Structure, 4-2 Startup, 4-3

MAINCFG

Program Structure, 3-2

Starting, 3-3 Mechanical Checks, 2-7 Mechanical Installation, 2-2 Network

Connection, 2-6

Software, 3-1

IB-103-300

I-1

Operation, 4-1

Optic Filter, 2-4

Parts Replacement, 9-1 Photometric Calibration, 3-7 Photometrically Compensated, 4-8 Preventive Maintenance, 6-1 Program

MAINCFG, 3-2 MAIN, 4-2

Raman Probe, 2-2 Raw Data, 4-8 Replacement Parts, 9-1 Returning Equipment, 10-1

Screens

ABOUT, 4-16 ANALOG INPUT MEAURMENTS, 4-9 ANALOG OUTOUT DIAGNOSTIC, 5-4 ANALOG OUTOUT SCALING SETUP, 5-2 ANALYZER ALARMS STATUS, 4-11 ANALYZER SOFTWARE STATUS, 4-10 CALIBRATION PATH & MODEL, 4-14 CCD MAP, 3-5 CONFIGURE MODBUS, 3-5 DARK CURRENT & PHOTOMETRIC

CORRECTION, 4-14 DARK CURRENT CALIBRATION, 3-8 DIAGNOSTIC MENUS, 4-7, 4-8, 4-15, 5-4 DIGITAL I/O STATE, 4-9 GRAB DARK SCAN, 4-16 GRAB SCAN, 4-6 GRAB SCAN MENUS, 4-5 KNOWN CLIENTS, 3-1 NETSUPPORT CONTROL, 3-1 OPERATOR MENUS, 4-3, 4-5, 4-7, 4-15, 5-1 PASSWORD VERIFICATION, 4-3, 4-12, 5-2 PERFORMANCE MEASURES, 4-13 PHOTOMETRIC CALIBRATION, 3-7 PLS SETUP, 3-4 RAMAN ANALYZER DATALOG UTILITY, 4-5

RAMAN PROCESS ANALYZER, 4-3, 5-2 SAVE AS, 4-6 SET PASSWORDS, 4-16 SET SECURITY, 4-16 SETUP MENUS, 3-3, 4-4, 5-1 SMART DIAGNOSTICS MENUS, 4-10, 4-13 SYSTEM CONFIGURATION, 3-4 SYSTEM CONFIGURATION MENU, 3-3 TRENDS, 4-12 VIEW CALCULATIONS, 4-7 ZERO CLIP OPTION, 4-4

Security, 4-16

Set Passwords, 4-16 Service, 8-1 Setup, 3-1 SMA Connectors, 2-1, 2-4 Smart Diagnostics, 4-10 SNV Standard Spectrum, 4-8 Software

Changing a Setup Variable, 4-1

Screen Options, 4-1

Selecting a Menu Item, 4-1

Usage Conventions, 4-1 Spectrograph, 1-3 Standardized Spectrum, 4-8 SURE Calibration Kit, 1-1, 1-3

Troubleshooting, 7-1 Troubleshooting Flowchart, 7-2, 7-3, 7-4

View Analog Signals, 4-8 View Calculations, 4-7 View Digital I/O State, 4-9 Vortex Cooler, 1-3, 2-5

Wavenumbers, 4-8

X-axis Corrected, 4-8

Zero Clip, 4-4

IB-103-300

I-2

2732

3552/6-01

Rosemount RAMAN Process Analyzer-Rev 1.0 Manuals & Guides

Specifications and Main Features

Frequently Asked Questions

User Manual