Teledyne LGA-3500 User Manual
OPERATING INSTRUCTIONS FOR
Model 3500 Series
Laser Gas Analysis System
P/N MXXXX
ECO:
DANGER
Toxic gases and or flammable liquids may be present in this monitoring system.
Personal protective equipment may be required when servicing this instrument.
Hazardous voltages exist on certain components internally which may persist
for a time even after the power is turned off and disconnected.
Only authorized personnel should conduct maintenance and/or servicing.
Before conducting any maintenance or servicing, consult with authorized
supervisor/manager.
Copyright © 2005 Teledyne Analytical Instruments
Teledyne Analytical Instruments
Model 3500
All Rights Reserved. No part of this manual may be reproduced, transmitted, transcribed,
stored in a retrieval system, or translated into any other language or computer language in
whole or in part, in any form or by any means, whether it be electronic, mechanical,
magnetic, optical, manual, or otherwise, without the prior written consent of Teledyne
Analytical Instruments, 16830 Chestnut Street, City of Industry, CA 91749-1580.
Warranty
This equipment is sold subject to the mutual agreement that it is warranted by us free from
defects of material and of construction, and that our liability shall be limited to replacing or
repairing at our factory (without charge, except for transportation), or at customer plant at our
option, any material or construction in which defects become apparent within one year from
the date of shipment, except in cases where quotations or acknowledgements provide for a
shorter period. Components manufactured by others bear the warranty of their manufacturer.
This warranty does not cover defects caused by wear, accident, misuse, neglect or repairs
other than those performed by Teledyne or an authorized service center. We assume no
liability for direct or indirect damages of any kind and the purchaser by the acceptance of the
equipment will assume all liability for any damage which may result from its use or misuse.
We reserve the right to employ any suitable material in the manufacture of our apparatus,
and to make any alterations in the dimensions, shape or weight of any parts, in so far as
such alterations do not adversely affect our warranty.
Important Notice
This instrument provides measurement readings to its user, and serves as a tool by which
valuable data can be gathered. The information provided by the instrument may assist the user
in eliminating potential hazards caused by his process; however, it is essential that all
personnel involved in the use of the instrument or its interface, with the process being
measured, be properly trained in the process itself, as well as all instrumentation related to it.
The safety of personnel is ultimately the responsibility of those who control process
conditions. While this instrument may be able to provide early warning of imminent
danger, it has no control over process conditions, and it can be misused. In particular, any
alarm or control systems installed must be tested and understood, both as to how they
operate and as to how they can be defeated. Any safeguards required such as locks, labels,
or redundancy, must be provided by the user or specifically requested of Teledyne at the
time the order is placed.
Therefore, the purchaser must be aware of the hazardous process conditions. The purchaser
is responsible for the training of personnel, for providing hazard warning methods and
instrumentation per the appropriate standards, and for ensuring that hazard warning devices
and instrumentation are maintained and operated properly.
Teledyne Analytical Instruments, the manufacturer of this instrument, cannot accept
responsibility for conditions beyond its knowledge and control. No statement expressed or
implied by this document or any information disseminated by the manufacturer or its
agents, is to be construed as a warranty of adequate safety control under the user’s process
conditions.
Teledyne Analytical Instruments ii
Laser Gas Analyzer
Specific Model Information
Instrument Serial Number: _______________________
Instrument Range: _______________
Calibrated for: _______________
Background Gas: _______________
Zero Gas: _______________
Span Gas: _______________
Teledyne Analytical Instruments iii
Model 3500
Safety Messages
Your safety and the safety of others is very important. We have
provided many important safety messages in this manual. Please read
these messages carefully.
A safety message alerts you to potential hazards that could hurt you
or others. Each safety message is associated with a safety alert symbol.
These symbols are found in the manual and inside the instrument. The
definition of these symbols is described below:
GENERAL WARNING/CAUTION: Refer to the instructions
for details on the specific danger. These cautions warn of
specific procedures which if not followed could cause bodily
Injury and/or damage the instrument.
CAUTION: HOT SURFACE WARNING: This warning is
specific to heated components within the instrument. Failure
to heed the warning could result in serious burns to skin and
underlying tissue.
WARNING: ELECTRICAL SHOCK HAZARD: Dangerous
voltages appear within this instrument. This warning is
specific to an electrical hazard existing at or nearby the
component or procedure under discussion. Failure to heed this
warning could result in injury and/or death from
electrocution.
