Yokogawa TDLS200 User Manual

User’s Manual

TDLS200

Tunable Diode Laser Spectroscopy Analyzer

Start-up Manual

IM11Y01B01-11E-A

Yokogawa Corporation of America

Yokogawa Corporation of America 2 Dart Road, Newnan, Georgia U.S.A. 30265 Tel: 1-800-258-2552 Fax: 1-770-254-0928

IM11Y01B01-11E-A

5th Edition

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Introduction

Thank you for purchase the TDLS200 Tunable Diode Laser Analyzer. Please read the following respective documents before installing and using the TDLS200.

Notes on Handling User’s Manuals

• This manual should be passed on to the end user.

• The contents of this manual are subject to change without prior notice.

• The contents of this manual shall not be reproduced or copied, in part or in whole, without permission.

• This manual explains the functions contained in this product, but does not warrant that they are suitable for the particular purpose of the user.

• Every effort has been made to ensure accuracy in the preparation of this manual. However, when you realize mistaken expressions or omissions, please contact the nearest Yokogawa Electric representative or sales ofﬁ ce.

• This manual does not cover the special speciﬁ cations. This manual may be left unchanged on any change of speciﬁ cation, construction or parts when the change does not affect the functions or performance of the product.

• If the product is not used in a manner speciﬁ ed in this manual, the safety of this product may be impaired.

Yokogawa is not responsible for damage to the instrument, poor performance of the instrument or losses |resulting from such, if the problems are caused by:

• Improper operation by the user.

• Use of the instrument in improper applications

• Use of the instrument in an improper environment or improper utility program

• Repair or modiﬁ cation of the related instrument by an engineer not authorized by Yokogawa.

Drawing Conventions

Some drawings may be partially emphasized, simpliﬁ ed, or omitted, for the convenience of description. Some screen images depicted in the user’s manual may have different display positions or character types (e.g., the upper / lower case). Also note that some of the images contained in this user’s manual are display examples.

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Safety Precautions

Safety, Protection, and Modiﬁ cation of the Product

• In order to protect the system controlled by the product and the product itself and ensure safe operation,

observe the safety precautions described in this user’s manual. We assume no liability for safety if users fail to observe these instructions when operating the product.

• If this instrument is used in a manner not speciﬁ ed in this user’s manual, the protection provided by this instrument may be impaired.

• If any protection or safety circuit is required for the system controlled by the product or for the product itself, prepare it separately.

• Be sure to use the spare parts approved by Yokogawa Electric Corporation (hereafter simply referred to as YOKOGAWA) when replacing parts or consumables.

• Modiﬁ cation of the product is strictly prohibited.

• The following safety symbols are used on the product as well as in this manual.

DANGER

This symbol indicates that an operator must follow the instructions laid out in this manual in order to avoid the risks, for the human body, of injury, electric shock, or fatalities. The manual describes what special care the operator must take to avoid such risks.

WARNING

This symbol indicates that the operator must refer to the instructions in this manual in order to prevent the instrument (hardware) or software from being damaged, or a system failure from occurring.

CAUTION

This symbol gives information essential for understanding the operations and functions.

Note!

This symbol indicates information that complements the present topic.

This symbol indicates Protective Ground Terminal

" #

 Warning and Disclaimer

The product is provided on an “as is” basis. YOKOGAWA shall have neither liability nor responsibility to any person or entity with respect to any direct or indirect loss or damage arising from using the product or any defect of the product that YOKOGAWA cannot predict in advance.

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iii

TDLS200

CAUTION

SAFETY should be considered ﬁ rst and foremost importance when working on the equipment described in this manual. All persons using this manual in conjunction with the equipment must evaluate all aspects of the task for potential risks, hazards and dangerous situations that may exist or potentially exist. Please take appropriate action to prevent ALL POTENTIAL ACCIDENTS.

AVOID SHOCK AND IMPACT TO THE ANALYZER THE LASERS CAN BE PERMANENTLY DAMAGED

Laser Safety & Classiﬁ cation according to FDA Regulations. The TDLS200 is Registered with the United States FDA as a Laser Product.

