Related Manuals for Servomex SERVOTOUGH LaserExact 2950
Summary of Contents for Servomex SERVOTOUGH LaserExact 2950
- Page 1 PROCESS ANALYSERS SERVOTOUGH LaserExact (Model 2950) Operator Manual (For Windows Software v. 6.1) Part Number: 02950001A Revision: Language: UK English...
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Page 3: Table Of Contents
SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 TABLE OF CONTENTS INTRODUCTION ........................1 .......................1 AFETY NFORMATION ..........................1 ENERAL ......................2 EASURING PRINCIPLE ......................4 NSTRUMENT DESCRIPTION ..........................5 OFTWARE ......................6 ASER LASSIFICATION ........................7 RODUCT PREPARATIONS ........................8 ....................8 OOLS AND OTHER EQUIPMENT ........................8 LOW CONDITIONS ........................8 ATERIALS ..................8 ABLES AND ELECTRICAL CONNECTIONS... - Page 4 SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 RS-232 .................. 55 THERNET CONNECTIONS (4-20 (PLC) ............56 URRENT LOOP INPUT CONNECTIONS ..................57 AINS POWER CABLE CONNECTION LED’ ................57 RANSMITTER BOARD FUSES AND ....................... 58 ELAY INDICATIONS ....................60 ONFIGURING RELAY OUTPUT 6.9.1 Normal configuration of relay-3, «Gas Alarm»...
- Page 5 SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 FIGURES 1-1: M SERVOTOUGH L ..........3 IGURE EASURING RINCIPLE ASER XACT ONITOR 1-2: B ................5 IGURE LOCK DIAGRAM OF INSTRUMENT ELECTRONICS 3-1: SERVOTOUGH L ..............11 IGURE ASER XACT ONITOR VERVIEW 3-2:P ........................
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Page 7: Introduction
SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 INTRODUCTION Safety Information Read this manual and ensure that you fully understand its content before you attempt to install, use or maintain the Laser monitor. Important safety information is highlighted in this manual as WARNINGs and CAUTIONs, which are used as follows: WARNING Warnings highlight specific hazards which, if not taken into account, may result in personal injury or death. -
Page 8: Measuring Principle
SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 WARNING The Safe Area monitor is only suitable for use in unclassified areas. WARNING The ATEX Zone 2 and CSA CL I Div 2 Hazardous area variant cannot be used for oxygen enriched samples; that is, gases over 21% O . -
Page 9: Figure 1-1: Measuring Principle
SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 The line amplitude and line width are both extracted from the second harmonics line shape, which makes the measured concentration insensitive to line shape variations (line broadening effect) caused by background gases. NOTE: The SERVOTOUGH LaserExact Monitor measures the concentration of only the FREE molecules of the specific gas, thus not being sensitive to the molecules bound with some other molecules into complexes and to the molecules attached to or dissolved in particles and droplets. -
Page 10: Instrument Description
SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 Instrument description The SERVOTOUGH LaserExact Monitor consists of 3 modules: • Cabinet • LaserExact cell (under an optional protective cover) • Laser beam alignment chamber (under an optional protective cover) The cabinet is connected to the laser beam alignment chamber, which couples the laser beam into the LaserExact cell. -
Page 11: Software
SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 The RS-232 or Ethernet service port is connected to an external PC during installation, calibration and if service is required. Normally this port should not be in use. Optionally a modem can be implemented, which enables long distance communication with the instrument for service purposes. -
Page 12: Laser Classification
SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 Laser Classification The diode lasers used in the SERVOTOUGH LaserExact Monitors operate in the near infrared (NIR) range between 700 and 2400 nm depending on the gas to be measured. The lasers have an output power and optical arrangement, which according to IEC 60825-1 2007 classifies the SERVOTOUGH LaserExact Monitors as Laser Class 3R Laser Product. -
Page 13: Product Data
SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 Product Data Manufacturer NEO Monitors AS Country of origin Norway Model: SERVOTOUGH LaserExact (LaserGas II Multipass) Dimensions (L x H x W): 571 x 627 x 200mm Mass: 28kg Environmental conditions: Operating temperature: -20°C to +55°C Storage temperature -20°C to +55°C Apparatus is suitable for indoor use... -
Page 14: Preparations
A list of the standard cell materials is given below. As these materials are exposed to the gas mix; therefore, it should be verified that the gas does not adversely affect any of them. Other cell materials may be available on request (contact SERVOMEX). • Stainless steel, type AISI 316L •... -
Page 15: Sticky Gases
SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 Sticky gases Special care should be taken for reactive and “sticky” gases such as NH , HCl and S. Because of the nature of these gases, it is difficult to obtain the correct concentration in the cell due to possible adsorption and desorption in the connection tubes. -
Page 16: Installation
SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 INSTALLATION WARNING You must install and use the Laser monitor in accordance with the requirements of this section and subsequent sections of the manual. If you do not, people may be injured, the protection facilities incorporated into the design of the Laser monitor may not operate as intended, measurements may not be accurate, or the Laser monitor may be damaged. -
Page 17: Installation And Adjustments
SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 Installation and adjustments The installation procedure described in this section refers to Figure 3-1. Figure 3-1: SERVOTOUGH LaserExact Monitor Overview Cabinet Display LaserExact cell Gas inlet (std. 6 mm SS pipe) Gas outlet (std. 8 mm SS pipe) Laser beam alignment chamber Alignment Chamber Purge gas inlet (std. -
Page 18: Servotough Laserexact Installation
SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 3.2.1 SERVOTOUGH LaserExact installation WARNING You must not modify the Laser monitor in any way (either mechanically or electrically). If you do, the certification of the monitor will be invalidated, and it may not operate safely. WARNING The Laser monitor is heavy (see section 1.7). - Page 19 SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 WARNING If using toxic, asphyxiant or flammable sample or calibration gases, open cabinet or alignment chamber enclosures in a force ventilated open area, or in another appropriate environment in which any hazardous gases are directed away from the user. WARNING The ATEX Zone 2 and CSA CL I Div 2 Hazardous area variant cannot be used for oxygen enriched samples;...
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Page 20: Purging Of Laser Beam Alignment Chamber
SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 To install the instrument follow the steps below (see also Figure 3-1). Install the instrument in an upright position. Use the mounting tabs provided with the analyser. Connect the sample gas tubes as follows: Gas INLET 6mm OD (front of unit) Gas OUTLET 8mm OD (rear of unit) Metric Swagelok fitting are supplied loose for use, however other... -
Page 21: Laser Module Purge
SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 WARNING The user must monitor the sample flow rate out from the measuring cell. A fall in flow rate could indicate a gross leak of sample gas into the LaserExact enclosure. In the event of a suspected leak, ensure you follow all warnings regarding purging of the sample system before inspecting the unit. -
Page 22: Start-Up
SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 Start-up Switch on the electronics. The LCD on the cabinet will enter start-up mode showing: STL MONITOR 6.1a1 - power - Self-test Start-up 0.998 WARNING The laser beam is switched on when any indication is shown on the display, or the backlight is illuminated. - Page 23 SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 Remove the outer protective cover by removing front screws and lifting off the cover. Make sure that the following bolts and nuts are tightened firmly: • The four bolts fastening the laser unit to the alignment chamber (accessible from the inside of the cabinet) •...
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Page 24: Figure 3-3:Alignment Chamber Access Panel
SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 Mirror access hatch Figure 3-3: Alignment chamber access panel Adjusting Screws Output Coupling Mirror Input Coupling Mirror Figure 3-4: Coupling mirrors HAPTER... -
Page 25: Connecting Apc
SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 Connecting a PC The software for service communication with the SERVOTOUGH LaserExact is supplied with the instrument and will run under Windows98/2000/XP/Vista/7. The service program requires no installation. Please note that the PC should be placed in an explosion safe area. -
Page 26: The Service Program
SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 THE SERVICE PROGRAM The instrument calculates the gas concentration from the measured signal, which depends on several process parameters. The instrument must therefore be configured for the specific installation. With the service program the user communicates with the instrument and changes installation or process relevant settings. - Page 27 SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 The version of the service program is printed in the right bottom corner (in the example above V1.2.7.3). For direct serial or modem connection, select the PC serial port from the dropdown list of available ports and press the corresponding button. When using a modem, you will be asked for a telephone number to dial.
