Servomex 2500 Series Installation Manual
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Servomex 2500 Series Installation Manual

Process gas analysers
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Servomex 2500 Series
Process Gas Analysers
Installation Manual
Ref:02500/005C/2
Order as part 02500005C

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Summary of Contents for Servomex 2500 Series

  • Page 1 Servomex 2500 Series Process Gas Analysers Installation Manual Ref:02500/005C/2 Order as part 02500005C...
  • Page 3 RESORT AND MUST BE CARRIED OUT BY PERSONS FULLY AWARE OF THE DANGER INVOLVED. NOTE This instruction manual for the 2500 Series range of analysers covers installation, routine maintenance and fault diagnosis procedures, and it should be thoroughly read and retained by the personnel responsible.

  • Page 5: Table Of Contents

    Table of Contents SECTION 1 INTRODUCTION ......... 1.1 Introduction .
  • Page 6 INSTRUMENT SPECIFICATIONS ......7.1 Generic 2500 Series Performance ........7.1 7.1.1...
  • Page 7 SECTION 8 CE MARKING AND OTHER SAFETY APPROVALS ... . 8.1 EMC Directive ..........8.1 Low Voltage Directive .
  • Page 8 2500 AC Power and Valve Connections (Non-Purged Filter) ..3.4 Figure 3.2 2500 Series Terminal Locations ......3.5 Figure 3.3 Signal Cable Connections .

  • Page 9: Introduction

    02500/008C that details the hazardous area approvals and declarations applicable. Details of the hardware and instructions for servicing, by qualified personnel only, are presented in the 2500 Service Manual. This may be ordered from Servomex, reference part number 02500/002C. Technical assistance and spare parts are available from Servomex outlets (or their local agents) listed on the back cover.

  • Page 10: General Description

    The general layout of the 2500 Series is shown in Figure 1.1. It has been designed for modern industrial environments with the emphasis on rugged construction, reliable performance, simple operation and easy servicing.

  • Page 11: Basic Construction

    2500 with the minimum of familiarisation. NOTE Full technical specifications for 2500 Series Analysers are presented in section 7 of this manual. Basic Construction The basic construction of the 2500 is shown in Figure 1.2. It comprises 2 cast end assemblies (with hinged opening/removable covers), connected by a rigid mounting beam, or chassis.

  • Page 12: Options And Accessories

    Figure 1.2 2500 Construction The detector end (left side) contains the detector assembly and also the main electronic circuit boards. The display and control panel is also mounted in the hinged lid of this end. Options and Accessories The 2500 supplied may have been fitted with customer specified options and/or accessories.

  • Page 13: Heated Sample Cell - Steam

    1.4.2 Heated Sample Cell – Steam Where fitted, this is a steam heating coil which must be supplied with low pressure steam by the user and vented to atmosphere, to maintain a cell temperature of approximately 100°C. This allows cell heating in hazardous areas up to Zone 1/Div. I classification, and is normally used with the EU1 version only.

  • Page 14: Application Options

    WARNING Standard transducers are not suitable for oxygen service. Sample Temperature Compensation • A type 'K' thermocouple in stainless steel sheath is supplied, and a continuous temperature measurement is made by the 2500 over the range -50 to 200°C (-58 to 392°F).

  • Page 15: Installation - General

    Lift in the approved manner and remove the 2500 analyser from its packing and inspect for any damage incurred during transit. If any damage has occurred inform Servomex or their agents immediately. Retain packing, in case it is required to return the analyser...

  • Page 16: Electrical Connections

    After the initial visual inspection, carry out the following checks. Beware gas strut action of the hinged covers. • Check that the serial number of the 2500 (located inside source end and also marked on the external rating label) corresponds to the serial number given in the Manufacturing Data Sheet found at the front of this manual.

  • Page 17: Installation

    EU2 versions must be protected against the entry of solid particles or liquids by a suitable cover or enclosure where necessary. EU1 versions must be used with either a Servomex 485 Purge Control Unit with the associated Servomex 486 Relay Unit, or another suitable Purge Control System, which must meet the necessary pressurisation requirements, and is supplied with the necessary pressurisation and control components.

