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SS500/SS2000

SS3000 H2O/CO2SS3000 H2O/H2O

SS500/SS2000/SS3000Gas Analyzer

Hardware Installationand Maintenance Manual

P/N 4900002215 rev D

Hardware Installation andMaintenance Manual

SS500/SS2000/SS3000 Gas Analyzer

Hardware Installation and Maintenance Manual

Use this manual with the Firmware Operator’s Manual

Products of

4333 W Sam Houston Pkwy N, Suite 100Houston, TX 77043-1223

Tel: 800.619.2861Fax: 713.856.6623

www.spectrasensors.com

Copyright © 2016 SpectraSensors, Inc. No part of this manual may be reproduced inwhole or in part without the express written permission of SpectraSensors, Inc.SpectraSensors reserves the right to change product design and specifications at anytime without prior notice.

Revision History

Revision Engineering Order Date

A EO15547 4/8/2014

B ECR16086 3/10/2015

C ECR16353 1/22/2016

D ECR16701 7/29/2016

TABLE OF CONTENTS

List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v

1: Introduction Who Should Read This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1How to Use This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

General Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Conventions Used in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

SpectraSensors Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3About the Gas Analyzers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Differences between the SS500, SS2000, and SS3000 . . . . . . . . . . . . . . . . . 1-3How the Analyzers Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Wavelength Modulation Spectroscopy (WMS) Signal Detection . . . . . . . . . . . 1-7Getting Familiar with the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

2: Installation What Should be Included in the Shipping Box . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Inspecting the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Installing the Analyzer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Hardware and Tools for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Mounting the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Lifting/carrying the analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Connecting Electrical Power to the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3Protective chassis and ground connections . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Connecting the Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6Changing the 4-20 mA Current Loop Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Calibrating the analog output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9Testing and adjusting the 4-20 mA zero and span . . . . . . . . . . . . . . . . 2-10

Connecting the Gas Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10Conditioning the SCS Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

3: Sample Conditioning System (SCS) About the SCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Checking the SCS Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Starting up the SCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Shutting Down the SCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Appendix A: Specifications Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-19

Appendix B: Maintaining & Troubleshooting Potential Risks Affecting Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Mitigating risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1Electrocution hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1Explosion hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Gas Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2Excessive Sampling Gas Temperatures and Pressures . . . . . . . . . . . . . . . . . . . . B-3Electrical Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

Hardware Installation and Maintenance Manual i

SS500/SS2000/SS3000 Analyzer

Peak Tracking Reset Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3Cleaning the Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

Determining the type of cell mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4To replace the stainless steel mirror: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7

Pressure Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8Periodic SCS Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-14

Regular SCS Status Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-15Instrument Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-15Service Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-21

Customer Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-21Before contacting Technical Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-21Service Repair Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-21

Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-22Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-23Disclaimers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-23Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-23

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-1

ii 4900002215 rev. D 7-29-16

LIST OF FIGURES

Figure 1–1. SS500/SS2000 analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4Figure 1–2. SS3000 Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4Figure 1–3. Schematic of a typical laser diode absorption spectrometer . . . . . . 1-5Figure 1–4. Typical raw signal from a laser diode

absorption spectrometer with and without mirror contamination. . . 1-6Figure 1–5. Typical normalized absorption

signal from a laser diode absorption spectrometer . . . . . . . . . . . . 1-7Figure 1–6. Typical normalized 2f signal; species concentration is

proportional to the peak height . . . . . . . . . . . . . . . . . . . . . . . . . 1-8Figure 1–7. Analyzer Overview (SS3000 pictured) . . . . . . . . . . . . . . . . . . . . . 1-9Figure 1–8. Electronics control board (AC) for single-channel systems

(SS500/SS2000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10Figure 1–9. Electronics control board (DC) for single-channel systems

(SS500/SS2000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11Figure 1–10. Electronics control board (AC) for dual-channel

systems (SS3000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12Figure 1–11. Electronics control board (DC) for dual-channel

systems (SS3000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Figure 2–1. Internal view of electronics enclosure (SS500) . . . . . . . . . . . . . . . 2-5Figure 2–2. AC and DC connection terminal blocks in electronics enclosure. . . . 2-6Figure 2–3. Mating terminal block (TB2) in electronics enclosure for

connecting signal cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7Figure 2–4. 4-20 mA output board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Figure 3–1. Typical full-featured, single-channel SCS (SS500/SS2000) on a panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Figure A–1. SS500/SS2000 0.8-m cell (moisture) outline andmounting dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6

Figure A–2. SS500/SS2000 0.1-m cell (carbon dioxide) outline andmounting dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7

Figure A–3. Drawing of typical full-featured single-channel SCS (SS500/SS2000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8

Figure A–4. Drawing of typical full-featured single-channel SCS (SS500/SS20000) in 24x24 enclosure . . . . . . . . . . . . . . . . . . . . . A-9

Figure A–5. Drawing of typical full-featured single-channel SCS (SS500/SS20000) in 30x30 enclosure . . . . . . . . . . A-10

Figure A–6. Electrical schematic for SS500/SS2000 . . . . . . . . . . . . . . . . . . . A-11Figure A–7. Interconnect diagram for single-channel system

(SS500/SS2000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-12Figure A–8. SS3000 0.8-m/0.1-m cells (H2O/ CO2) outline and

mounting dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-13Figure A–9. SS3000 0.8-m/0.8-m cells (H2O/H2O) outline and

mounting dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-14

Hardware Installation and Maintenance Manual iii


Figure A–10. Drawing of typical full-featured dual-channel, dual-stream SCS (SS3000). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-15

Figure A–11. Drawing of typical full-featured dual-channel, dual-stream SCS (SS3000) in a 36 X 36 enclosure . . . . . . . . . . . . . . . . . . . . . . . A-16

Figure A–12. Electrical schematic for SS3000 . . . . . . . . . . . . . . . . . . . . . . . . A-17Figure A–13. Interconnect diagram for dual-channel system (SS3000). . . . . . . A-18

Figure B–1. Measurement cell types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4Figure B–2. Stainless steel mirror marking . . . . . . . . . . . . . . . . . . . . . . . . . . B-5Figure B–3. Stainless steel mirror - mirror side up . . . . . . . . . . . . . . . . . . . . . B-8Figure B–4. Analyzer component locations . . . . . . . . . . . . . . . . . . . . . . . . . B-10Figure B–5. Removed measurement cell with pressure sensor face up . . . . . . B-10Figure B–6. Removing the old pressure sensor . . . . . . . . . . . . . . . . . . . . . . B-11Figure B–7. Removing excess seal tape from flange . . . . . . . . . . . . . . . . . . . B-11Figure B–8. Replacing seal tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-12Figure B–9. Replacing pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-12Figure B–10. Newly installed pressure sensor positioning . . . . . . . . . . . . . . . . B-13

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LIST OF TABLES

Table 1–1. Fuse specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Table 2–1. Output signal connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Table A–1. SS500 H2O analyzer specifications . . . . . . . . . . . . . . . . . . . . . . . A-1Table A–2. SS2000 single-channel H2O analyzer specifications. . . . . . . . . . . . A-2Table A–3. SS2000 single-channel CO2 analyzer specifications . . . . . . . . . . . . A-3Table A–4. SS3000 dual channel H2O/H2O analyzer specifications . . . . . . . . . A-4Table A–5. SS3000 dual channel H2O/CO2 analyzer specifications . . . . . . . . . A-5Table A–6. Replacement parts for SS500/SS2000/SS3000 analyzers . . . . . . A-19

Table B–1. Potential instrument problems and solutions . . . . . . . . . . . . . . . B-16

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vi 4900002215 rev. D 7-29-16

1 - INTRODUCTION

SpectraSensors’ SS500/SS2000/SS3000 products are high-speed, diode-laser based extractive analyzers designed for extremely reliable monitoring of very low or trace concentrations of specific components in various background gases. In order to ensure that the analyzer performs as specified, it is important to closely review the installation and operation sections of this manual. This manual contains a comprehensive overview of the SS500/SS2000/SS3000 analyzer and step-by-step instructions on:

• Getting familiar with the analyzer

• Installing the analyzer and SCS

• Maintaining and troubleshooting the system

For instruction on operating the analyzer through firmware programming, please consult the Firmware Operations Manual.

Who Should Read This ManualThis manual should be read and referenced by anyone installing, operating or having direct contact with the analyzer.

How to Use This ManualTake a moment to familiarize yourself with this manual by reading the Table of Contents.

There are a number of options and accessories available for the SS500/SS2000/SS3000 analyzers. This manual has been written to address the most common options and accessories. Images, tables and charts have been included to provide a visual understanding of the analyzer and its functions. Special symbols are also used to provide the user with key information regarding the system configuration and/or operation. Pay close attention to this information.

General Warnings and CautionsInstructional icons are provided in this manual to alert the user of potential hazards, important information and valuable tips. Following are the symbols and associated warning and caution types to observe when servicing the analyzer. Some of these symbols are provided for instructional purposes only and are not labeled on the system.

Equipment Labels

Warning statement for hazardous voltage. Contact may cause electric shock or burn. Turn off and lock out system before servicing.

Hardware Installation and Maintenance Manual 1–1


Instructional Symbols

Failure to follow all directions may result in damage or malfunction of the analyzer.

INVISIBLE LASER RADIATION - Avoid exposure to beam. Class 3b Radiation Product. Refer servicing to the manufacturer or qualified personnel.

Removing label from measurement cell optical head will void analyzer warranty.

General notes and important information concerning the installation and operation of the analyzer.

Failure to follow all directions may result in fire.

INVISIBLE LASER RADIATION - Avoid exposure to beam. Class 3b Radiation Product. Refer servicing to the manufacturer-qualified personnel.

Failure to follow all directions may result in damage or malfunction of the analyzer.

Maximum voltage and current specifications for fuses.

CAUTIONCLASS 3B INVISIBLE LASER

RADIATION WHEN OPENAVOID EXPOSURE TO THE BEAM

!

V A

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Introduction

Conventions Used in this ManualIn addition to the symbols and instructional information, the electronic version of this manual is created with “hot links” to enable the user to quickly navigate between different sections within the manual. These links include table, figure and section references and are identified by a pointing finger cursor when rolling over the text. Simply click on the link to navigate to the associated reference.

SpectraSensors OverviewSpectraSensors, Inc. is a leading manufacturer of technologically advanced electro-optic gas analyzers for the industrial process, gas distribution and environmental monitoring markets. Headquartered in Houston, Texas, SpectraSensors was incorporated in 1999 as a spin-off of the NASA/Caltech Jet Propulsion Laboratory (JPL) for the purpose of commercializing space-proven measurement technologies initially developed at JPL. SpectraSensors was acquired by the Endress + Hauser Group in 2012, which has expanded our reach in the global marketplace.

About the Gas AnalyzersThe SS500/SS2000/SS3000 are tunable diode laser (TDL) absorption spectrometers operating in the near infrared region of the spectrum. Each compact sensor consists of a TDL light source, sample cell and detector specifically configured to enable high sensitivity measurement of a particular component within the presence of other gas phase constituents in the stream. The sensor is controlled by microprocessor-based electronics with embedded software that incorporates advanced operational and data processing algorithms.

The SS500/SS2000/SS3000 analyzer may be integrated with a sample conditioning system (SCS) that has been specifically designed to meet the sample condition requirements for the analyzer, while preserving sample integrity and minimizing sample lag time.

A sample conditioning system may also be included with the system that has been specifically designed to deliver an optimum sample stream that is representative of the process systems stream at the time of sampling. Most SS500/SS2000/SS3000 analyzer systems are configured for use at extractive natural gas sampling stations.