WARNING

THIS ANALYZER CONTAINS A LASER PRODUCT THAT IS GENERALLY IN ACCORDANCE WITH THE REGULATIONS FOR THE ADMINISTRATION AND ENFORCEMENT OF THE RADIATION CONTROL FOR HEALTH AND SAFETY ACT OF 1968 (TITLE 21, CODE OF FEDERAL REGULATIONS, SUBCHAPTER J). REFER SECTION

1002.10 OF THE REGULATIONS REFERENCED ABOVE.

CAUTION INVISIBLE LASER RADIATION AVOID DIRECT EXPOSURE

MAXIMUM OUTPUT POWER < 1 MW (Oxygen)

MAXIMUM OUTPUT POWER < 20 mW (other Gases) DURING NORMAL OPERATION THIS ANALYZER IS:

CLASS I LASER PRODUCT (according to IEC 60825-1)

CAUTION

The Instrument is packed carefully with shock absorbing materials, nevertheless, the instrument may be damaged or broken if subjected to strong shock, such as if the instrument is dropped. Handle with care.

Warranty and service

Yokogawa products and parts are guaranteed free from defects in workmanship and material under normal use and service for a period of (typically) 12 months from the date of shipment from the manufacturer. Individual sales organizations can deviate from the typical warranty period, and the conditions of sale relating to the original purchase order should be consulted. Damage caused by wear and tear, inadequate maintenance, corrosion, or by the effects of chemical processes are excluded from this warranty coverage.

In the event of warranty claim, the defective goods should be sent (freight paid) to the service department of the relevant sales organization for repair or replacement (at Yokogawa discretion). The following information must be included in the letter accompanying the returned goods:

• Part number, model code and serial

• Number

• Original purchase order and date

• Length of time in service and a description of the process

• Description of the fault, and the circumstances of failure

• Process/environmental conditions that may be related to the failure of the device.

• A statement whether warranty or nonwarranty service is requested

• Complete shipping and billing instructions for return of material, plus the name and phone number of a contact person who can be reached for further information.

Returned goods that have been in contact with process ﬂ uids must be decontaminated/ disinfected before shipment. Goods should carry a certiﬁ cate to this effect, for the health and safety of our employees. Material safety data sheets should also be included for all components of the processes to which the equipment has been exposed.

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DANGER

Dont install “general purpose type” instruments in the hazardous area.

CAUTION

The intrument is packed carefully with shock absorbing materials, nevertheless, the instrument may be damaged or broken if subjected to strong shock, such as if the instrument is dropped. Handle with care.

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TOC-1

Model TDLS200

Tunable Diode Laser Spectroscopy Analyzer

Start-up Manual

IM 11Y01B01-11E-A 5th Edition

CONTENTS

Introduction .......................................................................................................................................................... i

Safety Precutions ............................................................................................................................................... ii

1 Instrument Check ......................................................................................................................................1-1

2 Quick Start ................................................................................................................................................2-1

3 Installation and Wiring .............................................................................................................................3-1

3.1 Process Measurement Point Considerations .....................................................................................3-1

3.2 Position of Process Flanges for Launch and Detect Units .................................................................3-2

3.3 Process Flange Welding Alignment and Line-Up ...............................................................................3-4

3.4 Process Flange Clear Aperture ...........................................................................................................3-5

3.5 Mounting the Launch and Detect Units to the Process Flange .........................................................3-5

3.5.1 Process Window Purge Gas Connection .....................................................................................3-6

3.6 Mounting the Process Interface .........................................................................................................3-6

3.7 Typical Purge Gas Conﬁ guration, In-Situ ...........................................................................................3-7

3.8 Typical Purge Gas Conﬁ guration, Extractive trace ppm H2O system.................................................3-7

3.9 Dimensional Drawings ........................................................................................................................3-8

3.10 Wiring Drawings ...............................................................................................................................3-15