  • Page 18: Mounting Details

    Safety Certificate Manual. If the 2500 has been supplied with a Servomex 485 Purge Unit with the associated Servomex 486 Relay Unit, installation information is provided in a separate manual part no.

  • Page 19: Figure 2.1 2500 Positioning Restrictions

    When mounting the analyser ensure that the panel or brackets employed are adequate to take the weight and there is a minimum clearance above the casing of 500mm (20") to provide space to open the end covers. Fig 2.2 provides mounting details and a table of mounting hole spacings for the various cell lengths.

  • Page 20: Figure 2.2 2500 Mounting Details

    Figure 2.2 2500 Mounting Details Once mounted, the two yellow lifting handles and their spacers MUST be removed by unscrewing the securing screws. Press the black pop-in plugs supplied into the vacant screw holes and retain the handles for possible future use.

  • Page 21: Instructions Specific To Hazardous Area Installations

    Instructions Specific to Hazardous Area Installations (Reference European ATEX Directive 94/9/EC, Annex ll, 1.0.6.) The following instructions apply to equipment covered by certificate numbers: Sira 02ATEX1395X and Sira 03ATEX2236X 2.5.1 The equipment may be located where flammable gases and vapours of groups llA, llB and llC may be present.

  • Page 22: Atex Label Information

    ATEX Label Information 2.6.1 EU1 T5 (Unheated Cell) 2.6.2 EU1 T4 (Heated Cell)
  • Page 23 2.6.3 EU2 T3 2.6.4 EU2 T4...
  • Page 24 2.10...

  • Page 25: Installation - Electrical

    SECTION 3 INSTALLATION – ELECTRICAL WARNINGS • Lethal voltage: mains AC power supplies are potentially lethal. The installer must ensure that the power supply has been isolated before commencing installation. • The installer must be satisfied that the 2500 analyser installation conforms to the relevant safety requirements, national electrical code and any other local regulations, and that the installation is safe for any extremes of conditions which may be experienced in the operating...
  • Page 26 WARNING (EU1 VERSION) AC Power for Zone 1 (EU1) versions may only be connected via a suitably certified Purge Control System. Refer to the PCS manual for details. The mains power connection to the instrument is made via the purged electrical filter unit attached to the outside of the case.

  • Page 27: Figure 3.1A 2500 Ac Power And Valve Connections (Purged Filter)

    Figure 3.1a 2500 AC Power and Valve Connections (Purged Filter)

  • Page 28: Figure 3.1B 2500 Ac Power And Valve Connections (Non-Purged Filter)

    Figure 3.1b 2500 AC Power and Valve Connections (Non-Purged Filter)

  • Page 29: Figure 3.2 2500 Series Terminal Locations

    Figure 3.2 2500 Series Terminal Locations...

  • Page 30: Signal Connections

    To minimise the effects of interference from the RF fields, a Steward type 28B0562- 200 or equivalent ferrite sleeve (Servomex Part No. 2824-0017) shall be placed over each mA output cable pair. Refer to Figure 3.3.

  • Page 31: Analogue Outputs

    3.2.1 Analogue Outputs Figure 3.4 SIB and Optional Output PCB's Each analogue output is supplied set for current output and may be configured by the user to be 0-20mA or 4-20mA, and be assigned a particular range of operation, in software.

  • Page 32: Table 3.1 Analogue Output Connections

    WARNING (EU1 VERSION) Where the 2500 is in a Zone 1 area, a suitable Relay Box should be used to isolate the outputs. This Relay Box should be switched from the Purge Control System. Each analogue output (and each relay output) has an individual identity in software. This identity is a number, which relates to the "slot"...