Differences between the SS500, SS2000, and SS3000The SS500 and SS2000 are single-channel analyzers designed to continuously measure the moisture content in natural gas pipelines. The SS2000 offers higher measurement performance in those applications, and its single measurement channel can also be configured to monitor CO2 levels in natural gas pipelines, or to measure the moisture content in CO2 pipelines. For



performance specifications, refer to Table A–1 through Table A–3 and Figure 1–1 for an image of a standard SS500/SS2000 with a 0.8-m cell.

The SS3000 is a dual-channel version of the SS2000 and is usually configured to measure H2O and/or CO2 in the same or separate pipeline natural gas sample streams (for performance specifications, refer to Table A–4 and Table A–5). Refer to Figure 1–2 for an image of the analyzer with two 0.8-m cells.

Figure 1–1 SS500/SS2000 analyzer

Figure 1–2 SS3000 Analyzer

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How the Analyzers WorkThe SS500/SS2000/SS3000 analyzers employ tunable diode laser absorption spectroscopy (TDLAS) to detect the presence of trace substances in process gases. Absorption spectroscopy is a widely used technique for sensitive trace species detection. Because the measurement is made in the volume of the gas, the response is much faster, more accurate and significantly more reliable than traditional surface-based sensors that are subject to surface contamination.

In its simplest form, a diode laser absorption spectrometer typically consists of a sample cell with a mirror at one end, and a mirror or window at the opposite end, through which the laser beam can pass. Refer to Figure 1–3. The laser beam enters the cell and reflects off the mirror(s) making one or more trips through the sample gas and eventually exiting the cell where the remaining beam intensity is measured by a detector. With the SS500/SS2000/SS3000 analyzers, sample gas flows continuously through the sample cell ensuring that the sample is always representative of the flow in the main pipe.

Due to their inherent structure, the molecules in the sample gas each have characteristic natural frequencies (or resonances). When the output of the laser is tuned to one of those natural frequencies, the molecules with that particular resonance will absorb energy from the incident beam. That is, as the beam of incident intensity, I0(), passes through the sample, attenuation occurs via absorption by the trace gas with absorption cross section (). According

OPTICAL HEAD

DETECTOR

WINDOW

INLETFAR MIRROR

TECLASER

OUTLET

PRESSURE SENSOR

0.8-m Measurement Cell

Figure 1–3 Schematic of a typical laser diode absorption spectrometer


dmyers

Rectangle


to the Beer-Lambert absorption law, the intensity remaining, I(), as measured by the detector at the end of the beam path of length I (cell length x number of passes), is given by

, (1)

where N represents the species concentration. Thus, the ratio of the absorption measured when the laser is tuned on-resonance versus off-resonance is directly proportional to the number of molecules of that particular species in the beam path, or

. (2)

Figure 1–4 shows the typical raw data from a laser absorption spectrometer scan including the incident laser intensity, I0(), and the transmitted intensity, I(), for a clean system and one with contaminated mirrors (shown to illustrate the system’s relative insensitivity to mirror contamination). The positive slope of raw data results from ramping the current to tune the laser, which not only increases the wavelength with current, but also causes the corresponding output power to increase. By normalizing the signal by the incident intensity, any laser output fluctuations are canceled, and a typical, yet more pronounced, absorption profile results. Refer to Figure 1–5.

I I0 exp lN– =

N 1– l-------------- I

I0 --------------ln=

3.0

2.5

2.0

1.5

1.0

0.5

Incident Energy I0()Raw Signal, I()Raw Signal, I()(Contaminated Mirrors)

Wavelength [a.u.]

Sig

nal [

a.u.

]

0.0

Figure 1–4 Typical raw signal from a laser diode absorption spectrometer with and without mirror contamination

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Introduction

Note that contamination of the mirrors results solely in lower overall signal. However, by tuning the laser off-resonance as well as on-resonance and normalizing the data, the technique self calibrates every scan resulting in measurements that are unaffected by mirror contamination.

Wavelength Modulation Spectroscopy (WMS) Signal DetectionSpectraSensors takes the fundamental absorption spectroscopy concept a step further by using a sophisticated signal detection technique called wavelength modulation spectroscopy (WMS). When employing WMS, the laser drive current is modulated with a kHz sine wave as the laser is rapidly tuned. A lock-in amplifier is then used to detect the harmonic component of the signal that is at twice the modulation frequency (2f), as shown in Figure 1–6. This phase-sensitive detection enables the filtering of low-frequency noise caused by turbulence in the sample gas, temperature and/or pressure fluctuations, low-frequency noise in the laser beam or thermal noise in the detector.

1.0

0.99

0.98

0.97

0.96

0.95Normalized Absorption Signal

Wavelength [a.u.]

Sig

nal [

a.u.

]

Figure 1–5 Typical normalized absorption signal from a laser diode absorption spectrometer



With the resulting low-noise signal and use of fast post-processing algorithms, reliable parts per million (ppm) or parts per billion (ppb) detection levels are possible (depending on target and background species) at real-time response rates (on the order of 1 second).

All SpectraSensors TDL gas analyzers employ the same design and hardware platform. Measuring different trace gases in various mixed hydrocarbon background streams is accomplished by selecting a different optimum diode laser wavelength between 750-3000nm, which provides the least amount of sensitivity to background stream variations.

Getting Familiar with the AnalyzerSpectraSensors’ SS500/SS2000/SS3000 analyzers are typically comprised of a single electronics enclosure and associated measurement cell(s). Refer to Appendix A for system drawings. On the front panel of the analyzer, the keypad and LCD display serve as the user interface to each analyzer. The analyzer control electronics drive the laser, collect the signal, analyze the spectra and provide measurement output signals. Refer to Figure 1–7.

Normalized2f Signal

Wavelength [a.u.]

Sig

nal [

a.u.

]

Figure 1–6 Typical normalized 2f signal; species concentration is proportional to the peak height

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Introduction

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V

Power is connected to the analyzer from an external power source through the bottom of the enclosure. Refer to Table A–1 through Table A–5 for system specifications. The measurement cell(s) along with flow devices to control flow and pressure for the measurement cell and the bypass loop are mounted on a panel alongside the enclosure.

Inside the SS500/SS2000 analyzer electronics enclosure is the electronics assembly as shown in Figure 1–8 and Figure 1–9.

Inside the SS3000 analyzer electronics enclosure is the electronics assembly as shown in Figure 1–10 and Figure 1–11.

Fuses are located on the electronics control board, as shown in Figure 1–8, Figure 1–9, Figure 1–10 and Figure 1–11.

If you need to replace a fuse, use only the same type and rating of fuse as the original as listed in Table 1–1.

Table 1–1 Fuse specifications

DWG Ref. Voltage Description Rating

Figure 1–8Figure 1–10 F1

120 VAC Miniature Fuse, 5 x 20 mm, Time Delay 250VAC/0.8A

240 VAC Miniature Fuse, 5 x 20 mm, Time Delay 250VAC/0.5 A

Figure 1–9Figure 1–11 F2

12 VDC Miniature Fuse, 5 x 20 mm, Time Delay 250 VAC/3.15 A

24 VDC Miniature Fuse, 5 x 20 mm, Time Delay 250 VAC/1.6 A

Figure 1–7 Analyzer Overview (SS3000 pictured)

LCD/KEYPAD

ANALYZERELECTRONICS

ENCLOSURE

MEASUREMENT CELL AND LASER

POWER CONNECTION

MEASUREMENTCELL AND LASER

CHASSIS GROUND

A



P

4-20

LADRIBO

BACKP

MER D

TIVE D

NENT D

Figure 1–8 Electronics control board (AC) for single-channel systems (SS500/SS2000)

TEMPERATURECONTROL BOARD

4-20 mA CURRENT LOOBOARD (STACKED)

FUSE(F1)

mA & SERIAL SIGNALCONNECTIONS

ASSIGNABLEALARM RELAYGENERAL FAULTALARM RELAY

NO

COMMONNC

SERVERARD

LANE

POWERSUPPLY

CUSTOGROUN

PROTECGROUN

COMPOGROUN

1–10 4900002215 rev. D 7-29-16

Introduction

LDB

R

VE

NT

BACKP

Figure 1–9 Electronics control board (DC) for single-channel systems (SS500/SS2000)


4-20 mA CURRENT LOOP BOARD (STACKED)

POWERSUPPLY

FUSE (F2)

TB2

ASSIGNABLEALARM FAULT

GENERAL FAULTALARM FAULT

ASERRIVEROARD

4-20 mA & SERIALSIGNAL CONNECTIONS

NO

NCCOMMON

CUSTOMEGROUND

PROTECTIGROUND

COMPONEGROUND

LANE



DB

BACK

4-20 m

ER

IVE

ENT

Figure 1–10 Electronics control board (AC) for dual-channel systems (SS3000)



POWERSUPPLY

FUSE(F1)

GENERAL FAULTALARM RELAY (Ch. A)

GENERAL FAULTALARM RELAY (Ch. B)

ASSIGNABLE ALARMRELAY (Ch. B)

LASERRIVEROARD

PLANE

ASSIGNABLEALARM RELAY (Ch. A)

A & SERIAL SIGNALCONNECTIONS

NO

NCCOMMON

CUSTOMGROUND

PROTECTGROUND

COMPONGROUND

1–12 4900002215 rev. D 7-29-16

Introduction

R

IVE

ENT

BAC

Figure 1–11 Electronics control board (DC) for dual-channel systems (SS3000)



POWERSUPPLY

FUSE (F2)

TB2

4-20 mA & SERIAL SIGNALCONNECTIONS

ASSIGNABLEALARM RELAY (Ch. A)GENERAL FAULTALARM RELAY (Ch. A)

CUSTOMEGROUND

PROTECTGROUND

COMPONGROUND

GENERAL FAULTALARM RELAY (Ch. B)

ASSIGNABLE ALARMRELAY (Ch. B)

NO

NCCOMMON

LASERDRIVERBOARD

KPLANE




1–14 4900002215 rev. D 7-29-16

2 - INSTALLATION

This section describes the processes used to initially install and configure your SS500, SS2000, or SS3000 and optional sample conditioning system (SCS). Once the analyzer arrives, you should take a few minutes to examine the contents before installing the unit.

What Should be Included in the Shipping BoxThe contents of the crate should include:

• The SpectraSensors SS500, SS2000, or SS3000

• Documentation media, which includes this manual and other system manuals

• One (SS500 or SS2000) or two (SS3000) external serial cable(s) to connect the analyzer to a computer

• Additional accessories or options as ordered.

If any of these contents are missing, consult “Customer Service” on page B-21.

Inspecting the AnalyzerUnpack and place the unit on a flat surface. Carefully inspect all enclosures for dents, dings, or general damage. Inspect the inlet and outlet connections for damage, such as bent tubing. Report any damage to the carrier.

Each analyzer is configured with various accessories and options. If there is any discrepancy in your order, please contact “Customer Service” on page B-21.

The safety of the analyzer is the responsibility of the installer and the organization he/she represents.

Avoid jolting the instrument by dropping it or banging it against a hard surface. Do not attempt to pick up the instrument using the sample cell. Either action may disturb the optical alignment.



Installing the Analyzer Installing the analyzer is relatively easy requiring only a few steps that, when carefully followed, will ensure proper mounting and connection. This section includes:

• Hardware and Tools for Installation

• Mounting the Analyzer

• Connecting Electrical Power to the Analyzer

• Connecting the Output Signals

• Connecting the Gas Lines

Hardware and Tools for InstallationDepending on the particular model, the configuration of accessories and options ordered, you may need the following hardware and tools to complete the installation process.