3.11 Hazardous Area Systems .................................................................................................................3-19

3.11.1 Purging Analyzer for Hazardous Areas (with On-Line Validation) ..............................................3-20

3.11.2 Purging Analyzer for Hazardous Areas (without On-Line Validation) ..........................................3-20

3.11.3 Purging Analyzer and Universal Power Supply and/or URD for Hazardous Areas

(with On-Line Validation) .............................................................................................................3-21

3.11.4 Purging Analyzer and Universal Power Supply and/or URD (not using On-Line Validation) ......3-21

3.12 Cyclops Division 2/ zone 2 Purge Indicator, with Switch .................................................................3-22

Revison Record .................................................................................................................................................... i

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1 INSTRUMENT CHECK

Upon delivery, unpack the instrument carefully and inspect it to ensure that it was not damaged during shipment. If damage is found, retain the original packing materials (including the outer box) and then immediately notify the carrier and the relevant Yokogawa sales ofﬁ ce.

Make sure the model number on the nameplate of the instrument agrees with your order.

The nameplate will also contain the serial number and any relevant certiﬁ cation marks. Be sure to apply correct power to the unit, as detailed on the nameplate.

For products used within the European Community or other countries requiring the CE mark and/or ATEX classiﬁ cation, the following



labels are attached (as appropriate):

1-1<1 INSTRUMENT CHECK>

For Zone 2 (CAT 3) ATEX use the following labels will be attached as appropriate:

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For YR-200 (Remote Interface Unit, RIU) Zone 2 (CAT 3) ATEX use the following labels will be attached as appropriate:

1-2<1 INSTRUMENT CHECK>

CAUTION - For Cleaning of the labels and LCD window, please use wet cloth to avoid electrostatic condition.

NOTE - ATEX Hazardous Area Operation:

Product MUST NOT be used in Zone 0 (CAT 1) locations

Product MUST NOT be used in Group I (Dust/Grain) locations

Product MUST NOT be used in Group III (Fibers) locations

Conditions of Certiﬁ cation

On loss off purge an alarm shell be made to inform the user, action shall then be taken by the user to ensure continued use is safe.

A functional test shall be carried out in accordance with clause 17.1 of EN 60079-2:2007 to verify the parameters of the Purge Control Unit when ﬁ tted.

A leakage test shall be carried out in accordance with clause 17.2 of EN 60079-2:2007. The manufacturer shall record and retain these results.

Only Lithium batteries speciﬁ ed in manual are to be used in this enclosure.

Special Conditions of Certiﬁ cation:

A suitability certiﬁ ed Purge Control Unit must be sued with the TDLS Analyzer that is capable providing the requirements listed on label/certiﬁ cate and that either provides a suitable exhaust through a particle barrier of to a safe area.

When installed there shall be a minimum of two pressure regulators in the air/nitrogen supply line.

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Materials of Construction

The analyzer incorporates a variety of materials in its construction and they should therefore be used in an appropriate manner. Any chemicals (liquid or gas) that may have a detrimental effect on the product’s structural integrity should not be allowed come in contact.

The electronic enclosures are constructed from Aluminum Alloy AL Si 12 (ASTM A413) and have a protective epoxy powder coated surface ﬁ nish. The welded bodies are constructed of stainless steel grade 316 The fasteners are constructed of stainless steel grade 18-8 The windows (when ﬁ tted) are constructed of laminated safety glass

Maintenance Work by Qualiﬁ ed Personnel

Unqualiﬁ ed work on the product may result in severe personal injury and/or extensive damage to property. If the Warnings contained herein are not adhered to the result may also be severe personal injury and/or extensive damage to property.

1-3<1 INSTRUMENT CHECK>

This product is designed such that maintenance work must be carried out by trained personnel. Trained personnel are considered as below:

- Engineers familiar with the safety approaches of process analytical instrumentation (and/or general automation technology) and who have read and understood the content of this User Guide.

- Trained start-up/commissioning analyzer technicians who have read and understood the content of this Instruction Manual.