  • Page 33: Analogue Output Link Selections On Sensor Interface Board (Sib) Pcb

    3.2.2 Analogue Output Link Selections on Sensor Interface Board (SIB) PCB After connecting up the required analogue outputs, the user should make the following hardware link selections on the SIB PCB and (where fitted) Option PCB(s). Refer to Figure 3.3.4 for general schematic of both these types of PCB. Carefully remove the PCB for link selection and be sure to replace it in the correct slot and in the correct orientation.

  • Page 34: Relay Outputs

    3.2.3 Relay Outputs NOTE Each relay output is supplied set for NC (i.e. Normally Closed under "Safe" condition) operation, and may be assigned to a particular alarm or signalling function in software. This is described in the Quickstart manual. User selection of NC or NO operation is described in Section 3.2.4. As with the analogue outputs, each relay has its own software identity relating to the slot in which the PCB, on which it is physically located, resides.

  • Page 35: Control Connections

    WARNING Setting the relays to Normally Open (N.O.) operation will mean that there is no fail-safe action since any loss of cable continuity will prevent an alarm being signalled. NOTE Regardless of N.O./ N.C. setting, the relays will always be in "alarm" state wherever there is no power applied to the 2500, or when they are unassigned.

  • Page 36: Range Change Input

    3.3.1 Range Change Input Every analogue output can be independently scaled in software to represent some or all of the calibrated range of the instrument, as described in the Quickstart manual. However, under some process conditions (e.g. plant start-up) it may be desirable to have different output ranges on demand.

  • Page 37: Sample Flow Sensor Input

    WARNING If the Keyswitch is left "ON" (contacts closed), access is continuously available to all normally protected areas of the software. 3.3.4 Sample Flow Sensor Input If the sampling system supplying the process sample to the 2500 is fitted with a loss of flow sensor, this can be connected to the 2500 to enable the "loss of sample flow"...

  • Page 38: Externally Powered Solenoid Valve Connections

    WARNING If installation is in a hazardous area, use suitable certified solenoid valves. NOTE Valve (SV3) reverts to OFF in Shutdown (Serious Fault) condition. The use of the optional 3rd "Sample/Inert valve will prevent sample entering the 2500 sample cell while the cell or chopper box under temperature diagnostic is activated, i.e.

  • Page 39: Internally Powered Solenoid Valve Connections

    3.3.7 Internally Powered Solenoid Valve Connections Connect to solenoid valve relays SV1, SV2 and SV3 as detailed below. Take care to ensure that internal 12VA (total) rating of the 24VDC supply is not exceeded. Table 3.5 – Internally Powered Solenoid Valve Connections Valve State (ON=Current Flow Through Solenoid) Span/Zero...

  • Page 40: Digital Connections

    Figure 3.5 Autocalibration Valve Configuration Digital Connections NOTE All digital cables must have a braided overall screen or armour. The screen must be terminated at the point of entry to the case. This will be by using a gland, which makes a connection between the cable screen and the case.

  • Page 41: Table 3.6 Serial Data Format

    Table 3.6 – Serial Data Format Item Size Description <CR> 1 byte Carriage return character (ASCII code 13). date; 8 bytes dd/mm/yy or mm/dd/yy depending on user settings. time; 8 bytes hh:mm:ss number of 1 byte 1 byte Number of components fitted components (range 1-3) <CR><LF>...
  • Page 42 Table 3.6 – Serial Data Format component 2 Max5 bytes Concentration for component 2 as defined concentration; for measure display. (if fitted) component 2 units; Max 3 bytes Units defined for component 2. (if fitted) component 2 alarm 4 bytes One byte for each alarm.
  • Page 43 Table 3.6 – Serial Data Format component 3 1 byte or Indicates Autocalibration phase. Autocalibration 15 bytes 0 = Not in Autocalibration status; 1 = In span preflush 2 = In zero cal 3 = zero corrected. This is then followed by two additional values, which are separated by commas, each 6 bytes that represent the zero before calibration and the zero after...
  • Page 44 Table 3.6 – Serial Data Format checksum; 4 bytes ASCII representation of 16 bit checksum (modulo 65536), calculated by adding all data preceding the checksum together. <CR><LF> 2 bytes Carriage return and Line Feed characters (ASCII codes 13 and 10 respectively). <CR><LF>...