Hardware• 1/2” Unistrut® (or equivalent) bolts and spring nuts

• 1/4” lag bolts or 1/4” machine screws and nuts

• Stainless steel tubing (SpectraSensors recommends using 1/4” O.D. x0.035” wall thickness, seamless stainless steel tubing)

• 1/2” conduit hubs

• Conduit

Tools• Hand drill and bits

• Tape measure

• Level

• Pencil

• Socket wrench set

• Screw driver

• Crescent wrench

• 9/16” open-end wrench

Mounting the AnalyzerThe SS500/SS2000/SS3000 analyzer is manufactured for wall or Unistrut® (or equivalent) metal framing installations. Depending on your application and configuration, the analyzer may come premounted on a SCS panel to be mounted on a wall or Unistrut framing, or without a panel requiring mounting

2–2 4900002215 rev. D 7-29-16

Installation

via the standard electronics enclosure tabs. Refer to the layout diagrams in Appendix A for detailed mounting dimensions.

Lifting/carrying the analyzerAt approximately 25 lbs (11.5 Kg), the SS500/SS2000/SS3000 can easily be lifted from the packaging and moved to the installation location. Take care not to lift or carry the analyzer by the measurement cells or the cables connected at the top of the analyzer, or damage may occur.

To mount the analyzer:1. Select a suitable location to mount the analyzer. Choose a shaded area

or use an optional analyzer hood (or equivalent) to minimize sun exposure.

2. Locate the mounting holes on your unit. Refer to drawings in Appendix A.

3. For wall installations, mark the centers of the top mounting holes.

4. Drill the appropriate size holes for the screws you are using.

5. Hold the analyzer in place and fasten with the top screws.

6. Repeat for the bottom mounting holes.

Once all four screws are tightened the analyzer should be very secure and ready for the electrical connections.

Connecting Electrical Power to the AnalyzerThe analyzer will be configured for 100-240 VAC @ 50/60 Hz single-phase input or optionally 9–16 VDC or 18–32 VDC input. Check the manufacturing data label or the terminal block labels to determine the power input requirements. All work must

When mounting the analyzer, be sure to position the instrument so that it is not difficult to operate adjacent devices. Allow 3 feet of room in front of the analyzer and any switches.

It is critical to mount the analyzer so that the inlet and outlet lines reach the inlet and outlet connections on the chassis while still maintaining flexibility so that the sample lines are not under excessive stress.

SpectraSensors analyzers are designed for operation within the specified ambient temperature range of –4 °F to 122 °F (–20 °C to 50 °C). Intense sun exposure in some areas may cause the analyzer temperature to exceed the maximum.



be performed by personnel qualified in electrical conduit installation. Conduit seals should be used where appropriate in compliance with local regulations.

Depending on the analyzer configuration, the electrical wiring can typically be connected to the analyzer through a conduit hub located at the bottom right or left of the electronics enclosure. Refer to Appendix A for system drawings.

Protective chassis and ground connectionsBefore connecting any electrical signal or power, the protective and chassis grounds must be connected. Requirements for the protective and chassis grounds are as follows:

• The protective and chassis grounds must be of equal or greater size than any other current-carrying conductors, including the heater located in the sample conditioning system.

• The protective and chassis grounds must remain connected until all other wiring is removed.

• If the protective and chassis ground is insulated, it must use the green/yellow color.

Refer to Figure 1–8, Figure 1–9, Figure 1–10 and Figure 1–11 for the protective and ground locations. Chassis ground location can be found in Figure 1–7.

To connect electrical power to the analyzer:1. Open the electronics enclosure door. Take care not to disturb the

electrical assembly inside. Refer to Figure 2–1.

Hazardous voltage and risk of electric shock. Before attaching the wiring to the analyzer, make sure all power to the wires is off.

Careful consideration should be taken when grounding. Properly ground the unit by connecting ground leads to the grounding studs provided throughout the system that are labeled with the ground symbol .

Interconnection of the analyzer enclosure and cell enclosure shall be accomplished using wiring methods approved for Class 1, Division 2 hazardous locations as per the Canadian Electrical Code (CEC) Appendix J and the National Electric Code (NEC) Article 501. The installer is responsible for complying with all local installation codes.

Hazardous voltage and risk of electric shock. Failure to properly ground the analyzer may create a high-voltage shock hazard.

2–4 4900002215 rev. D 7-29-16

Installation

2. Run conduit from the power distribution panel to the conduit hub on the electronics enclosure labeled for power input.

3. For AC systems, pull ground, neutral and hot wires (#14 AWG minimum) into the electronics enclosure.

For DC systems, pull ground, plus and minus wires.

4. Strip back the jacket and/or insulation of the wires just enough to connect to the power terminal block.

5. For AC systems, attach the neutral and hot wires to the power terminal block by connecting the neutral wire to the terminal marked “NEU” and the hot wire to the terminal marked “LINE” as shown in Figure 2–2.

Conduit seals should be used where appropriate in compliance with local regulations.

Because the breaker in the power distribution panel or switch will be the primary means of disconnecting the power from the analyzer, the power distribution panel should be located in close proximity to the equipment and within easy reach of the operator, or within 10 feet of the analyzer.

An approved switch or circuit breaker rated for 15 amps should be used and clearly marked as the disconnecting device for the analyzer.

Figure 2–1 Internal view of electronics enclosure (SS500)



For DC systems, connect the minus wire to the terminal marked “” and the positive wire to the terminal marked “+” as shown in Figure 2–2.

6. Connect the ground wire to the ground terminal marked .

7. Close and tighten the electronics enclosure door.

Connecting the Output SignalsThe 4-20 mA current loop and serial output(s) are supplied from the mating terminal block (TB2) located inside the analyzer electronics enclosure as shown in Figure 1–8, Figure 1–9, Figure 1–10 or Figure 1–11. By default, the 4-20 mA current loop output is factory set to source current.

Connections can be made with customer-supplied cables for the current loop(s) and factory-supplied cable for the serial connection(s). Consult the wiring diagrams in Appendix A.

The 4-20 mA current loop output is factory set to source current. To change the 4-20 mA current loop output from source to sink, see “To change the 4-20 mA board from source to sink” on page 2-8.

Hazardous voltage and risk of electric shock. Be sure power to the analyzer is turned off before opening the electronics enclosure and making any connections.

NEU LINE

AC TERMINAL BLOCK

— +

DC TERMINAL BLOCK

Figure 2–2 AC and DC connection terminal blocks in electronics enclosure

2–6 4900002215 rev. D 7-29-16

Installation

To connect the output signals:1. Disconnect power to the analyzer and open the electronics enclosure

cover. Take care not to disturb the electrical assembly inside.

2. Run conduit from the signal/alarm receiving station to the conduit hub on the electronics enclosure labeled for signal connections.

3. Pull the customer-supplied cable(s) for the current loop(s), digital output relays, and the SpectraSensors external serial cable(s) (included in the shipping box) through the conduit into the electronics enclosure.

4. Strip back the jacket and insulation of the current loop, digital output relays and serial cables (shown in Figure 1–8, Figure 1–9, Figure 1–10 or Figure 1–11) just enough to connect to the mating terminal block (TB2), shown in Figure 2–3. The mating terminal block can be pulled up and removed from its base to make the cable connection process easier.

5. Connect the 4-20 mA current loop signal wires to the appropriate terminals, as indicated in Table 2–1.

6. Connect the serial cable wires to the appropriate terminals according to Table 2–1. For reference, Table 2–1 also shows the corresponding pin numbers for configuring a nine-pin Sub-D connector for connection to a computer serial port.

7. Connect the digital output relays according to the call-outs shown in Figure 1–8, Figure 1–9, Figure 1–10 or Figure 1–11.

8. Reinsert the mating terminal block into its base and verify that each connection is secure.

Conduit seals should be used where appropriate in compliance with local regulations.

Figure 2–3 Mating terminal block (TB2) in electronics enclosure for connecting signal cables

121110987654321

TB2



9. Close and tighten the electronics enclosure cover.

10. To complete the connections, connect the other end of the current loop wires to a current loop receiver and each external serial cable to a serial port on your computer.

Changing the 4-20 mA Current Loop Mode

By default, the 4-20 mA current loop output is factory set to source current. In some instances it may be necessary to change the 4-20 mA current loop output in the field from source to sink. The work must be performed by personnel qualified in electronics assembly.

To change the 4-20 mA board from source to sink:1. Disconnect power to the analyzer and open the electronics enclosure

cover. Take care not to disturb the electrical assembly inside.

2. Locate the 4-20 mA board(s) in the center of the electronics enclosure, as shown in Figure 1–8, Figure 1–9, Figure 1–10 or Figure 1–11.

3. Remove the jumper (JMP1), shown in Figure 2–4, connecting the center hole to point “A.”

Table 2–1 Output signal connections

Terminal Description D-Conn Color

1 Ch. A Serial RX Pin-3 Black

2 Ch. A Serial TX Pin-2 Red

3 COM Serial Ground Pin-5 Shield

4 Ch. B Serial RX Pin-3 Black

5 Ch. B Serial TX Pin-2 Red

6 Ch. A Current Loop +

7 Ch. A Current Loop -

8 Ch. B Current Loop +

9 Ch. B Current Loop -

10 N/C

11 N/C

12 N/C

NOTE: The description “N/C” indicates no connection.

2–8 4900002215 rev. D 7-29-16

Installation

4. For 4-20 mA sink, carefully replace the jumper to connect the center hole with point “P.”

5. Repeat steps 2-4 as necessary for any remaining 4-20 mA boards.

6. Reconnect power to the analyzer. Confirm the 4 mA (min.) and 20 mA (max.) points. Close and tighten the electronics enclosure cover. Follow the programming instructions below.

Calibrating the analog output

1. Connect a calibrator and digital multi-meter into the circuit.

2. On the analyzer keypad, press #2 (Mode 2), the password (3142) and *.

3. Continue pressing the * key until the 4-20 mA % Test parameter displays.

Needle nose pliers may be required to remove the jumper.

Figure 2–4 4-20 mA output board

JMP1Potentiometers

<CH A SET PARAMETER>4-20 mA % Test101Enter a % (101=Off)



4. Enter the desired percentage of full scale and press *.

a. Set 4-20 mA % Test = 0; this displays the 4 mA on the AO circuit when #1 (Mode 1) is pressed.

b. Set 4-20 mA Test = 50; this displays the 12 mA on the AO circuit when #1 (Mode 1) is pressed.

c. Set 4-20 mA Test = 100; this displays the 20 mA on the AO circuit when #1 (Mode 1) is pressed.

Testing and adjusting the 4-20 mA zero and span

1. Press #1 (Mode 1) and note the 4-20 mA % Test parameter setting displayed on the analyzer.

2. Adjust the potentiometers on the end of the board to change the zero and span readings. Refer to Figure 2–4.

3. Press # and 1 to return to Normal Mode.

For more information on the analyzer programming, refer to the Firmware Operator’s Manual.

Connecting the Gas LinesOnce you have verified that the analyzer is properly wired, you are ready to connect the sample supply, sample return, and sample bypass (if applicable). Consult the layout and flow diagrams in Appendix A for guidance. All work must be performed by technicians qualified in instrument tubing.

SpectraSensors recommends using 1/4” O.D x 0.035” wall thickness, seamless stainless steel tubing.

Process samples may contain hazardous material in potentially flammable and/or toxic concentrations. Personnel should have a thorough knowledge and understanding of the physical properties and safety precautions for the sample contents before installing the SCS.

<CH A SET PARAMETER>4-20 mA % Test0.0Enter a % (101=Off)

2–10 4900002215 rev. D 7-29-16

Installation

To connect the sample supply line:1. First, confirm that the sample probe is correctly installed at the

process supply tap and that the sample probe isolation valve is closed.