Technician Symbol: All operations marked with this symbol
are to be performed by qualified maintenance personnel only.
No
Symbol
CAUTION: THE ANALYZER SHOULD ONLY BE USED FOR THE
NOTE: Additional information and comments regarding a
specific component or procedure are highlighted in the form
of a note.
PURPOSE AND IN THE MANNER DESCRIBED IN
THIS MANUAL.
Teledyne Analytical Instruments iv
Laser Gas Analyzer
IF YOU USE THE ANALYZER IN A MANNER OTHER
THAN THAT FOR WHICH IT WAS INTENDED,
UNPREDICTABLE BEHAVIOR COULD RESULT
POSSIBLY ACCOMPANIED WITH HAZARDOUS
CONSEQUENCES.
This manual provides information designed to guide you through
the installation, calibration operation and maintenance of your new
analyzer. Please read this manual and keep it available.
Occasionally, some instruments are customized for a particular
application or features and/or options added per customer requests.
Please check the front of this manual for any additional information in
the form of an Addendum which discusses specific information,
procedures, cautions and warnings that may be peculiar to your
instrument.
Manuals do get lost. Additional manuals can be obtained from
Teledyne at the address given in the Appendix. Some of our manuals are
available in electronic form via the internet. Please visit our website at:
www.teledyne-ai.com.
Teledyne Analytical Instruments v
Model 3500
Table of Contents
Peter.Adam@linde-gas.com
List of Figures ..............................................................................ix
List of Tables................................................................................xi
Introduction................................................................................... 1
1.1 Overview 1
1.2 Models Available in the 3500 Series 1
1.2.1 Available Options 1
1.2 Classification of LGA-2000 Laser Gas Analysis
Systems 2
1.2 Typical Applications 3
1.3 Features 4
1.4 System Components 4
Operational Theory.......................................................................7
2.1 Introduction 7
2.2 Principles of Operation 8
2.3 Software 10
Installation................................................................................... 11
3.1 Unpacking the Instrument 11
3.2 Installation Preparation 11
3.2.1 Installation and Adjustment Tools 11
3.2.2 Choosing Installation Spot 13
3.3 Analysis Section Installation 13
3.3.1 Welding Flanges 13
3.3.2 Installing Instrument Flanges 14
3.3.3 Checking Offset Using the Laser Pen and Target 15
3.3.3.1 Checking the Laser Pen for Alignment 15
3.3.3.2 Adjusting the Coaxial Offset of the Instrument
Flanges 16
Teledyne Analytical Instruments vi
Laser Gas Analyzer
3.3.4 Installing the Transmitter Unit and the Receiver Unit 17
3.4 Central Processing Unit Installation 17
3.5 Purge System Installation 18
3.6 Electric Wiring and Connection 19
3.7 Optimize of the Optical Transmission Alignment 22
Operation .....................................................................................23
4.1 Front Panel 23
4.2 System Mode 24
4.2.1 Start-up Mode 24
4.2.2 Normal Mode 26
4.2.3 Error Mode 27
4.3 System Menu 27
4.3.1 MainMenu 28
4.3.2 Display 33
4.3.3 System 38
4.3.3.1 System Parameter Input Method 39
4.3.3.2 System sub menus 41
4.3.4 Cali. 46
4.3.4.1 Adjust Zero: 47
4.3.4.2 Cali. Co: 48
4.3.4.3 Backup 51
4.3.4.4 Restore 51
4.3.5 Com 51
4.3.6 Alarm 52
4.3.7 Additional Menus 57
4.3.7.1 Message Code: 57
4.3.7.2 Password Input: 58
4.3.7.3 Error Protection Menu: 58
Alarm Messages..........................................................................61
5.1 Relay Alarm 61
5.2 4-20mA Analog Output 61
5.3 LCD Alarm Message Display 62
Teledyne Analytical Instruments vii
Model 3500
Maintenance and Calibration .....................................................67
6.1 Maintenance 67
6.1.1 Adjusting the Purge Gas Flow 67
6.1.2 Clean the Optical Parts 68
6.1.3 Optimize the Optical Transmission Alignment 70
6.2. Calibration 70
6.2.1 Calibration Procedure 72
6.2.2 Calibration Software 74
Extended Communication Functions........................................ 75
Appendix...................................................................................... 77
Specifications 77
Recommended Spare Parts List 79
Reference Drawings 79
Index............................................................................................. 81
Teledyne Analytical Instruments viii
Laser Gas Analyzer
List of Figures and Screens
Figure 1-1 Control Section...............................................................5
Figure 1-2: Model 2500 Laser Gas Analysis System.......................6
Figure 2-1: System Diagram for the Model 3500 Series Analyzers.7
Figure 2.2 Schematic of “Single line” Spectroscopy........................9
Figure 3-1: General Layout of the Model 3500 Series Analyzer....12