  • Page 45: Table 3.7 Fault Number Reference

    Table 3.7 – Fault Number Reference Fault Number Display Message OPTICAL BENCH POWER FAILURE SOURCE VOLTAGE HIGH SOURCE VOLTAGE LOW INFRARED SOURCE FAILURE CHOPPER MOTOR OUT OF LOCK SAMPLE FLOW FAILURE CHOPPER TEMP HIGH CHOPPER TEMP LOW CHOPPER TEMP SENSOR FAILURE CELL TEMP HIGH CELL TEMP LOW CELL TEMP SENSOR FAILURE...

  • Page 46: Table 3.8 Ascii Characters

    Some characters defined by the 2500 are non-standard characters, i.e. not part of the ASCII character set. These either occupy the ASCII codes above 127 or redefine an ASCII code as another character. When these characters are used, for example in the component formula, they will be substituted with a valid ASCII character prior to output on the RS232.

  • Page 47: Pressure Transducer Connections - (If Supplied)

    WARNING Do not use an uncertified dcs, datalogger or printer in a hazardous area. Pressure Transducer Connections – (If Supplied) The pressure transducer cabling is terminated to the source end right hand side (RHS) of the analyser. The pressure transducer is supplied pre-wired to the analyser. The cabling is connected to PCB 02500911A TB35 as shown in Table 3.10 Table 3.10 –...

  • Page 48: Figure 3.6 Typical Pressure Transducer Assembly

    Figure 3.6 Typical Pressure Transducer Assembly 3.24...

  • Page 49: Installation Gas Connections

    WARNING (EU1 VERSION) Where appropriate, the user must refer to the detailed instructions provided in the manual supplied with the Servomex 485/486 purge units or other Purge Control System, and use them in conjunction with the following instructions. Figure 4.1...
  • Page 50 The general schematic for a hazardous area purge system is shown in Figure 4.1. WARNINGS (FIGURE 4.1) If this component is mounted in a hazardous area it should be protected by one of the norms listed in EN 50014. Cable glands used in EEx 'd' apparatus shall be approved Ex 'd' components, which maintain the degree of protection necessary.

  • Page 51: End Boss Purge Connection

    End Boss Purge Connection Depending on application, fittings for 1/8" o.d. tube may be provided to purge the end bosses on either side of the sample cell and these should now be connected. Refer to the following application notes and Figure 4.2 where necessary. 4.2.1 Introduction The 2500 measuring cell is mounted on two short tubes or "end bosses"...

  • Page 52: End Boss Vents

    4.2.3 End Boss Vents When a flammable, severely corrosive or toxic gas or liquid is present in the sample cell, either as the sample or a background gas, additional issues arise. The construction of the cell window seal is such that any leak of the seal or failure of the window will result in the sample gas entering the end boss, but not being released to the surrounding atmosphere or directly into the analyser enclosure.

  • Page 53: Figure 4.2 Cell End Boss Connection

    NOTE Vent lines, if required, should be connected to end boss bottom tappings. Purge gas should be connected to top tappings when required. When not required, top tappings should be plugged. IF FITTED, COMMENCE END BOSS PURGE FROM THIS POINT ONWARDS. WARNING Where the sample is corrosive or toxic, the vent lines from the end bosses must take away any potential leakage to a safe disposal point.

  • Page 54: Steam Heated Cell

    Steam Heated Cell Some 2500's are fitted with steam heated cells, and at this stage suitable low pressure steam, typically at 14-21kPa, 2-3 psig venting to atmosphere after the cell, should be connected ready for use, but do not pass steam into the heating coil yet. Fittings for 1/8"...
  • Page 55 The normal measurement display will then appear and the 2500 will be operational. NOTES • The measurement will not be valid at this point since process sample is not yet flowing. • If a heated cell is fitted, it will not yet be up to temperature and the intermittent "warming up"...