2. Also, confirm that the field pressure reducing station is installed properly at the sample probe and that the pressure regulator at the field pressure reducing station is closed (adjustment knob turned fully counter-clockwise).

3. Determine appropriate tubing route from the field pressure reducing station to the SCS.

4. If configured with this analyzer, install the heat trace bundle in the heat trace sample inlet.

a. Remove the white foam supplied with the SCS.

b. Run the entire heat trace bundle into the enclosure.

c. Once installed, seal the rubber tube around the heat trace by applying heat until the tube shrinks down around the heat trace bundle.

5. If configured with this analyzer, install the heat trace terminal box external to the SCS enclosure using the supplied GFI Heat Trace Power conduit hub.

a. Run the heat trace power back out of the enclosure and into the heat trace terminal box through the GFI Heat Trace Power conduit hub.

Consult sample probe manufacturer instructions for proper installation procedures.

The process sample at the sample tap may be at a high pressure. Use extreme caution when operating the sample probe isolation valve and field pressure reducing regulator.

All valves, regulators, switches, etc. should be operated in accordance with site lock-out/tag-out procedures.

Hazardous voltage and risk of electric shock. Follow your plant safety guidelines or refer to your safety engineer before attempting to heat the rubber tube.



6. Run stainless steel tubing from the field pressure reducing station (set for the specified inlet pressure) to the sample supply port of the SCS. Bend tubing using industrial grade benders, check tubing fit to ensure proper seating between the tubing and fittings. Fully ream all tubing ends. Blow out the lines for 10–15 seconds with clean, dry nitrogen or air prior to making the connection.

7. Connect the inlet tube to the SCS using the 1/4” stainless steel compression-type fitting provided.

8. Tighten all new fittings 1-1/4 turns with a wrench from finger tight. For connections with previously swaged ferrules, thread the nut to the previously pulled up position, then tighten slightly with a wrench. Secure tubing to appropriate structural supports as required.

9. Check all connections for gas leaks. SpectraSensors recommends using a liquid leak detector.

To connect the sample return:1. Confirm that the atmospheric vent header shut-off valve is closed, if

applicable.

2. Determine appropriate tubing route from the SCS to the atmospheric vent header.

3. Run stainless steel tubing from the sample return port to the atmospheric vent header connection.

a. Bend tubing using industrial grade benders, check tubing fit to ensure proper seating between the tubing and fittings.

b. Fully ream all tubing ends.

c. Blow out the lines for 10–15 seconds with clean, dry nitrogen or air prior to making the connection.

4. Connect the sample return tube to the SCS using the 1/4” stainless steel compression-type fitting provided.

5. Tighten all new fittings 1-1/4 turns with a wrench from finger tight. For connections with previously swaged ferrules, thread the nut to the previously pulled up position, then tighten slightly with a wrench. Secure tubing to appropriate structural supports as required.

Do not exceed 10 PSIG (0.7 barg) in sample cell. Damage to cell may result.


2–12 4900002215 rev. D 7-29-16

Installation


7. Be sure to vent the bypass return port and pressure relief vent port (if applicable) in a similar fashion when the unit is in use.

Conditioning the SCS TubingNewly installed systems invariably have some trace contaminants and/or are intended for measuring trace amounts of gas constituents that tend to cling to system walls, which can result in erroneous readings if the constituents are not in equilibrium with the system walls. Therefore, once the analyzer and SCS are completely connected, the entire system (i.e., from the sample source valve to the vent or return) should be conditioned by flowing sample gas through the system for up to 12 hours (or until reading stabilizes) after the system is powered up and before actual readings are taken. Progress of the system conditioning can be monitored via the gas concentration readings. Once the gas constituents have reached equilibrium with the system walls, the readings should stabilize.

Do not exceed 10 PSIG (0.7 barg) in sample cell. Damage to cell may result.




2–14 4900002215 rev. D 7-29-16

3 - SAMPLE CONDITIONING SYSTEM (SCS)

SS500/SS2000/SS3000 systems may be ordered with an optional integrated Sample Conditioning System (SCS). Each SCS has been specifically designed to deliver a sample stream to the analyzer that is representative of the process stream at the time of sampling. To ensure the integrity of the sample stream and its analysis, care must be taken to install and operate the SCS properly. Therefore, any personnel intending to operate or service the analyzer and SCS should have a thorough understanding of the process application and the design of the analyzer and SCS.

Most problems experienced with sample systems tend to result from operating the system differently than intended. In some cases, the actual process conditions may be different than originally specified (e.g., flow rates, presence of contaminants, particulates, or condensables that may only exist under upset conditions). By establishing understanding of the application and the design of the system, most issues can be avoided altogether or easily diagnosed and corrected ensuring successful normal operation.

If there are any remaining questions concerning the design, operation, or maintenance of the SCS, contact your factory service representative.

Personnel should have a thorough understanding of the operation of the SS500/SS2000/SS3000 analyzer and the procedures presented here before operating the sample conditioning system.

The process sample at the sample tap may be at a high pressure. A field pressure reducing regulator is located at the sample tap to reduce the sample pressure and enable operation of the sample conditioning system at a low pressure. Use extreme caution when operating the sample probe isolation valve and field pressure reducing regulator.

The process sample at the sample tap may be at a high pressure. Make sure that the field pressure reducing regulator is equipped with an appropriate pressure relief valve.

Process samples may contain hazardous material in potentially flammable and/or toxic concentrations. Personnel should have a thorough knowledge and understanding of the physical properties and safety precautions for the sample contents before operating the SCS.



About the SCS

For a typical full-featured SCS, as shown in Figure 3–1, sample gas enters the sample conditioning unit [at the specified supply pressure set by a customer-supplied upstream regulator] via the sample supply port, passes through a shut-off valve, pressure regulator that maintains constant pressure in the measurement cell, and membrane separator where any liquid in the stream is removed. Liquid removed by the membrane separator passes through the bypass loop and collects in a filter housing. A continuous flow (set to the specified level by a metering valve with integrated flowmeter) not only flushes the liquid from the membrane separator but also maintains flow through the sample lines, which reduces sample variation.

The system drawings and schematics found in Appendix A of this manual are for illustration purposes only. Always refer to the system drawings for your specific system configuration and specifications.

Figure 3–1 Typical full-featured, single-channel SCS (SS500/SS2000) on a panel

3–2 4900002215 rev. D 7-29-16

Sample Conditioning System (SCS)

The flow exiting the bypass loop is combined with the flow exiting the measurement cell and sent out the sample return port to be vented to a safe location.

Checking the SCS InstallationBefore operating the system for the first time, a careful check of the installation of the entire SCS from the sample probe to the vent is recommended.

To perform SCS installation checks:1. Confirm that the sample probe is correctly installed at the process

supply tap and that the sample probe isolation valve is closed.

2. Confirm that the field pressure reducing station is installed properly at the sample probe.

3. Confirm that the relief valve at the field pressure reducing station has been set to the specified setpoint.

4. Confirm that all valves are closed.

5. Confirm that the power is available to the analyzer, and if applicable, that the local switch is off.

6. Confirm that the field analog and alarm signal wiring is connected properly (see “Connecting the Output Signals” on page 2-6).

7. Confirm that the atmospheric vent is properly connected.

8. Confirm that the analyzer house atmospheric vent is properly installed, if applicable.

9. Confirm that all sample system tubing has been thoroughly leak checked.

Starting up the SCSAfter the SCS installation has been thoroughly checked, you are ready to begin preparing for initial SCS startup.

To prepare for SCS startup:1. If applicable, apply AC power to the heat-traced sample transport

tubing at the tracer control system.

If applicable, personnel should have a thorough understanding of the operation of the tracer power supply and control system before operating the SCS.



2. If applicable, confirm that the sample supply line electric tracer temperature controller at the tracer control system is set to the temperature specified.

3. If applicable, confirm proper heating of the sample supply tubing.

4. Confirm that all sample system shut-off valves are closed.

5. Confirm that the sample bypass and analyzer flowmeter control valves are gently closed (adjustment knob turned clockwise).

To start up the field pressure reducing station:

1. Confirm that the sample probe isolation valve is closed.

2. Confirm that the pressure regulator at the field pressure reducing station is closed (adjustment knob turned fully counterclockwise).

3. Slowly open the sample probe process shut-off valve at the sample supply tap.

4. Slowly open the pressure regulator at the field pressure reducing station (adjustment knob turned clockwise) and set the pressure regulator to the specified pressure.

5. Blow sample through the sample transport tubing to flare or safe vent to ensure that dirt or liquids are in the sample tubing.

6. Reconnect the sample transport tubing and set the pressure or the regulator to the specified pressure.

To start up the sample bypass stream on process sample:1. Open the atmospheric vent header shut-off valve for the combined

sample bypass and measurement cell effluent from the SCS, if applicable.

2. Open the sample supply port shut-off valve and slowly open the pressure regulator (turning knob clockwise).

3. Set the inlet pressure regulator on the panel to a setting that will maintain the specified flowmeter settings and provide good control using the analyzer and bypass flow control valves.

Do not overtighten the control valves or damage could occur.

The process sample at the sample tap may be at a high pressure. Use extreme caution when operating the sample probe isolation valve and field pressure reducing regulator.

3–4 4900002215 rev. D 7-29-16


4. Open the bypass flowmeter control valve to establish sample flow from the sample probe and set the flowmeter to the specified value.

To start up the analyzer on process sample:1. Open the sample flowmeter control valve to approximately the

specified flow.

2. If required, adjust the pressure regulator at the field pressure reducing station to the specified setpoint.

3. Adjust the sample flowmeter control valve to the specified flow.

4. Confirm the sample flow and pressure setpoints and readjust the control valves and pressure regulator to the specified setpoints, if necessary.

5. Confirm the sample bypass flow and readjust the bypass control valve to the specified setpoint, if necessary. The SCS is now operating with the process sample.

6. Power up the analyzer according to the procedure given in “To power up the analyzer” in the Firmware Manual.

Shutting Down the SCS

Do not exceed 10 PSIG at any time in the cell. Refer to Appendix A for analyzer specifications.

The adjustment setpoints of the analyzer flowmeter and pressure regulator will be interactive and may require multiple adjustments until the final setpoints are obtained.

The analyzer system has been designed for the sample flow rate specified. A lower than specified sample flow rate may adversely affect analyzer performance. If you are unable to attain the specified sample flow rate, contact your factory sales representative.




To isolate the analyzer for short-term shutdown:The analyzer can be isolated from the process sample tap for short-term shutdown or maintenance of the analyzer without requiring the shutdown of the field pressure reducing station.

1. Close the sample supply shut-off valve.

2. Allow the sample to flow until all residual gas has dissipated from the lines as indicated by no flow on the sample and sample bypass flowmeters.

3. Close the atmospheric vent header shut-off valve for the combined sample bypass and measurement cell effluent from the SCS.

The process sample at the sample tap is at a high pressure. A pressure reducing regulator is located at the sample tap to reduce the sample pressure and enable operation of the SCS at a low pressure. Use extreme caution when operating the sample probe isolation valve and field pressure reducing regulator.


Due to the high pressure of the process sample, it is advisable to allow the sample bypass flow to continue during short-term isolation of the analyzer. Continuing sample bypass flow allows the field pressure regulator to continue normal operation without possible overpressure and activation of the relief valve in the event the pressure regulator leaks when the downstream flow is discontinued.

The sample transport line must be vented to the atmospheric vent header through the bypass flowmeter to avoid pressure surges. The procedure given in the following steps can be followed regardless of whether or not the SCS has been isolated from the process tap as described in the previous section.