Figure 3.2: Allowed offset for welded flanges................................14
Figure 3-3: Instrument Flange.......................................................15
Figure 3.4 Adjusting the Instrument Flanges with Laser Pen and
Target.....................................................................................16
Figure 3.5 Dimension of the Central Processing Unit (in mm).......17
Figure 3.6 Typical Purging System for the Model 3500.................19
Figure 3.7 Electric Connection Ports on the Central Processing
Unit for Non-fiber Optic Analysis Systems..............................20
Figure 3.8: Electric Connection Ports on the Central Processing
Unit for Analysis Systems Using Fiber Optic Pigtail ...............21
Figure 4-1: Model 3500 Series Front Panel...................................23
Figure 4.2 System Start-up Screen...............................................25
Figure 4.3 System Init Screen.......................................................25
Figure 4.5: System Menu Structure...............................................28
Figure 4-6: MainMenu—Graphic...................................................29
Figure 4.7 Numerical Value Mode of the MainMenu .....................30
Figure 4.8 Display menu................................................................33
Figure 4.9 Display Mode Options..................................................34
Figure 4.10 Unit Menu...................................................................34
Figure 4.11 Set Con. Unit menu....................................................35
Teledyne Analytical Instruments ix
Model 3500
Figure 4.12 Pop-up Window for Language Selection....................36
Figure 4.13 TimeDate Menu..........................................................36
Figure 4.14 Admin. Menu.............................................................. 37
Figure 4.15 System main menu ....................................................38
Figure 4.16 Set Optical Path Length............................................. 40
Figure 4.22 Schematic showing purging gas channel...................45
Figure 4.35 Time sequence of the alarm relay automatic
restoration..............................................................................56
Figure 6.1 Schematic of the calibration setup ...............................70
Figure 6.2 Removing the Transmitter Receiver Units.................... 72
Figure 7.1 Schematic for Networked Multiple-point Remote
Measurement on Model 3500 Systems.................................. 75
Teledyne Analytical Instruments x
Laser Gas Analyzer
List of Tables
Table 1-1 Instrument Designation for Selected Options..................2
Table 1-2: Typical Gas Analysis and Range....................................3
Table 3.1 Electric connections & definitions of Input, Output
Signals of Central Processing Unit.........................................21
Table 5.1 Relays and output status for Various Operation Modes 62
Table 5.2: LCD Display Alarm Messages......................................63
Teledyne Analytical Instruments xi
Model 3500
DANGER
COMBUSTIBLE GAS USAGE
Depending on the selected options, some instruments may
be used in hazardous environments. This may involve the
measurement or monitoring of flammable or explosive
gases. It is the end user’s responsibility to ensure that all
safety related features of this instrument are properly
functioning and that the operator is fully trained in the
operation of the system as well as procedures for handling
the gases employed.
WARNING
Some instruments are approved as an intrinsically safe gas
analyzers for usage in a category (ia) Group IIC hazardous
area. This approval only to the equipment specified installed
in accordance with the information contained within this
manual. It is the customer's responsibility to ensure safety
especially when combustible gases are being analyzed since
the potential of gas leaks always exist.
The customer should ensure that the principles of operating
of this equipment is well understood by the user and that the
instrument as well as any approved support equipment is
properly installed. Misuse of this product in any manner,
tampering with its components, or unauthorized substitution
of any component may adversely affect the certification and
the safety of this instrument.
Since the use of this instrument is beyond the control of
Teledyne, no responsibility by Teledyne, its affiliates, and
agents for damage or injury from misuse or neglect of this
equipment is implied or assumed.
Teledyne Analytical Instruments xii
Laser Gas Analyzer
DANGER
LASER RADIATION
This instrument produces laser radiation which can cause
damage to human tissue especially the eyes. Do not look at
the laser beam nor open any chamber or device without first
powering off the instrument.