  • Page 57: Fault Diagnosis And Cell Maintenance

    Section 3.2.2). NOTE For detailed instructions on all Service and Maintenance operations for suitably skilled personnel, please refer to the 2500 Series Service Manual part number 02500/002C. Diagnostics The diagnostics listed in Table 5.1 can be interrogated via the DIAGNOSTICS function...

  • Page 58: Table 5.1 Diagnostic Displays

    Table 5.1 – Diagnostic Displays Display Description CHOPPER TEMP °C Chopper box temperature COMPENSATION °C Detector temperature CELL TEMP °C Cell temperature (if enabled) SAMPLE TEMP °C Sample Temperature * [Measurement 1] ABS au Absolute absorbance units (M1) [Measurement 2] ABS au Absolute absorbance units (M2) * [Measurement 3] ABS au Absolute absorbance units (M3) *...

  • Page 59: General Fault Conditions

    General Fault Conditions When the Fault LED is illuminated, the DISPLAY FAULTS function should be used to determine the nature of the fault. The diagnostics (Section 5.2) may assist in defining the cause, together with the comments given in Table 5.2. Action to cure the fault should be taken as soon as possible.
  • Page 60 Table 5.2 – General Fault Messages SPAN OUT OF SPAN OUT TOL Failed Autocalibration – bad span TOLERANCE sample – use One Cycle or Manual Span AUTOCAL BAD BAD PREFLUSH Failed Autocalibration – bad PREFLUSH preflush – use One Cycle PASSWORD BAD PASSWORD 3 consecutive Password failures...

  • Page 61: Serious Fault (Shutdown) Conditions

    Serious Fault (Shutdown) Conditions If the Fault LED is illuminated and the Analogue Outputs have been driven HIGH (or LOW, depending on selection), a Serious Fault exists and the Measurement Display will show "Measurement Invalid". Immediate action should be taken to rectify the fault, and qualified service personnel should be called.

  • Page 62: Figure 5.1 General Cell Construction

    Figure 5.1 General Cell Construction CAUTION Use only Servomex supplied spare parts. The use of inferior replacement components may degrade the performance and safety of the instrument.
  • Page 63 WARNING • Lethal voltages: mains AC power supplies are potentially lethal. The maintainer must ensure that all mains power supplies are disconnected from the supply before maintenance work is started. • Purge the measuring cell and associated pipework with an inert gas before work is started.
  • Page 64 To remove the window, seal the outlet and with the cell in a vertical position, connect a hand operated aspirator (Servomex p/n 2387-0514) to the inlet. Apply a gentle pressure to lift the window up squarely and remove it.

  • Page 65: Routine Leak Checks

    Ensure all items are thoroughly clean and dry before reassembly, which is the reverse procedure but with the following points noted: • The windows should be 'floated' into place squarely using a hand aspirator or equivalent, reversing the removal procedure. •...
  • Page 66 5.10...

  • Page 67: Spares Lists

    SECTION 6 SPARES LISTS Spares List The following spares list applies to all versions of the 2500 covered by this manual. The 2500's Model and Serial Number MUST be advised when ordering spares. NOTE For ATEX versions EU1 and EU2 only those boards listed may be used as spares 6.1.1 General Table 6.1 –...

  • Page 68: Sample Cell Spares

    Table 6.1 – General Spares List Special Tools Kit S2500979 Enclosure Earth Studs S2500984 Pressure Transducer S2500985 Chopper Motor S2500986 Chopper Box Seals Kit S2500988 Gas Strut Kit S2500989 Motor Connection PCB S2500906 Fuse Kit 02501996 Multi component Adaptor PCB (2550 only) S2550901 10 x Gas Filter Correlation Adaptor PCB (2510 only) S2510901A...

  • Page 69: Source Units

    6.1.3 Source Units (Refer to Final Specification Sheet) Table 6.3 – Source Unit Spares Description Part Number Long Wave, CaF S2500931C Long Wave, BaF S2500931B Long Wave, ZnSe S2500931A Short Wave, CaF S2500943A Short Wave, Glass S2500943B Soft UV CaF (2520 Only) S2520933 6.1.4...