3–6 4900002215 rev. D 7-29-16


4. Turn off power to the analyzer.

To isolate the analyzer for long-term shutdown:If the analyzer is to be out of service for an extended period, the analyzer must be isolated at the process sample tap.

1. Open (or confirm open) the or atmospheric vent header shut-off valve for the effluent from the SCS.

2. Confirm flow in the sample bypass flowmeter (the actual flow is not critical).

3. Close the sample probe process shut-off valve at the sample supply process tap.

4. Allow pressure in the field pressure reducing regulator to dissipate until only a low residual pressure is indicated on the pressure gauge at the field station.

If the system will not be out of service for an extended period, it is advised that power remain applied to the sample transport line electric tracer, if applicable.


Due to the high pressure of the process sample, it is advisable to allow the sample bypass flow to continue during long-term isolation of the analyzer. Continuing sample bypass flow allows the field pressure regulator to continue normal operation without possible overpressure and activation of the relief valve in the event the pressure regulator leaks when the downstream flow is discontinued.

The sample transport line must be vented to the atmospheric vent header through the bypass flowmeter to avoid pressure surges. The procedure given in the following steps can be followed regardless of whether or not the SCS has been isolated from the process tap as described in the previous section.




5. Close the field pressure reducing regulator (adjustment knob turned fully counterclockwise).

6. Close the sample supply shut-off valve.

7. Leave the flowmeter control valves open.

8. Close the atmospheric vent header shut-off valve for the sample bypass and measurement cell effluent from the SCS.

9. Turn off power to the analyzer.

10. Turn off the AC power to the sample tracer, if applicable, at the power distribution panel.

Although power could be shut off to the sample supply electric tracer, it is advisable to allow this line to remain heated unless the SCS is to be out of service for an extended period or maintenance is required on the line.

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Hardware Installation and Maintenance Manual A–1

Appendix A: Specifications

Table A–1 SS500 H2O analyzer specifications

PerformanceConcentration 1

1. Consult factory for alternative ranges.

Refer to Calibration Report

Repeatability Refer to Calibration Report

Accuracy Refer to Calibration Report

Measurement Update Time 2

2. Software adjustable.

1 second

Application DataEnvironmental Temperature Range -4 to 122 °F (-20 to 50 °C)

Environmental Relative Humidity 5%-95%, non-condensing

Altitude Up to 2000 m

Maximum Cell Pressure 70kPaG (10 PSIG)

Sample Cell Pressure Range 700-1400 mbara

Sample Flow Rate 0.5–1.0 SLPM (1–2 SCFH) typical (not flow dependent)

Recommended Validation Bureau of Mines chilled mirror, portable TDL or binary gas with methane background

Electrical & CommunicationsInput Voltages 3

3. Supply voltage not to exceed 10% of nominal. Transient over-voltages according to Overvoltage Category II.

100–240 VAC, 50/60 Hz9–16 VDC or 18–32 VDC - Optional

Contact Rating(Inductive Load)

250V, 3A N.O. contact, 1.5A N.C. contact24V, 1A N.O. and N.C. contact

Communication Analog: (2) 4-20mA Isolated, 1200 ohms @ 24VDC max loadSerial: RS-232CProtocol: Modbus Gould RTU, Daniel RTU or ASCII

Digital Output (2) General Fault and Assignable alarms

Physical SpecificationsClass 1, Div 2

System Dimensions 439 mm H x 371 mm W x 146 mm D (17.27" H x 14.59" W x 5.75" D)

Weight Approx. 25 lbs (11.5 Kg)

Enclosure Type NEMA 3R-304 Stainless Steel

Area ClassificationCertification CSA Class 1, Division 2, Groups A, B, C & D; T3C


Table A–2 SS2000 single-channel H2O analyzer specifications

PerformanceConcentration 1 Refer to Calibration Report



Measurement Update Time 2 1 second


Environmental Relative Humidity 80% for temperatures up to 31°C MAX






Electrical & CommunicationsInput Voltages 3 100–240 VAC, 50/60 Hz

9–16 VDC or 18–32 VDC - Optional

Contact Rating (Inductive Load)


Communication Analog: (2) 4-20mA Isolated, 1200 ohms @ 24 VDC max loadSerial: RS-232CProtocol: Modbus Gould RTU, Daniel RTU or ASCII



System Dimensions 439 mm H x 371 mm W x 146 mm D(17.27" H x 14.59" W x 5.75" D)



Area ClassificationCertification CSA Class I, Division 2, Groups A, B, C & D; T3C

1. Consult factory for alternative ranges.2. Software adjustable.3. Supply voltage not to exceed 10% of nominal. Transient over-voltages according to Overvoltage

Category II.

A–2 4900002215 rev. D 7-29-16

Specifications

Table A–3 SS2000 single-channel CO2 analyzer specifications











Recommended Validation Binary cal gas bottle with methane background



Contact Rating(Inductive Load)




LCD Display Concentration, cell pressure, temperature & diagnostics


System Dimensions 444 mm H x 376 mm W x 135 mm D(17.5" H x 14.8" W x 5.8" D)





Category II.



Table A–4 SS3000 dual channel H2O/H2O analyzer specifications






15 to 140 °F (-10 to 60 °C) - Optional





Sample Flow Rate 0.5–1.0 SLPM (1–2 SCFH) typical (not flow depen-dent)








LCD Display Concentration, cell pressure, temperature & diag-nostics

Physical SpecificationsSize 439 mm H x 475 mm W x 146 mm D

(17.27" H x 18.68" W x 5.75" D)


Sample Cell Construction 316L Series Polished Stainless Steel


1. Consult factory for alternative ranges.2. Software adjustable.3. Supply voltage not to exceed 10% of nominal. Transient over-voltages according to Overvolt-

age Category II.

A–4 4900002215 rev. D 7-29-16

Specifications

Table A–5 SS3000 dual channel H2O/CO2 analyzer specifications

PerformanceConcentration (H2O) 1 Refer to Calibration Report

Repeatability (H2O) Refer to Calibration Report

Concentration (CO2) 1 Refer to Calibration Report

Repeatability (CO2) Refer to Calibration Report




15 to 140 °F (-10 to 60 °C) - Optional



Sample Inlet Pressure to Sample System 25–50 PSIG (1.7–3.4 barg)

Cell Operating Pressure 700-1400 mbara

Sample Flow Rate 0.5–1.0 SLPM (1–2 SCFH) typical (not flow depen-dent)

Recommended Validation H2O: Bureau of Mines chilled mirror, portable TDL or binary gas with methane backgroundCO2: Binary cal gas bottle with methane background





Communication Analog: (1 or 2) 4-20mA Isolated, 1200 ohms @ 24 VDC max loadSerial: RS-232CProtocol: Modbus Gould RTU, Daniel RTU or ASCII


LCD Display Concentration, cell pressure, temperature & diagnos-tics

Physical SpecificationsSize 439 mm H x 475 mm W x 146 mm D

(17.27" H x 18.58" W x 5.758" D)


Sample Cell Construction 316L Series Polished Stainless Steel



Category II.



Figure A–1 SS500/SS2000 0.8-m cell (moisture) outline and mounting dimensions

A–6 4900002215 rev. D 7-29-16

Specifications

Figure A–2 SS500/SS2000 0.1-m cell (carbon dioxide) outline and mounting dimensions


SS

50

0/

SS

20

00

/S

S3

00

0 A

nalyzer

A–8

4900002215 rev. D 7-29-16 00/SS2000)
Figure A–3 Drawing of typical full-featured single-channel SCS (SS5

Sp

ecifications

Hardw

are Installation and Maintenance M

anual A –

9 20000) in
Figure A–4 Drawing of typical full-featured single-channel SCS (SS500/SS24x24 enclosure

SS

50

0/

SS

20

00

/S

S3

00

0 A

nalyzer

A–10

4900002215 rev. D 7-29-16 00/SS20000) in
Figure A–5 Drawing of typical full-featured single-channel SCS (SS5
30x30 enclosure

Sp

ecifications

Hardw


anual A –

11

CH

AN

NE

L A

CE

LL

Figure A–6 Electrical schematic for SS500/SS2000

TO

PROCESSOR

TO

PROCESSOR

120/240

VAC

120/240 VAC

ANALYZER POWER

INPUT

CH. A

4-20 mA/RS232 SIGNAL

OUTPUT

SS

50

0/

SS

20

00

/S

S3

00

0 A

nalyzer

A–12

4900002215 rev. D 7-29-16 00/SS2000)
Figure A–7 Interconnect diagram for single-channel system (SS5

Specifications

Figure A–8 SS3000 0.8-m/0.1-m cells (H2O/ CO2) outline and mounting dimensions



Figure A–9 SS3000 0.8-m/0.8-m cells (H2O/H2O) outline and mounting dimensions

A–14 4900002215 rev. D 7-29-16

Sp

ecifications

Hardw


anual A –

15 S (SS3000)
Figure A–10 Drawing of typical full-featured dual-channel, dual-stream SC

SS

50

0/

SS

20

00

/S

S3

00

0 A

nalyzer

A–16

4900002215 rev. D 7-29-16

am SCS (SS3000)
Figure A–11 Drawing of typical full-featured dual-channel, dual-strein a 36 X 36 enclosure

Sp

ecifications

Hardw


anual A –

17

CH

AN

NE

L A

CE

LL

CH

AN

NE

L B

CE

LL

TO CH. B

PROCESSOR

120/240

VAC

120/240 VAC

ANALYZER POWER

INPUT4-20 mA/RS-232 SIGNAL

OUTPUT

TO CH. A

PROCESSOR

TO CH. A & CH. B

PROCESSORS

R4 R3 R2 R1

CH. ACH. B

CH. BCH. A

Figure A–12 Electrical schematic for SS3000

SS

50

0/

SS

20

00

/S

S3

00

0 A

nalyzer

A–18

4900002215 rev. D 7-29-16

0)
Figure A–13 Interconnect diagram for dual-channel system (SS300

Specifications

Spare PartsBelow is a list of spare parts for the SS500/SS2000/SS3000 analyzers with recommended quantities for 2 years of operation. Due to a policy of continuous improvement, parts and part numbers may change without notice. Not all parts listed are included on every analyzer. When ordering, please specify the system serial number to ensure that the correct parts are identified.

Table A–6 Replacement parts for SS500/SS2000/SS3000 analyzers

Part Number Description 2 YR QTY

Electronics

0190217106 Cable, External, Serial (RS-232C) 1

0190213000 Temperature Control Board 1

1. Contact SpectraSensors service department before attempting replacement. Replacing this component without technical support could cause damage to other components.