WARNING: THE WAVELENGTH OF THE LASER BEAM INSIDE
THE MODEL 3500 SERIES OF ANALYZERS IS IN THE
RANGE OF 0.7 ~ 2µM. IT IS INFRARED AND
INVISIBLE. DO NOT LOOK DIRECTLY OR WITH
OPTICAL INSTRUMENT AT THE DIRECTION OF THE
LASER RADIATION
HAZARD
Teledyne Analytical Instruments xiii
Model 3500
Teledyne Analytical Instruments xiv
Laser Gas Analyzer Introduction
Introduction
1.1 Overview
The Model 3500 series Laser Gas Analysis System comprises a
range of instruments based on the features and configuration chosen at
the time of purchase. The system uses laser spectroscopy to accurately
measure and monitor the composition of a single or multiple gas species
in a gas mixture. It is especially useful for in-situ measurements and is
designed for online processes analysis. Options are available for
applications involving hazardous environments.
This manual describes the installation, calibration, operation, and
maintenance of the LGA system. The principles of instrument operation
are detailed in Section 2.
1.2 Models Available in the 3500 Series
The Model 3500 series of instruments are classified depending on
the options specified at the time of purchase. The specific model number
assigned is described below following a brief description of the available
options to choose from.
1.2.1 AVAILABLE OPTIONS
The standard Model 3500 LGA System is configured for single gas
species detection in a gas mixture using a flange mounted laser transmitter
and receiver for online in-situ measurements in non-hazardous environments.
The following list indicates available options for the Model 3500
series of analyzers (see also Table 1-1):
• Two gas detection in a gas mixture
• Fiber optic connection to remove sensitive laser and electronics
from monitoring environment
• Explosion-proof housing
• Intrinsically safe instrumentation
Teledyne Analytical Instruments 1
Introduction Model 3500
Table 1-1 Instrument Designation for Selected Options
3500C
3500P
3500CS
3500PS
3500-2C
3500-2P
3500-2CS
3500-2PS
3500F
3500I
3500FS
3500IS
3500-2F
3500-2I
3500-2FS
3500-2IS
Number
of Gas
Species
One Two
√
√
√
√
√ √
√ √
√
√
√
√
√
√
√ √
√ √
√
√
Detection Optical
Signal
Transmission
By-
In
Pass
Situ
√
√
√
√
√
√
√
√
√ √
√ √
√ √
√ √
Optical
Fiber
√
√
√
√
Non-
optical
Fiber
√ √
√
√ √
√
√ √
√
√ √
√
General
Purpose
√
√
√
√
Analysis Environment Model
Explosion-
proof
Positive
Pressure
√
√
√
√
Intrinsically
Safe
√
√
√
√
1.2 CLASSIFICATION OF LGA-2000 LASER GAS ANALYSIS SYSTEMS
The instruments in the Model 3500 range are named according to
the following rule:
Model 3500: Single gas analyzer
Model 3500-2: Two gas analyzer
Suffix C: Standard configuration without optical fiber
Suffix F Standard configuration with optical fiber
Suffix I: Intrinsically safe
Suffix P: Explosion-proof
Teledyne Analytical Instruments 2
Laser Gas Analyzer Introduction
Suffix S: Bypass sampling mode
For example, the Model 3500C would indicate a standard (nonexplosion proof) single gas analyzer without an optical fiber capable of
in-situ analysis in non-hazardous environments. Similarly, the Model
3500F would indicate the same instrument but with an optical fiber
connection with the laser source located remotely from the monitoring
site.
1.2 Typical Applications
The Model 3500 Laser Gas Analysis System is a versatile tool for
online analysis and monitoring of a gas flow process. The Model 3500 is
suitable for a wide range of industrial applications including
petrochemical and steel industries where critical monitoring of process
gases is vital. Depending on the gas specie or species of interest, the
instrument is capable of measuring from the parts per million (ppm) to
100% range of concentration.
Table 1-1 shows typical gas species and their measurement range
for the Model 3500.
Table 1-2: Typical Gas Analysis and Range
Gases Threshold
O
HCL
HF
NH
CO
H2O
H2S
0.01%Vol. 0-2% Vol.,
2
0.1 ppm 0-15 ppm,
0.02 ppm 0-5 ppm,
0.2 ppm 0-20 ppm,
3
200 ppm 0-8000 ppm,
0.05 ppm 0-10 ppm, 0-
5 ppm 0-1000 ppm,
Measurement
Range
0-100% Vol.