  • Page 70: Windows

    6.1.5 Windows (Refer to Final Specification Sheet) Table 6.5 – Window Spares Description Part Number S2500980A S2500980B ZnSe S2500980C IR Quartz S2500980D Glass S2500980E Germanium S2500980F Sapphire S2500980G 6.1.6 Scrubbers (Refer to Final Specification Sheet) Table 6.6 – Scrubber Spares Detector / Cell Boss Scrubber (H O) Marked 'W' S1200921...

  • Page 71: Recommended Spares

    Recommended Spares Quantity for 2 years. Table 6.7 – Recommended Spares Item Part Number 1-3 Analysers 4-9 Analysers Fuse Kit 02501996 Cell Servicing Kit S2500981 PTFE Tape 1835-3026 Chopper Motor S2500986 Cell sealing Kit Refer to application Hand Aspirator 2387-0514 Windows Refer to application Chopper Box Scrubber...

  • Page 73: Instrument Specifications

    SECTION 7 INSTRUMENT SPECIFICATIONS Generic 2500 Series Performance 7.1.1 Environmental Specifications Table 7.1 – General Environmental Specifications Operating Temperature GEN, EU1, EU2, FM2, HTV 0-55°C (32-131°F) Operating Humidity 0-95% RH, non-condensing Storage Temperature -40°C(-104°F) to +70°C (158°F) Storage Humidity 0-95% RH, non-condensing...

  • Page 74: Performance Characteristics (Each Component)

    Fitted with an unscreened power cable. Also included were two separate mA output cables, each individually screened. Each signal pair was fitted with ferrite bead (Servomex part No. 2824-0017). The screens and drain wires were terminated at the glands. Results: Met the requirements of EN 61326, Table 4, Class B (Equipment for use in domestic establishments) in respect of conducted and radiated emissions.

  • Page 75: Sample Specification

    Table 7.3 – Sampling Specification Sample Temperature 0-180°C/32-356°F (see sampling influences) Sample Pressure 0-150 psig/0-10 barg (normal) (For special high pressure operation consult Servomex) Sample Flow (typical) GAS 0.2-5.0 litres/min LIQUIDS 0.3-1.0 litres/min (Constant flow rate preferred) Sample Wetted Materials Refer to Final Specification Sheet 7.1.7...

  • Page 76: Analogue Outputs

    7.1.9 Analogue Outputs 2 x mA outputs, plus 3 x relay outputs. Optionally additional 2 x mA, plus 2 x relay outputs. All analogue mA outputs are assignable and selected as 0-20mA or 4-20mA (max. impedance 1KOhm) or alternatively 0-10V or 2-10V (min. impedance 1MOhm). Dual ranges on every Analogue output.

  • Page 77: 485 Purge Controller (2500 Eu1 Only)

    7.1.14 485 Purge Controller (2500 EU1 Only) Requires maximum of 40 l/min clean dry Nitrogen or clean dry Air at 3-7 barg, depending on application. 7.1.15 Alternative Purge Controller (2500 EU1 Only) Minimum flow rate = 10 SLPM for 11 minutes. Minimum overpressure = 0.5 mBar.
  • Page 79 2500V. Pressure Directive All the relevant design aspects of the 2500 series analysers have been assessed in respect of the requirements of the Pressure Equipment Directive (97/23/EC). These products are excluded from the scope of this directive when installed and operated...

  • Page 80: Table 8.1 02500 Safety Approvals

    ATEX Directive and other non-European Hazardous Area approvals ATEX Directive 94/9/EEC NOTE Depending on the variant ordered an additional Safety Certificate Manual may be supplied. This contains all the relevant safety certificates and declarations for the EU1, EU2 and FM2 variants. WARNING The installer and/or the user of the analyser must be satisfied that the installation complies with any "Special Conditions for Safe Use"...

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