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Page 28: The Measurement Menu
SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 instrument. Your local distributor or SERVOMEX can provide the password on request. Note that if the connection is moved to another instrument the program must be shut down and run again. It is possible to run several program windows simultaneously to communicate with different instruments using one PC. - Page 29 SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 pressing the buttons or by pressing the underlined shortcut letters (e.g. <S> for Second harmonic signal). By pressing <Exit menu> one can always go back to the previous menu. The description of each menu will follow. The rest of the screen is used to display different readings parameters.
- Page 30 SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 Line position: The position of the line peak (maximum absorption) in samples of the AD converter [0..63]. The value should be close to the reference line position, which is given in the menu <Gas specific parameters> for the corresponding line. The instrument automatically tracks the line, i.e.
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Page 31: The Program Menus
SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 Dark Direct: Optical zero of the direct signal measured when the laser is switched off for a short period. The unit is the same as for Max. Direct. Laser temp. (V): The voltage across the thermistor located in the vicinity of the diode laser. -
Page 32: Log Readings
SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 as Line position and Line amplitude described in previous Section 4.2. The line position must be within the acceptance window marked by the two vertical red lines. For some instruments such as dual gas instruments more than one absorption line is plotted. -
Page 33: View Error Log
SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 mode (0 (ok)/ 1 (zero)/ 2 (span)). Parameters can be added to or deleted from the logging file without interrupting the logging process. The configuration of the logging file may be modified (e.g. specify text qualifier, data separator, add comment on top etc.). -
Page 34: Measurement Configuration
SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 In case of instrument failure it is always useful to download the error log and the system log and send both files to SERVOMEX for diagnostics. 4.3.5 Measurement configuration In this menu the most important parameters can be set:... - Page 35 Method “Spectral” (only for temperature) sets the gas temperature equal to the temperature measured spectroscopically. This method is only applicable for instruments measuring gas temperature like the O +Temperature monitor. Method “Serial”: Pressure and temperature input through RS-232 or Ethernet connector (requires special data packet, contact SERVOMEX for details). SERVICE PROGRAM...
- Page 36 SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 Optical path variables The signal detected by the SERVOTOUGH LaserExact is proportional to the total absorption between the laser and the detector. To compensate properly for the absorption in air inside the optical units, the monitor must know some parameters described below.
- Page 37 SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 chamber can be specified, whereas the pressure is assumed the same as in the sample gas. Note: The gas temperature and the optical path length through the laser beam alignment chamber are specified with the parameters <G AS TEMPERATURE IN >...
- Page 38 SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 Instrument time The instrument has a built-in clock, which also runs when power is off. Using this menu the instrument time should be set equal to the local time. The current instrument time is only downloaded from the instrument after an update of parameters or explicitly after pressing <Reload readings (P, T, date)>.
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Page 39: Gas Specific Parameters
SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 where N is the originally measured gas concentration on wet basis and H O(%) is the input H O concentration in % vol. The factor that multiplies N is Dry conversion factor which can be monitored in the Measurements menu. O input method The following input methods for the H O concentration can be selected: Fixed,... - Page 40 SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 The relative units g/Nm , mg/Nm and ug/Nm are the values obtained from the conversion of the absolute units (g/m , mg/m and ug/m ) to standard pressure and temperature assuming the ideal gas law. According to the European standard which applies for the SERVOTOUGH LaserExact Monitor these values are P = 1.013 Bar and T = 0°C.
- Page 41 SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 Gas conc. alarm level The gas concentration level for which the alarm relay is activated. The gas alarm level is specified in the currently active unit for gas concentration. If a different unit is later selected, the gas alarm level will not automatically be converted to the new unit but must be set manually.
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Page 42: Calibrate Instrument
SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 The constant used to calculate the line width, which in turn is used to calculate the gas concentration. The line width constant can be modified together with the calibration constant after calibration (see Section 4.3.7). The value cannot be modified manually in this menu if the program runs in User mode. - Page 43 The new calibration will be stored permanently. The calibration time will be updated automatically. SERVOMEX calibrates all instruments under controlled conditions using certified gas. This calibration is then verified for the specified range of temperature and pressure. There is no need to calibrate the instrument upon reception.