0-8000 ppm
0-1000 ppm
0-10000 ppm
0-100% Vol.
70% Vol.
0-30% Vol.
Teledyne Analytical Instruments 3
Introduction Model 3500
CH
HCN
CO
C2H
C2H
20 ppm 0-200 ppm,
4
0-10% Vol.
0.5 ppm 0-40 ppm,
0-10000ppm
1 ppm 0-100 ppm
2
(min)
0.2 ppm 0-20 ppm
2
(min)
2.0 ppm 0-200 ppm
4
(min)
1.3 Features
Compared to conventional gas analysis systems, the DLGA-3500
series have the following advantages:
• On-the-spot online measurement ability
• Options available for use in adverse environment conditions
• Quick response
• High measurement accuracy
• Minimal maintenance
• No replacement parts
• No cross interference from background gas species
• Enhanced accuracy over conventional IR and photonic
measurement systems
1.4 System Components
The Model 3500 consists of:
• Control unit
• Analysis section
• Purging system
Teledyne Analytical Instruments 4
Laser Gas Analyzer Introduction
The central processing or control unit is a separate wall-mounted
enclosure located remotely from the process or point of analysis. It
houses the system electronics and includes the operator interface panel
on the front door. Figure 1 shows the Model 3500 control unit. A
separate enclosure is provided for the power supply
The operator interface consists of a panel of membrane switches for
controlling the operational mode of the instrument as well as entering
data. A large LCD display provides feedback to the user and indicates
the gas composition during analysis.
Figure 1-1 Control Section
The system is equipped with a separate power supply and output
control section which is also mounted remotely from the measurement
site. It houses power supplies and connectors for signal and relay output.
See Figure 1-2.
Teledyne Analytical Instruments 5
Introduction Model 3500
The analysis section is typically mounted at the point of
measurement and consists of the laser transmitter, receiver and flanges
for interfacing the unit with the process.
The transmitter unit and the receiver unit are mounted on flanges
which are welded onto the gas flow pipe. The transmitter is mounted
onto one flange with special adjustable fittings while the receiver is
mounted onto a similar flange diametrically opposed from the
transmitter. The transmitter unit launches a collimated laser beam into
the environment under test, and onto the sensor in the receiver unit. The
signal is sent to the central processing unit housed in the control unit.
An integral purging unit is incorporated to keep dust and gas
deposits from collecting on the analysis section windows thus
eliminating any interference or degradation of the laser induced signal.
Figure 1-2 shows a typical Model 3500 Laser Gas Analysis System
with the control section remotely located from the analysis portion.
Figure 1-2: Model 2500 Laser Gas Analysis System
Teledyne Analytical Instruments 6
Laser Gas Analyzer Operational Theory
Operational Theory
2.1 Introduction
The Model 3500 Laser Gas Analysis System is a high precision gas
concentration measurement and monitoring system capable of on-thespot online operation. It is comprised of three subsystems:
1. Central Processing Unit (Control Unit)
2. Analysis Section
3. Purge System
In the analysis section, the transmitter launches a laser beam across
the diameter of the industry pipe under test onto the receiver placed at
the other end. The resulting electrical signal is then sent to the central
processing unit and analyzed to yield the gas concentration and
displayed on the LCD screen. Signal and relay output is taken from the
power supply/control box. See Figure 2-1.
Figure 2-1: System Diagram for the Model 3500 Series Analyzers
Teledyne Analytical Instruments 7
Operational Theory Model 3500
2.2 Principles of Operation
The Model 3500 Laser Gas Analysis System uses laser
spectroscopy to generate a signal based on the composition of a gas
mixture. While similar in nature to other photonic analyzers, the Model
3500 Laser Gas Analysis System offers many advantages over these
technologies.
Traditional online gas analyzers such as the Non-dispersive
Infrared (NDIR) Spectroscopy Online Gas Analyzer are subject to
interference from other constituents in the environment (including dust
and other gas species such as water vapor). This could be especially
severe when the measured gas is of low concentration. However, the
Model 3500 Laser Gas Analysis System series employ advanced Laser
Absorption Spectroscopy (DLAS) gas analysis and measurement
technology, i.e. “single-line” spectroscopic methods.