-

2900000090 4-20 mA Current Loop Board (not for 12VDC analyzer) 1 -

2300000030 4-20 mA Current Loop Board (for 12VDC analyzers) 1 -

1100002128 Kit, 2nd 4-20 mA Current Loop Board (not for 12VDC or SS3000) 1

-

0190216300 Power Supply, 12 VDC 1 -

0190216400 Power Supply, 24 VDC 1 -

0190216500 Power Supply, 100-240 VAC 50/60 Hz, CSA 1 -

0190230011 Keypad Assembly 1 -

0190231000 Display Assembly 1 -

0219900005 Kit, O-rings Viton, 2-Pass Cell 1 1

0219900011 Kit, Fuse, AC, DC 1

0900002146 Stainless steel mirror (0.1-m and 0.8-m cell only) -

Pressure Sensor Options

5500002016 Pressure Sensor, 30 psia, 5V, 1/8” MNPT DIN4365 NACE 1

6000002244 Cable, Pres/Temp, EXT, 22” 1 1

6000002245 Cable, Pres/Temp, Dual, EXT, 22” 1 1

Maintenance

0219900001 Spares Kit, (O-rings, fuses), (Domestic U.S.) 1

0219900005 Spares Kit, (O-rings, fuses), (International) -

0219900007 Cleaning Kit (Domestic U.S./Canada) 1 1

0219900017 Cleaning Kit (International) 1 1



Table A-6 Replacement parts for SS500/SS2000/SS3000 analyzers (Continued)

Part Number Description 2 YR QTY

Sample Conditioning Systems

61303042S4 Ball Valve, 1/4” TF (SS) -

6100002193 Membrane & O-Ring, Membrane Separator 2

2800002057 Membrane Separator Cover O-ring, Viton 1

6101671208 Membrane Separator, 1/4” FNPT (SS) -

6134100274 Flowmeter, 0-2 SLPM, Glass, Valve -

6132125254 Pressure Regulator, 0–25 PSIG, 1/4” FNPT (SS) -

6101510004 Filter Housing, Mini SS/Glass -

Cables

0190217205 Hrns, Ribbon, 10 Cond., 9 in -

0190217204 Cable, PWR Supply Output, 14 in -

0190217208 Cable, TE Cooler -

0190217206 Cable, Signal Output -

0190217101 Cable, External, Optical Head -

0190217201 Cable, Internal, Optical Head -

0190217202 Cable, Int, Temp/Pres -

0190217211 Cable, Int, Temp/Pres, Dual -

6000002221 Cable, 4X Relay Ctrl, 9.5 in -

6000002222 Cable, 2X Relay Ctrl, 10 in -

General

4900002215 SS500/SS2000/SS3000 Hardware Installation and Maintenance Manual, additional copies

-

4900002225 Firmware v2.51 Operator’s Manual, additional copies

-

For a complete listing of new or updated certificates, please visit the product page at www.spectrasensors.com.

A–20 4900002215 rev. D 7-29-16

Appendix B: Maintaining & Troubleshooting

This section presents recommendations and solutions to common problems, such as gas leaks, contamination, excessive sampling gas temperatures and pressures, and electrical noise. If your analyzer does not appear to be hampered by one of issues discussed in this chapter, contact “Customer Service” on page B-21.

Potential Risks Affecting PersonnelThis section addresses the appropriate actions to undertake when faced with hazardous situations during or before service of the analyzer. It is not possible to list all potential hazards within this document. The user is responsible for identifying and mitigating any potential hazards present when servicing the analyzer.

Mitigating risksRefer to the instructions for each situation listed below to mitigate associated risks.

Electrocution hazard

1. Shut off power at the main disconnect external to the analyzer.

2. Open enclosure door.

If service must be performed with power engaged (gain adjustment, etc.):

1. Note any live electrical components and avoid any contact with them.

2. Only use tools with a safety rating for protection against accidental contact with voltage up to 1000V (IEC 900, ASTF-F1505-04, VDE 0682/201).

Technicians are expected to follow all safety protocols established by the customer that are necessary for servicing the analyzer. This may include, but is not limited to, lockout/tagout procedures, toxic gas monitoring protocols, PPE requirements, hot work permits and other precautions that address safety concerns related to performing service on process equipment located in hazardous areas.

Complete this action before performing any service that requires working near the main input power or disconnecting any wiring or other electrical components.

Hardware Installation and Maintenance Manual B–1


Explosion hazard

Any work in a hazardous area must be carefully controlled to avoid creating any possible ignition sources (e.g., heat, arching, sparking, etc.). All tools must be appropriate for the area and hazards present. Electrical connections must not be made or broken with power on (to avoid arching).

Gas LeaksProbably the most common cause of erroneous measurements is outside air leaking into the sample supply line. It is recommended the supply lines be periodically leak-tested, especially if the analyzer has been relocated or has been replaced or returned to the factory for service and the sample lines have been reconnected.

ContaminationContamination and long exposure to high humidity are valid reasons for periodically cleaning the gas sampling lines. Contamination in the gas sampling lines can potentially find its way to the sample cell and deposit on the optics or interfere with the measurement in some other way. Although the analyzer is designed to withstand some contamination, it is recommended to always keep the sampling lines as contamination free as possible. If mirror contamination is suspected, see “Cleaning the Mirrors” on page B-3.

To keep the sampling lines clean:1. Make sure that a membrane separator filter (included with most

systems) is installed ahead of the analyzer and operating normally. Replace the membrane if necessary. If liquid enters the cell and accumulates on the internal optics, a Power Fail Error will result.

2. Turn off the sample valve at the tap in accordance with site lock-out, tag-out rules.

3. Disconnect the gas sampling line from the supply port of the analyzer.

Do not use plastic tubing of any kind for sample lines. Plastic tubing is permeable to moisture and other substances which can contaminate the sample stream. SpectraSensors recommends using 1/4” O.D x0.035” wall thickness, seamless stainless steel tubing.


B–2 4900002215 rev. D 7-29-16

Maintaining & Troubleshooting

4. Wash the sampling line with alcohol or acetone and blow dry with mild pressure from a dry air or nitrogen source.

5. Once the sampling line is completely free of solvent, reconnect the gas sampling line to the supply port of the analyzer.


Excessive Sampling Gas Temperatures and PressuresThe embedded software is designed to produce accurate measurements only within the allowable cell operating range (see Appendix A). Pressures and temperatures outside these ranges will trigger a P/T Fail Error fault. Refer to the Firmware Manual for this analyzer for instruction on system faults.

Electrical NoiseHigh levels of electrical noise can interfere with laser operation and cause it to become unstable. Always connect the analyzer to a properly grounded power source. Refer to “Protective chassis and ground connections” on page 2-4.

Peak Tracking Reset ProcedureThe analyzer’s software is equipped with a peak tracking function that keeps the laser scan centered on the absorption peak. Under some circumstances, the peak tracking function can get lost and lock onto the wrong peak. If the difference between PkDf and PkDl is more than 4, or Track Fail Error is displayed, the peak tracking function should be reset. Refer to the Firmware Manual for this analyzer for instruction.

Cleaning the MirrorsIf contamination makes its way into the cell and accumulates on the internal optics, a Power Fail Error will result. If mirror contamination is suspected, please consult with your factory sales representative before attempting to clean the mirrors. If advised to do so, use the following procedure.

If the pressure, temperature, or any other readings on the LCD appear suspect, they should be checked against the specifications (see Appendix A).



Determining the type of cell mirrorMeasurement cells will come equipped with either a glass or stainless steel mirror. Before determining whether to clean or replace the mirror, identify the type of measurement cell being used in the analyzer. Analyzers will come equipped with one or more, depending on configuration, of the cell types shown in Figure B–1.

The stainless steel mirrors have been identified with either an “X” engraved on the external bottom side of the mirror or a groove around the rim of the mirror. Glass mirrors can be used on any size cell. To determine the type of mirror being used for the system cell:

Do not attempt to clean the cell mirror until you have consulted with your factory service representative and have been advised to do so.

The sample cell assembly contains a low-power, 10 mW MAX, CW Class 3b invisible laser with a wavelength between 700-3000 nm. Never open the sample cell flanges or the optical assembly unless the power is turned off.

Always handle the optical assembly by the edge of the mount. Never touch the coated surfaces of the mirror.

Figure B–1 Measurement cell types

0.1-m CELL

0.8-m CELL

B–4 4900002215 rev. D 7-29-16


1. Feel at the bottom of the cell for the engraved “X” marking or the side of the mirror for a groove. Refer to Figure B–2 below.

a. If the bottom surface is smooth, a glass mirror is being used.

b. If the bottom surface is rough or engraved, or a groove on the side of the mirror is detected, a stainless steel mirror is being used.

To clean the mirror, refer to the instructions “To clean the mirrors” on page B-6. "To replace the stainless steel mirror:" refer to the instructions on page B–7.

Tools and Supplies:• Lens cleaning cloth (Cole Parmer® EW-33677-00 TEXWIPE®

Alphawipe® Low-Particulate Clean Room Wipes or equivalent)

• Reagent-grade isopropyl alcohol (ColeParmer® EW-88361-80 or equivalent)

• Small drop dispenser bottle (Nalgene® 2414 FEP Drop Dispenser Bottle or equivalent)

• Acetone-impenetrable gloves (North NOR CE412W Nitrile Chemsoft™ CE Cleanroom Gloves or equivalent)

• Hemostat (Fisherbrand™ 13-812-24 Rochester-Pean Serrated Forceps)

• Bulb blower or dry compressed air/nitrogen

• Torque wrench

Do not attempt to replace a glass mirror with a stainless steel mirror or system calibration may be adversely affected.

Figure B–2 Stainless steel mirror marking

MIRROR MARKED WITH ‘X’

MIRROR GROOVED RIM - SIDE VIEW



• Permanent marker

• Flashlight

To clean the mirrors:1. Power down the analyzer following the procedure outlined in “To

power down the analyzer” in the Firmware Manual for this analyzer.

2. Isolate the analyzer from the sample bypass flow by following the procedure outlined in “To isolate the analyzer for short-term shutdown” on page 3-6.

3. If possible, purge the system with nitrogen for 10 minutes.

4. Carefully mark the orientation of the mirror assembly on the cell body.

5. Gently remove the mirror assembly from the cell by removing the six socket-head cap screws and set on a clean, stable and flat surface.

6. Look inside the sample cell at the top mirror using a flashlight to ensure that there is no contamination on the top mirror.

7. Remove dust and other large particles of debris using a bulb blower or dry compressed air/nitrogen. Pressurized gas duster products are not recommended as the propellant may deposit liquid droplets onto the optic surface.

8. Put on clean acetone-impenetrable gloves.

9. Double fold a clean sheet of lens cleaning cloth and clamp near and along the fold with the hemostats or fingers to form a “brush.”

10. Place a few drops of isopropyl alcohol onto the mirror and rotate the mirror to spread the liquid evenly across the mirror surface.

Careful marking of the mirror orientation is critical to restoring system performance upon reassembly after cleaning.

Due to its proximity to the optical head, SpectraSensors does not recommend cleaning the top mirror. If the top mirror is visibly contaminated, contact your factory service representative.

B–6 4900002215 rev. D 7-29-16


11. With gentle, uniform pressure, wipe the mirror from one edge to the other with the cleaning cloth only once and only in one direction to remove the contamination. Discard the cloth.

12. Repeat with a clean sheet of lens cleaning cloth to remove the streak left by the first wipe. Repeat, if necessary, until there is no visible contamination on the mirror.

13. Carefully replace the mirror assembly onto the cell in the same orientation as previously marked making sure the O-ring is properly seated.

14. Tighten the 6 socket-head cap screws evenly with a torque wrench to 13 in-lbs.

To replace the stainless steel mirror:If your system has been configured with a stainless steel mirror in the 0.1-m or 0.8-m measurement cell, use the following instructions to replace the mirror, if necessary.

1. Power down the analyzer as instructed in the section called “Powering Down the Analyzer” in the Firmware Manual for this analyzer.

2. Isolate the analyzer from the sample bypass flow by shutting off the appropriate valve(s) and/or pressure regulator.

3. If possible, purge the measurement cell with nitrogen for 10 minutes.

Never rub an optical surface, especially with dry tissues, as this can mar or scratch the coated surface.

If stainless steel mirrors are replacing another version of mirror in the field, such as glass, the analyzer may need to be returned to the factory for re-calibration to ensure optimal cell function. Refer to “Service Repair Order” on page B-21.





4. Gently remove the mirror assembly from the cell by removing the socket-head cap screws and set on a clean, stable and flat surface.