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Page 44: Tcp/Ip And Modem Configuration
SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 measurements for the gas, which should be calibrated proportionally, must be switched OFF in Gas specific parameters menu (only for the program running in Advanced mode). It can be switched back ON after the calibration. Calibration mode is not applicable to the spectral temperature. -
Page 45: File Download / Upload
SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 Gateway IP address The address of a server used to route TCP/IP traffic to/from the Ethernet board to another network. This is normally not needed for local communication, but may be needed when the Ethernet board is setup for internet connection. 4.3.9 File download / upload The menu allows the user to save/restore instrument data to/from file. -
Page 46: Manual Instrument Control
SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 It is possible to upload instrument settings from a PC, thus updating the instrument with new settings or restoring a previously saved instrument configuration. It is important to ensure that the settings file is correct and actually belongs to this SERVOTOUGH LaserExact Monitor. -
Page 47: Operation, Maintenance And Calibration
SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 OPERATION, MAINTENANCE AND CALIBRATION Operating modes After having set all necessary instrument parameters as described in chapter 4, the instrument is ready for operation. During continuous operation, the SERVOTOUGH LaserExact Monitor may be in any of these three modes: 1. - Page 48 SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 The measuring mode is defined by input through digital communication (e.g. with service program see Section 4.2), a) In normal mode the measured gas concentration is periodically 1) printed on the LCD, 2) output to the 4-20 mA current loop (PLC) (optional), and 3) output to the optical fibre cable (optional).
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Page 49: Maintenance
“zero gas” line (e.g. H O line for an HF instrument). Contact SERVOMEX if you are in doubt about your instrument. • Check calibration every 12 months (depending on the required accuracy). Recalibrate if necessary. (See below.) •... -
Page 50: Servicing The Laserexact Cell
SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 5.2.2 Servicing the LaserExact cell Dust or other contamination on the cell mirrors will reduce the signal level. The instrument is designed to allow a considerable reduction of the signal level (down to 10-30%) without influencing the quality of the measurements. However, if the signal level drops below the level of reliable measurements, the LCD shows «Low transmission», and the cell should be cleaned. -
Page 51: Calibration Of The Instrument
SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 Calibration of the instrument The SERVOTOUGH LaserExact Monitor is factory calibrated using a certified gas mixture and a calibration certificate is supplied together with the instrument. There is therefore no need for the user to calibrate the instrument upon reception. After some period of operation the instrument parameters may change due to ageing of the diode laser. - Page 52 SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 If only a gas mixture with higher gas concentration is available, dilute the gas mixture with nitrogen using a calibrated gas mixing system to the specified values above. Significantly lower concentrations should not be used because the measurements might be influenced by noise as well as by adsorption and desorption processes in the cell and the tubes.
- Page 53 SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 • Use Teflon connection tubes. • Use the shortest possible length of the tubes. • When flushing calibration gas through the cell, use large flow rates such as 5-7 L/min. • Wait until the concentration in the cell has stabilised. •...
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Page 54: Proportional Versus Global Calibration
SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 5.3.1 PROPORTIONAL versus GLOBAL calibration Line broadening compensation requires a large number of parameters to be measured. These parameters are critical for accuracy, but only when line broadening compensation is used. Most of the parameters seldom or never need to be adjusted. PROPORTIONAL calibration: This calibrates the span of the gas concentration by adjusting the proportionality between the peak amplitude of the absorption line and the gas concentration. - Page 55 SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 Fault message Explanations and actions « Low transmission » WARNING The optical transmission has dropped below the limit for reliable measurements. This might indicate misalignment of the optical units or contamination of the mirrors in the cell. Check alignment and replace cell if necessary.
- Page 56 SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 Fault message Explanations and actions « Ex-read out of range » WARNING Input current from external gas sensor is either above 22 mA or below 3.2 mA. Check Extra (Flow) current input. « Voltage supply fail » The power supply voltage input to the instrument is exceeding acceptable range (for standard instrument;...