Conventional infrared spectroscopy uses light sources such as
lamps or LED’s that are normally non-laser and have very broad linewidths. The absorption spectrum obtained includes not only the spectral
lines from the gas under test, but also those from background gas species
which introduces cross interference. DLAS gas analyzers use diode
lasers that have line-widths of less than 0.0001nm, or only 1/106 of that
of the non-laser sources. By selecting a laser that will emit a specific
absorption line close to that of the gas under test and tuning its
wavelength through changing its temperature and driving current, an
absorption spectrum that only covers a single line of the gas under test
can be obtained and eliminates cross interference. See Figure 2-2.
The line-width of a diode laser is much narrower than that of the
gas molecule absorption spectrum. The Laser spectral line is depicted in
the figure as a light solid line.
The diode laser output from the transmitter goes through the
environment under test, gets absorbed by the target gas molecules, and
the resulted attenuated light is collected by the optical sensor in the
receiver unit. The attenuation is in proportion to the concentration of the
target gas. Varying the wavelength of the diode laser within the carefully
selected laser spectral scanning range (Figure 1.2), a gas absorption
spectral line without interference from the absorption spectra of
background dust and other gas species can be obtained for high
precision data analysis. This feature, no interference from background
dust and gases, enables the laser gas analysis systems to be applied on
the spot for online gas analysis. Conventional infrared spectroscopy, due
Teledyne Analytical Instruments 8
Laser Gas Analyzer Operational Theory
to their vulnerability to interference from background gases and dust,
cannot or can hardly conduct on-the-spot measurement.
Figure 2.2 Schematic of “Single line” Spectroscopy.
The Model 3500 series of analyzers do not need complex gas
sampling and pretreatment. They have extremely quick response
because they skip the long gas sampling and transport process. As a
result, system maintenance is minimal since gas sampling and
pretreatment systems contribute to the majority of the maintenance
workload for conventional sampling gas analysis systems.
In conventional sampling gas analysis systems, it is the gas
concentration in the vicinity of the sampling tip that is sampled and
measured. Since gas concentration can have significant variance across
the section of gas flow pipe, inaccurate measurements result. No matter
how precise the subsequent data analysis is, the measurement results do
not accurately indicate the overall gas concentration in the gas flow pipe.
In contrast, the Model 3500 measures the average gas concentration
from the transmitter to the receiver. This represents the gas
concentration of the gas flow process much more accurately.
In addition, laser gas analysis systems have built-in temperature
and pressure auto-correction capability to enhance measurement
accuracy. These systems compensate for the temperature and pressure
Teledyne Analytical Instruments 9
Operational Theory Model 3500
variance in the environment under test using a proprietary algorithm by
having input for temperature and pressure.
2.3 Software
An executable program is embedded program in the microprocessor
of the central process unit and is programmed to perform a multitude of
tasks including:
Signal processing
Data analysis
Managing system I/O including keyboard operations and display
Performs the system self-test
Calibration,
Alarm activation
In addition, the software establishes data communication with PC
through the RS232 serial communication port and GPRS modules. TAI
provides WINDOWS-based PC service program for all models in the
3500 series. Please refer to Appendix A for details.
Teledyne Analytical Instruments 10
Laser Gas Analyzer Installation
Installation
Installation of the Model 3500 includes:
• Unpacking
• Mounting
• Flange connections
• Installing transmitter and receiver
• Electrical connections
• Optical transmission adjustments and fine tuning
3.1 Unpacking the Instrument
The unit is shipped with all the materials you need to install and
prepare the system for operation. Carefully unpack the analyzer and inspect
it for damage. Immediately report any damage to the shipping agent.
3.2 Installation Preparation
It is very important to prepare thoroughly before installing the
system. This includes having all the tools needed handy, choosing a
proper installation location, and correct welding of the flanges to the gas
flow pipe well. See section 3.3.1. Figure 3-1 shows the general layout of
the Model 3500 Laser Gas Analyzer.
3.2.1 Installation and Adjustment Tools
The following tools will be required for proper installation:
Wrenches M5 wrench—used to tighten the M5 bolts
connecting the instrument flange and
transmitter/receiver.
Two 12” adjustable wrenches—used to tighten
EMC and nut connector.
Teledyne Analytical Instruments 11
Installation Model 3500
Two 8” adjustable wrenches—used to tighten
socket screws in purging system.
Socket screwdrivers M6 hexagonal socket screwdriver—used
to tighten M6 hexagonal socket bolt on the
receiver and transmitter box cover.