5. Confirm need to replace mirror due to contamination. If yes, set mirror aside.

6. Put on clean acetone-impenetrable gloves.

7. Obtain the new stainless steel mirror. Refer to Figure B–3.

8. Check the O-ring.

a. If a new O-ring is needed, apply grease on fingertips and then to the new O-ring.

b. Place newly greased O-ring into the groove around the outside of the mirror taking care not to touch the mirror surface.

9. Carefully place the new stainless steel mirror onto the cell making sure the O-ring is properly seated.

10. Tighten the socket-head cap screws evenly with a torque wrench to 13 in-lbs.

Pressure Sensor ReplacementA pressure sensor may need to be replaced in the field as a result of one or more of the following conditions:

• Loss of pressure reading

• Incorrect pressure reading

The sample cell assembly contains a low-power, 10 mW MAX, CW Class 3b invisible laser with a wavelength between 750-3000 nm. Never open the sample cell flanges or the optical assembly unless the power is turned off.

Always handle the optical assembly by the edge of the mount. Never touch the optical surfaces of the mirror.

Figure B–3 Stainless steel mirror - mirror side up

B–8 4900002215 rev. D 7-29-16


• Pressure sensor not responding to pressure change

• Physical damage to the pressure sensor

Use the following information to replace a pressure sensor.

Tools and materials:• 9/16” wrench

• 7/8” wrench

• 9-64” Allen wrench

• Flat-head screwdriver

• Phillips-head screwdriver

• Metal pick

• Military grade stainless steel PFTE tape (or equivalent)

• Dry nitrogen

• Isopropyl alcohol

To replace the pressure sensor:

1. Close the external flow of gas at the sample inlet.

2. Power off the system. Refer to the Firmware Manual for this analyzer for “Powering down the analyzer”.

3. Purge the system by connecting dry nitrogen to the sample inlet. Allow the SCS to purge for 5-10 minutes.

4. Close the nitrogen flow.

5. Remove the optical cable harness at the circular connector. Refer to Figure B–4.

Alcohol can be hazardous. Follow all safety precautions when in use and thoroughly wash hands prior to eating.



ORS

T

CCONN

MOUNTBRACK

(BOTH SIDUREMENT

6. Disconnect the cell inlet using a 9/16” wrench.

7. Disconnect the cell outlet using a 9/16” wrench.

8. Disconnect the thermistor cable at the circular connector.

9. Remove the pressure sensor cable from the circular connector.

For new model pressure sensors with quick-disconnects, detach the pressure sensor cable from the pressure sensor at the connector using a Phillips-head screwdriver. Do not remove the black connector from the cable.

10. Remove the foam insulation from around the measurement cell.

11. Dismount the cell from the bracket by removing the four securing screws (four on top and four on the bottom) using a 9-64” Allen wrench. Place the measurement cell on a clean, flat surface with the pressure sensor facing up. Refer to Figure B–5.

Figure B–4 Analyzer component locations

MOUNTINGBRACKETS

(TOP & BOTTOMBOTH SIDES)

CELL INLET

PRESSURE SENSOR

MEASUREMENTCELL

CIRCULARCONNECT

CELL OUTLET

SS3000SS500/SS2000

CELLINLE

CELL OUTLET

IRCULARECTORS

INGETSES)

MEASUREMENTCELL

MEASCELL

Figure B–5 Removed measurement cell with pressure sensor face up

B–10 4900002215 rev. D 7-29-16


12. Using a 9/16” wrench, secure the flange while using a 7/8” wrench to remove the old pressure sensor. Refer to Figure B–6.

a. Hold the supporting wrench on the flange stable and parallel to the surface. Do not move.

b. Turn the 7/8” wrench counterclockwise to loosen the pressure sensor until it is able to be removed.

13. Remove excess seal tape from the flange opening and threads and check galling. Refer to Figure B–7.

Orient the measurement cell to avoid any debris from entering the cell.

Figure B–6 Removing the old pressure sensor

Figure B–7 Removing excess seal tape from flange



14. Remove the new pressure sensor from the packaging. Retain the black connector cap on the sensor - do not remove.

15. Wrap stainless steel PTFE tape around the threads at the top of the pressure sensor, beginning from the base of the threads to the top, approximately three times taking care to avoid covering the top opening. Refer to Figure B–8.

16. Insert the new pressure sensor into the threaded flange keeping the sensor parallel to the surface for proper fitting.

17. Hand tighten pressure sensor clockwise into the flange until no longer moving freely. Refer to Figure B–9.

Threads showing signs of galling indicate a possible leak. Refer to “Customer Service” on page B-21 to arrange for repair.

Figure B–8 Replacing seal tape

Figure B–9 Replacing pressure sensor

B–12 4900002215 rev. D 7-29-16


18. Using the 9/16” wrench to hold the flange in place, turn the sensor clockwise with a 7/8” wrench until tight. Two or three threads on the pressure sensor should still be visible.

19. Remove the black connector from the pressure sensor and discard.

20. Connect the new harness/cable to the new pressure sensor.

21. Conduct a leak test to determine that the new pressure sensor is not leaking.

22. Remount the cell to the mounting brackets using a 9-64” Allen wrench with the pressure sensor facing forward.

23. Replace the foam insulation around the measurement cell.

24. Reinstall cell inlet and cell outlet using a 9/16” wrench.

25. Reconnect the thermistor.

26. Connect the new pressure sensor harness and cable to the circular connector.

Make sure the black connector at the bottom of the pressure sensor is facing up from the measurement cell. Refer to Figure B–10.

If the new model pressure sensor cable is currently installed in the SCS, reattach the cable to the pressure sensor after the cell has been remounted.

Do not allow cell to exceed 10 PSIG or damage could occur.

For any questions related to leak testing the pressure sensor, refer to “Customer Service” on page B-21.

Figure B–10 Newly installed pressure sensor positioning



27. Reconnect the optical cable harness.

28. Turn the system power on. Refer to the Firmware Manual for this analyzer for “Powering up the analyzer.”

29. Run a validation on the analyzer. Refer to the Firmware Manual for instructions to “Start Validation.”

a. If the system passes, the pressure sensor replacement is successful.

b. If the system does not pass, refer to “Customer Service” on page B-21 for instruction.

Periodic SCS Maintenance

The status of the SCS should be checked regularly to confirm proper operation (pressures, flows, etc.) and detect potential problems or failures before damage occurs. If maintenance is required, isolate the part of the system to be serviced by following the appropriate procedure under “Shutting Down the SCS” on page 3-5.

All filter elements should be checked periodically for loading. Obstruction of a filter element can be observed by a decreasing supply pressure or bypass flow. If loading of a filter is observed, the filter should be cleaned and the filter element replaced. After observation for some time, a regular schedule can be determined for replacement of filter elements.

No other regularly scheduled maintenance should be required for the system.

Preventive and On-Demand SCS Maintenance

Preventive and on-demand maintenance will be required when components and parts deteriorate or fail as a result of continuous use. The performance of the entire SCS and individual components should be monitored regularly so that maintenance may be performed on a scheduled basis in order to prevent a failure that could take the system out of operation.

The SCS is designed for convenient removal and replacement of component parts. Complete spare components should always be available. In general, if a problem or failure occurs, the complete part should be removed and replaced

Due to the chemical properties of the process samples, care must be taken to repair or replace components with proper materials of construction. Maintenance personnel should have a thorough knowledge and understanding of the chemical characteristics of the process before performing maintenance on the SCS.

Due to the chemical properties of the process samples, care must be taken to repair or replace components with proper materials of construction. Maintenance personnel should have a thorough knowledge and understanding of the chemical characteristics of the process before performing maintenance on the SCS.

B–14 4900002215 rev. D 7-29-16


to limit system down time. Some components may be repaired (replacement of seats and seals, etc.) and then reused.

If the sample supply line does not appear to completely clear during normal operation, it may be necessary to clean the sample transport line to remove any liquid that may adhere to the wall of the tubing. The sample transport line should be purged dry with air or nitrogen before the system is placed back in operation.

If liquid makes it into the analyzer SCS, a filter element may become obstructed leading to a decreasing supply pressure or bypass flow. If obstruction of a filter is observed, the filter should be cleaned and the filter element replaced.

Regular SCS Status Check1. Read and record the flowmeter settings while the gas is flowing.

2. Compare the current readings with the past readings to determineany variations. Reading levels should remain consistent.

3. If reading levels decrease, check the filters.

To check filters:1. Shut down the system following the procedure in “Shutting Down

the SCS” on page 3-5.

2. Inspect, repair or replace the filter as required.

3. Restart the system following the procedure in “Starting up theSCS” on page 3-3.

Instrument ProblemsIf the instrument does not appear to be hampered by gas leaks, contamination, excessive sampling gas temperatures and pressures, or electrical noise, refer to Table B–1 before contacting Customer Sservice.

The system must be taken out of service during any cleaning of the sample transport line.

For additional information, contact SpectraSensors’ Technical Service Group at 800-619-2861.



Table B–1 Potential instrument problems and solutions

Symptom Response

Non-Operation (at start up) Is the power connected to both the analyzer and power source? Is the switch on?

Non-Operation (after start up) Is the power source good? (100-250 VAC @ 50-60 Hz, 9-16 VDC, 18-32 VDC).

Check fuse(s). If bad, replace with equivalent amperage, slow-blow fuse.

Contact a factory sales representative for service information.

Power Fail Error Turn off the power to the unit and check the optical head cables for a loose connection. Do not disconnect or reconnect any optical head cables with the power connected.

Refer to the Firmware Manual for this analyzer to verify a Power Fail error.

Check the inlet and outlet tubes to see if they are under any stress. Remove the connections to the inlet and outlet tubes and see if the power goes up. The existing tubing may need to be replaced with stainless steel flexible tubing.

Possible mirror contamination issue. Contact a factory sales representative for service information. If advised to do so, clean the mirrors by following the instructions under “To clean the mir-rors” on page B-6.

Possible alignment problem. Contact a factory sales representative for service information.

Capture diagnostic data and send the file to SpectraSensors (see “To read diagnostic data with HyperTermi-nal” in the Firmware Manual for this analyzer).

B–16 4900002215 rev. D 7-29-16


Table B-1 Potential instrument problems and solutions (Continued)

Symptom Response

Null Fail Error Refer to the Firmware Manual for this analyzer for instruction on verifying or clearing a Null Fail Error fault.

Move the jumper JMP1 on the electron-ics main board next to the pre-pot.


Spectrum Fail Error Turn off the power to the unit and check the optical head cables for a loose connection. Do not disconnect or reconnect any optical head cables with the power connected.

Turn the analyzer off for 30 seconds and then turn it on again.

Reset the peak tracking.


P/T Fail Error Check that the actual pressure in the measurement cell is within specification (see Appendix A).

Check that the actual temperature in the measurement cell is within specifi-cation (see Appendix A).

If the temperature reading is incorrect, check that the pressure/temperature cable is tight. Check the connector on the cell temperature sensor. Check the temperature connector on the back-plane board. (Note: A temperature reading greater than 150 °C indicates a short circuit on the temperature sensor leads; a reading of less than –40 °C indicates an open circuit).

If the pressure reading is incorrect, check that the pressure/temperature cable is tight. Check the connector on the pressure sensor. Check the pres-sure connector on the backplane board.




Symptom Response

Track Fail Error Refer to the Firmware Manual for instruction on PkDf and PkD1faults.

Reset the peak tracking. Refer to the Firmware Manual for this analyzer.

Front panel display is not lit and no char-acters appear

Check for correct voltage on terminal block input. Observe polarity on DC powered units.

Check for correct voltage after fuses.

Check for 5 VDC on red wires, 12 VDC on yellow wires, and 24 VDC on orange wires from power supply (black wires are ground).

Check connections on display commu-nication and power cables.