WARNING – Battery replacement

Replacement Battery Installation (Type CR2032 located on CPU).

The battery MUST be factory installed and cannot be installed by others at site (soldered connections, required) – Contact factory for further assistance

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2-1<2 QUICK START>

2 QUCIK START

Step Title Description

1.0

1.1 Ensure the process connections match the supplied process interface.

1.2 Ensure the appropriate utilities are available and ready for connection. These may include electrical

1.3 Ensure you comply with any local and/or site speciﬁ c safety requirements.

1.4

2.0

2.1 Attach the process interface (alignment ﬂ anges) to the site installed ﬂ anges (or isolation valves as

2.2 Carefully mount the Launch and Detect Units to their alignment ﬂ anges using the quick connect

2.3 Mount optional equipment such as Universal Power Supply (UPS), Universal Remote Display (URD),

2.4

Preparation

Installation

Ambient Temperature

3.0

3.1 Connect the appropriate electrical power supply.

3.2 Connect the Launch to Detect interconnect cable (supplied with analyzer) according to the supplied

3.3 Connect any analog I/O signals to the analog I/O Board. Outputs land on TB8 and Inputs land on TB9.

3.4 Connect any other equipment such as URD, Ethernet, solenoid valves, digital I/O, etc.

3.5

Wiring

Carefully un-pack and check equipment for any obvious damage. This includes ﬂ anges, Cables, Power Supplies, manuals and any other supplied options.

NOTES: There are 14 ferrules in the accessory bag for tubing-piping. The number of ferrule that are required for actual tubing-piping are different by application. Please see tubing-piping ﬁ gure speciﬁ c to project for exact detail.

power, nitrogen purge gas, instrument air, validation gas, etc.

Read the appropriate sections of the Instruction Manual BEFORE starting any installation work –

Contact Yokogawa Laser Analysis Division or Local Agent if any doubts!

If separate process isolation ﬂ anges have been provided for corrosive service, then install to the process/stack ﬂ ange/isolation valves.

appropriate).

If installing Large Aperture Optics, ensure the detect system is correctly mounted and purged to prevent damage to the large optical element.

coupling.

Remote Interface Unit (RIU), etc.

The analyzer and some accessories (such as LAO, RIU, UPS, URD, alignment ﬂ anges, etc.) are suitable for -20 to +50oC ambient operating temperature. Accessories and Options are available to increase these the operating conditions – please consult Yokogawa for further details.

Ensure that all wiring will enable the analyzer launch and detect units to be freely moved from their process location to an adjacent off-line calibration cell. This will entail the use of tray rated cables and/ or ﬂ exible conduit and/or other suitable armored cable. Rigid conduit systems are not recommended.

• 24 VDC to TB1 on the analyzer (launch Unit) backplane. Check that the actual voltage is >23.5VDC otherwise the SBC and other devices will not function!

• 110/240 50/60 Hz to UPS or URD, then take 24 VDC to analyzer

wiring detail (TB7 on the Launch and TB 13 on the Detect Unit).

Check terminations and ensure all cable shields are landed per supplied wiring details.

4.0

Utilities

4.1 Connect the appropriate process window purge gas (nitrogen for oxygen analyzers) and make site

4.2

4.3 Connect and check any other required utility connections (such as steam trace for heated isolation

NOTE! – All purge, Validation Gas and other gas utility lines should be thoroughly cleaned, dried and purged prior to connecting to the analyzer – Failure to do so can result in serious damage to the TDLS200 or contamination to the internal optical elements.

Connect the appropriate analyzer purge gas (nitrogen for oxygen analyzers) and make site connections per the supplied purge gas sequence details (including any Hazardous area purge system). Start the purge gas ﬂ ow accordingly.

ATEX purge requires dual regulators at the inlet purge gas supply to prevent overpressure damage in the event of a single regulator failure!

connections per the supplied purge gas sequence details. Start the window purge gas ﬂ ow accordingly – ensuring that any isolation valves are open.