M5 hexagonal socket screwdriver—used to
tighten M5 hexagonal socket bolt on the receiver.
Screwdrivers 6mm slotted screwdriver—used to rotate the M8
fastening screws between the instrument and the
weld flanges, and the purging apparatus snap ring
screws.
3mm slotted screwdriver—used to connect
electric parts and components.
Digital multimeter.
Tubing cutter.
Tube bender for 6 and 12 mm tubing
Figure 3-1: General Layout of the Model 3500 Series Analyzer
Teledyne Analytical Instruments 12
Laser Gas Analyzer Installation
3.2.2 Choosing Installation Spot
It is strongly recommended to install the system probes on a
straight section of the gas flow pipeline to ensure uniformity of the gas
flow. The length of straight pipe before the installation spot should be at
least twice (5 times, recommended) as much as the diameter of the pipe,
and half (twice, recommended) after the installation spot.
Note: The laser gas analysis system measures the average
concentration along the laser beam path (see Figure 1.2).
If there is no straight pipe section for mounting the flanges,
it may still be possible to get accurate measurements.
(Please contact our technical support center).
In addition, the installation spot should be chosen carefully
considering both safety and ergonomic factors. A platform should be
constructed when the chosen spot is not fully accommodating.
3.3 Analysis Section Installation
Installation of the analysis section involves:
• Welding flanges onto the process pipe
• Installing instrument flanges
• Checking the offset angle using the laser pen
• Adjusting the coaxial angle of the two instrument flanges,
• Installing the transmitter unit and the receiver unit.
3.3.1 Welding Flanges
The transmitter and receiver units of the analysis section are
mounted on DN50 flanges and mate to corresponding flanges which
must be welded onto the process pipe.
Note: The customer is responsible for correct welding of the
flanges onto the process pipe. The use of a competent
professional welder is required to ensure proper placement
of the flanges and provide a leak-free weldment.
The precision adjustment between the welding flange and the
instrument flange with the supplied O-ring can fine tune the optical
transmission to a limited extent. This allows for the two welding flanges
Teledyne Analytical Instruments 13
Installation Model 3500
to have a limited coaxial offset between them. When welding the two
welding flanges the offset angle between their axes must be held to less
than 4°. Typically, the two welded flanges are positioned horizontally on
the gas flow pipe well across the pipe diameter As Shown in Figure 3-2.
Figure 3.2: Allowed offset for welded flanges
3.3.2 Installing Instrument Flanges
After welding the flanges, the Model 3500 probes can be installed.
Before installing, apply a lubricant to all the screw connections. To
make adjustments easier it is suggested that you use the adjusting aid
tools available from TAI (P/N XXXXX). These include a visible light
laser pen and a scaled target for alignment.
WARNING: POWER TO THE SYSTEM MUST BE OFF DURING
THE INSTALLATION OF THE TRANSMITTER AND
RECEIVER UNITS. DO NOT CONNECT OR SWITCH
ON THE POWER SUPPLY AT THIS STAGE. THE
LASER BEAM IS INVISIBLE AND CAN CAUSE EYE
DAMAGE.
Mount the two instrument flanges onto the welded welding flanges
with 8 M16 bolts (with spring washer and plain washer) and 2 O-rings.
Raise the instrument flanges to the same height as the welded flanges,
then tighten the 8 M16 bolts to about half tight to make sure that the Orings are sealing. Typically the distance between the instrument flange
and the welding flange is around 3mm. See Figure 3.3.
Teledyne Analytical Instruments 14
Laser Gas Analyzer Installation
Figure 3-3: Instrument Flange
3.3.3 Checking Offset Using the Laser Pen and Target
The laser pen is an optical transmission adjustment aid tool
available through TAI. The part number is listed in the Spare Parts List
in the Appendix. The laser pen emits visible red light beam and is used
to adjust the coaxial offset of the two instrument flanges. This assumes
that the welded flanges were installed correctly and held to within 4
degrees total offset with respect to each other.
Prior to adjusting the instrument flanges the laser pen must first be
checked for alignment.
3.3.3.1 CHECKING THE LASER PEN FOR ALIGNMENT
To see if the laser pen is suitable for your installation, apply the
following test:
1. Mount the laser pen on one instrument flange and the scaled
target onto the other instrument flange. Tighten with mounting
nuts.
2. Turn on the laser pen and observe the light spot on the target.
Teledyne Analytical Instruments 15
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