Strange characters appear on front panel display

Check connections on display commu-nication cable.

No reading on device connected to current loop

Make sure that connected device can accept a 4-20 mA signal. The analyzer is set to source current.

Make sure the device is connected to the correct terminals on the green con-nector (see Figure 2–3 on page 2–7).

Check the open circuit voltage (35-40 VDC) across the current loops ter-minals on the green connector (see Figure 2–3 on page 2–7).

Replace the current loop device with a milliampere meter and look for current between 4 mA and 20 mA. A voltmeter connected across a 249-ohm resistor can be used instead of the milliampere meter; it should read between 1 and 5 volts.

Reading seems to always be low by a fixed amount

See “Adjusting Analyzer Reading to Match Specific Standard(s)” in the Firmware Manual for this analyzer.


B–18 4900002215 rev. D 7-29-16



Symptom Response

Reading seems to always be low by a fixed percentage


Reading is erratic or seems incorrect Check for contamination in the sample system, especially if the readings are much higher than expected.


Serial output is displaying garbled data Make sure the computer COM port is set for correct baud, 8 data bits, 1 stop bit, no parity, and no flow control.

Be sure no other programs are using the COM port selected.

Make sure the connections are good. Verify the correct pin connections with an ohmmeter.

Make sure to select the correct COM port that the cable is plugged into.

Serial output is providing no data Make sure the computer COM port is set for 19200 baud, 8 data bits, 1 stop bit, no parity, and no flow control.

Be sure no other programs are using the COM port selected.

Make sure to select the correct COM port into which the cable is plugged.

Make sure the connections are good. Verify the correct pin connections with an ohmmeter.

LCD does not update. Unit is locked up. Switch off power, wait 30 seconds, and then switch power back on.

Gas concentration is equal to zero.

Pressing keys on front panel does not have specified effect

Check connections on keypad cable.




Symptom Response

Current loop is stuck at 4 mA or 20 mA Check display for fault message. If alarm has been triggered, reset the alarm.

On the current loop board, check the voltage between the end of resistor R1 closest to the jumper and ground. If the concentration reading is high, the voltage should be near 1 VDC. If the concentration reading is low, the volt-age should be near 4.7 VDC. If not, the problem is probably on the HC12 main board. Return to factory for service.

Reading seems to always be high by a fixed amount



Reading seems to always be high by a fixed percentage

See “Adjusting Analyzer Reading to Match Specific Standard(s)” in the Firmware Manual of this analyzer.


Reading goes to “0” If 4-20 mA Alarm Action is set to 0, look on display for a fault message (see “To change parameters in Mode 2 or Mode 3” in the Firmware Manual for this analyzer).

Gas concentration is equal to zero.

Reading goes to full scale If 4-20 mA Alarm Action is set to 1, look on display for a fault message (see “To change parameters in Mode 2 or Mode 3” in the Firmware Manual for this analyzer).

Gas concentration is greater than or equal to full scale value.

B–20 4900002215 rev. D 7-29-16


Service ContactIf the troubleshooting solutions do not resolve the issues, contact customer service. To return the unit for service or replacement, refer to "Service Repair Order".

Customer Service4333 W Sam Houston Pkwy N, Suite 100Houston, TX 77043-1223United States of America

For SpectraSensors North America Service:

Phone: 1-800-619-2861, and press 2 for Technical ServiceFax: 1-713-856-6623 E-mail: [email protected]: Service engineers are on duty Monday-Friday, 8:00 a.m. to 5:00 p.m. Central Time.

For SpectraSensors International Service, please contact the SpectraSensors distributor or the E+H Sales Center in your area, or contact:

Phone: +1-713-466-3172, and press 2 for Technical ServiceFax: +1-713-856-6623 E-mail: [email protected]

Before contacting Technical ServiceBefore contacting Technical Services, prepare the following information to send with your inquiry:

• Diagnostic downloads using the procedures provided in the associated firmware manual or using AMS100 software from SpectraSensors.

• Contact information

• Description of the problem or questions

Access to the above information will greatly expedite our response to your technical request.

Service Repair OrderIf returning the unit is required, obtain a Service Repair Order (SRO) Number from Customer Service before returning the analyzer to the factory. Your service representative can determine whether the analyzer can be serviced on site or should be returned to the factory. All returns should be shipped to:

11027 Arrow Rte.Rancho Cucamonga, CA 91730-4866United States of America1-909-948-4100



PackingSpectraSensors analyzer systems and auxiliary equipment are shipped from the factory in appropriate packaging. Depending on the size and weight, the packaging may consist of a cardboard-skinned container or a wooden crate. All inlets and vents are capped and protected when packaged for shipment.

If the equipment is to be shipped or stored for any length of time, it should be packed in the original packaging when shipped when shipped from the factory, if possible. If the analyzer has been installed and or operated (even for purposes of a demonstration), the system should first be decontaminated (purged with an inert gas) before powering down the analyzer.

To purge the analyzer for shipment/relocation:

1. Refer to the procedure “To isolate the analyzer for long-term shutdown” on page 3-7.

2. Disconnect the sample tubing at the inlet to the analyzer.

3. Connect clean, dry nitrogen to the sample inlet. Set to 30 PSIG.

4. Open the low pressure flare or atmospheric vent header shut-off valve for the effluent from the sample bypass.

5. Allow the analyzer to purge for 20 minutes.

6. Shut off the nitrogen purge and disconnect.

7. Close the low pressure flare or atmospheric vent header shut-off valve for the effluent from the sample bypass.

8. Cap off all connections.

To prepare the analyzer for shipment or storage:1. Follow all instructions "To purge the analyzer for

shipment/relocation".

2. Cap all inlets, outlets, vents, conduit or gland openings (to prevent foreign material such as dust or water from entering the system)

Process samples may contain hazardous material in potentially flammable and/or toxic concentrations. Personnel should have a thorough knowledge and understanding of the physical properties of the sample and prescribed safety precautions before installing, operating or maintaining the analyzer.

If the analyzer is configured for differential measurements, purge the system with power “on” to ensure dry and wet portions of SCS are properly purged.

B–22 4900002215 rev. D 7-29-16


using the original fittings supplied as part of the packaging from the factory.

3. Pack the equipment in the original packaging in which it was shipped. If the original packaging material is no longer available, the equipment should be adequately secured (to prevent excessive shock or vibration). Contact "Customer Service" for any questions related to packaging.

4. If returning the analyzer to the factory, complete the Decontamination Form provided by SpectraSensors "Customer Service" and attach to the outside of the shipping package as instructed before shipping.

StorageThe packaged analyzer should be stored in a sheltered environment that is temperature controlled between -4 F (-20 C) and 122 F (50 C), and should not be exposed to direct sun, rain, snow, condensing humidity or corrosive environments.

DisclaimersSpectraSensors accepts no responsibility for consequential damages arising from the use of this equipment. Liability is limited to replacement and/or repair of defective components.

This manual contains information protected by copyright. No part of this guide may be photocopied or reproduced in any form without prior written consent from SpectraSensors.

WarrantyThe manufacturer warrants the items delivered shall be free from defects (latent and patent) in material and workmanship for a period of one year after delivery to the Buyer. The Buyer’s sole and exclusive remedy under this warranty shall be limited to repair or replacement. Defective goods must be returned to the manufacturer and/or its distributor for valid warranty claims. This warranty shall become inapplicable in instances where the items have been misused or otherwise subjected to negligence by the Buyer.

Notwithstanding any other provision of this contract, no other warranties, whether statutory or arising by operation of law, expressed or implied, including but not limited to those of merchantability or fitness for particular purpose, shall apply to the goods or services hereunder, other than the repair and replacement warranty above. Seller shall in no event be liable to Buyer or any third party for any damage, injury or loss, including loss of use or any direct or indirect incidental or consequential damages of any kind.




B–24 4900002215 rev. D 7-29-16

INDEX

Numerics4-20 mA current loop 2-6

AAbsorption profile 1-6Acetone B-3Acetone-impenetrable gloves B-5, B-6,

B-8Analyzer shutdown

Long-term 3-7Short-term 3-6

Attenuation 1-5

BBeer-Lambert absorption law 1-6

CCautions 1-1Cleaning

Gas sampling lines B-2Mirrors B-3

COM port B-19Contamination B-2

Mirrors 1-7Control system

Tracer 3-3, 3-4Current 1-6Current loop 2-6

Receiver 2-8

DDetector 1-5

EElectric tracer 3-4Electrical noise B-3Electronics enclosure 2-4, 2-6Enclosure

Electronics 2-6, 2-7, 2-8, 2-9Erroneous readings 2-13Excessive sampling

Gas pressure B-15

Gas temperature B-15Excessive sampling gas temperature B-3

FFaults

Null Fail Error B-17P/T Fail Error B-3, B-17Power Fail Error B-2, B-3, B-16Spectrum Fail Error B-17Track Fail Error B-3, B-18

Field pressure reducing regulator 3-1Field pressure reducing station 3-3, 3-4,

3-5, 3-6Flowmeter 3-2, 3-5, 3-6, 3-7

Sample 3-4Sample Bypass 3-7

GGas leaks 2-12, B-2, B-3Gas lines 2-10Ground wire 2-6

HHardware 2-2

IIncident intensity 1-5Installation 2-2

LLaser beam 1-5Laser output fluctuations 1-6Leak detector 2-12, B-3Lens tissue B-5Lock-in amplifier 1-7

MMating terminal block 2-7, 2-9Membrane separator 3-2, B-2Mirror contamination 1-7, B-2, B-3

Hardware Installation and Maintenance Manual Index–1


NNatural frequencies 1-5

OOptional analyzer hood 2-3Outline schematic A-8, A-9, A-10, A-12,

A-15, A-16, A-17, A-18Output Signal

4-20 mA current loop 2-6Serial output 2-6

PParameters

DiagnosticPkD1 B-18PkDf B-18

Measurement and control4-20 mA Alarm Action B-20

Peak tracking reset B-3Pin numbers 2-7Port

Bypass return 2-13Pressure relief vent 2-10, 2-13Sample inlet 2-12Sample return 2-12, 3-3Sample supply 3-2

Pressure regulator 3-2, 3-4, 3-5, 3-6

RRaw data 1-6Recommendations and solutions to

common problems B-1Resonances

Natural frequencies

SSample bypass 3-4, 3-6

Start-up 3-4Sample conditioning system (SCS) 3-1,

3-3, B-7Periodic maintenance B-14Preventive and on-demand

maintenance B-14Shut down 3-5Start-up 3-3

Sample gas 1-5, 3-2Sample probe 3-1, 3-3, 3-4, 3-5, 3-6Serial cable 2-7

Serial connection 2-6Service contact B-21, B-22Signal wires 2-7Stainless steel tubing 2-10, 2-12, B-2System conditioning 2-13System models

SS2000 1-3SS3000 1-4SS500 1-3

TTemperature controller

Electric tracer 3-4Tools 2-2Trace gas measurement (mixed

background) 1-8Troubleshooting

Cleaning mirrors B-3Tools and supplies B-5

Contamination B-2Electrical noise B-3Excessive sampling gas pressure B-3Gas leaks B-2

Tunable diode laser (TDL) 1-3Tunable diode laser absorption

spectroscopy (TDLAS) 1-5

VValve

Control 3-5Flowmeter control 3-5Isolation 3-1, 3-3, 3-4, 3-6Metering 3-2, 3-5Relief 3-3, 3-6, 3-7Shut-off 3-2, 3-4, 3-6, 3-7, 3-8

WWarnings

General 1-1Wavelength Modulation Spectroscopy

(WMS) signal detection 1-7

Index–2 4900002215 rev. D 7-29-16

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