Connect the appropriate analyzer on-line check gas ﬂ ow cell gas (nitrogen for oxygen analyzers) and make site connections per the supplied purge gas sequence details. Start the purge gas ﬂ ow accordingly.

ﬂ anges or ﬂ ow cells) or secondary window purges for lethal service gases. Start other utilities accordingly.

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2-2<2 QUICK START>

4.4

5.0

5.1 Use the internal On-Off switch to power-up the analyzer.

5.2 Observe the various LED clusters on the backplane and FPGA boards. All blue LEDs located on the

5.3 Observe the Green power indicator on the SBC.

5.4

6.0

6.1 If there is an installed optional Mini Display (4x20 VFD) – Observe the status line message.

6.2 If there is no installed User Interface, then connect a laptop PC via Ethernet to the SBC mounted

6.3

Power-Up

Checking

Alignment

Leak-check all connections and ensure pressure ratings are not exceeded!

Apply power to the analyzer and using a multi-meter, check for 24VDC power at TB1 on the launch unit back plane.

lower right side of the back-plane should be on.

Observe the LEDs on the analog I/O board.

If there is an installed optional 6.5” Display and Keypad – Observe the Main Menu messages and status information.

on the backplane. Initiate the supplied VNC software from the laptop to initiate a VNC session with the ‘blind’ analyzer and observe the analyzer Main Menu via the laptop.

At this time there may be one or more alarm message due to low transmission, out of range parameters or other – ﬁ nal system conﬁ guration is still required!

Please also note that the analyzer laser temperature control is disabled for the initializing period (5 minutes) – this means that even manual control of the laser temperature is disabled during this period.

Initially, observe the Transmission value through the appropriate user interface. The objective is to adjust alignment until the maximum transmission value is obtained. Perfect alignment in a clear process gas will yield close to 100% transmission.

If the analyzer displays a Warning “Validation Required”, this indicates there is no target gas absorption peak found at start-up.

7.0

7.1 Start by adjusting the Launch unit alignment ﬂ ange nuts up-down and left right. Look for increases

7.2 When it has been maximized at the launch side, adjust the detect unit accordingly.

7.3 Further adjustment can be made by maximizing the raw detector voltage signal (available at test

7.4

8.0

Alignment – check

Detector Gain

Conﬁ gure BASIC

8.1 Enter the Basic Menu and go to Conﬁ gure.

8.2

8.3

8.4

8.5 If any other parameters are required to be set (such as analog I/O ranges, alarms levels, Auto

Optical Path

Gas Pressure

Gas Temperature

Introduce some measured gas into the optical path and re-start or perform a validation with target gas. This will ensure that the analyzer is correctly tuned to the measurement gas absorption peak. If this Warning cannot be cleared by either method, please contact Yokogawa Laser Analysis Division or your local agent for further assistance.

If you have 100% certainty that the analyzer is already measuring the process gas and validation is not currently possible then, this alarm can be cleared via the Advanced Calibrate & Validate menu.

Initially, observe the Transmission value through the appropriate user interface. The objective is to adjust alignment until the maximum transmission value is obtained. Perfect alignment a clear process gas will yield close to 100% transmission.

and decreases in transmission strength to aid in the alignment.

points on both launch and detect). The signal should be maximized and will not exceed 5.3V DC for low temperature (<600C process) or 9.9V DC for high temperature (>600C process).

For Large Aperture Optics (LAO) systems, please refer to the Detector Gain Adjustment section of this User Guide to ensure correct functionality and adjustment.

By way of the appropriate user interface, the correct process parameters and other parameters can now be entered.

Enter in the correct optical path length.

Enter in the correct process gas pressure (if Active, see Advanced Conﬁ gure).

Enter in the correct process gas temperature (if Active, see Advanced Conﬁ gure).

Validation sequences) then the Advanced Menu needs to be accessed.

Advanced Menu access is Password protected and should only be used by skilled and trained persons - Contact Yokogawa Laser Analysis Division or Local Agent if any doubts!

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