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Page 57: Table 5-2: Instrument Lcd
SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 Fault message Explanations and actions « Low line position » ERROR « High line position » The instrument has detected a spectroscopic fault. This « No absorption line » can have several causes: 1) Unknown interference gas in process, 2) Incorrect laser temperature (wavelength). -
Page 58: Electrical Connections
SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 ELECTRICAL CONNECTIONS Note that in the table columns labelled “DESCRIPTION”, the indicated polarities of the items are for naming only and does not necessarily reflect the polarity of real voltages. All potentials are floating and none of them should be grounded to the cabinet. -
Page 59: Cabinet Interface
SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 Cabinet interface The electronic interface for the cabinet is depicted in Figure 6-1. NETWORK CONNECTOR [OPTIONAL]: • 10 or 10-100 Base-T Ethernet AUXILIARY I/O CONNECTOR: PURGE CONNECTOR: • • Relay outputs Compression fitting for •... -
Page 60: Power Cable Connections
SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 Power cable connections P o we r & 4-20mA Inp ut Junction list Terminal: Pair no: Color code: Description: N .C. Temperature Probe - N .C. Temperature Probe + N .C. Pressure Probe - N .C. -
Page 61: Thernet Connections
SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 set “NC”, normally closed. This may be changed to “NO”, normally open with dip switches marked “Rel ‘x’ NC/NO” on the AUX board. Note that external relays connected to the instrument may induce current or voltages that exceed the above ratings. -
Page 62: Current Loop (4-20 Ma) Input Connections (Plc)
SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 Junction list Terminal: Color code: Description: Comments: White/Orange for straight Orange through White/Green connection (hub) Green Junction list Terminal: Color code: Description: Comments: White/Green for cross over Green connection (direct White/Orange to PC) Orange Table 6-4: Cabinet –... -
Page 63: Mains Power Cable Connection
The 220 VAC power terminals inside the cabinet can accommodate conductors with area < 2.5 mm (SERVOMEX uses 1 mm Transmitter board - fuses and LED’s The transmitter board has one main fuse and some LED's to indicate status of different supply voltages. -
Page 64: Relay Indications
SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 Figure 6-4: Main board, fuses and LED’s layout Relay indications The following table shows the different relay indications (next page): Relay indications: X = Activated (conducting) O = Deactivated (not conducting) HAPTER... -
Page 65: Table 6-5: Relay Indications And Outputs
Notes: 1 «Relay 3: Gas alarm» is the only function of relay 3 in all software versions prior to 6.1c1 (check with your distributor or SERVOMEX if in doubt about the SW version of your instrument) 2 «Last» means the last valid measurement concentration before an error occurred. -
Page 66: Configuring Relay 3 Output
SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 The WARNING relay deactivates when the SERVOTOUGH Monitor detects a possible problem in the measurements, and the instrument measurements may not be correct or accuracy of the measurements reduced. Examples of such cases are low laser beam transmission due to dust on the optical windows or misalignment, or incorrect values of the 4-20 mA PLC inputs for pressure and temperature. -
Page 67: Inverted Configuration Of Relay-3, «Gas Alarm
SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 6.9.2 Inverted configuration of relay-3, «Gas alarm» This is defined by setting the parameter “Gas conc alarm level” < 0 (negative value) for gas-1. Inverted relay-3 function then also applies to gas-2 and gas-3 alarm levels (if applicable) irrespective of their sign. -
Page 68: Appendix 1 Compliance And Standards Information
It is suitable for operation when connected to a public utility power supply that also supplies residential environments. • Servomex Group Ltd is a BS EN ISO 9001 and BS EN ISO 14001 certified organisation. • NEO Monitors, Norway is a BS EN ISO 9001:2000 certified organisation. - Page 69 SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1 APPENDIX...
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Page 72: Appendix 2 Product Disposal/Applicability Of The Waste Electrical And Electronic Equipment (Weee) Directive 2002/96/Ec
+44 (0) 1892 652181 Fax: +44 (0) 1892 662253 Global email: info@servomex.com • All analysers returned to the Servomex Group or one of its appointed agents for servicing, disposal, or any other purpose must be accompanied by a completed decontamination certificate. APPENDIX...
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