SpectraSensors S2000 Manual

7/21/2019 SpectraSensors S2000 Manual

http://slidepdf.com/reader/full/spectrasensors-s2000-manual 1/92

SS500/SS2000/SS3000Gas Analyzer

Hardware Installationand Maintenance Manual

P/N 4900002215 rev B

SS500/SS2000

SS3000 H 2O/CO2SS3000 H 2O/H 2O



Hardware Installation andMaintenance Manual



Products of

4333 W Sam Houston Pkwy N, Suite 100

Houston, TX 77043-1223

Tel: 800.619.2861

Fax: 713.856.6623

www.spectrasensors.com

Copyright © 2015 SpectraSensors, Inc. No part of this manual may be reproduced in

whole or in part without the express written permission of SpectraSensors, Inc.

SpectraSensors reserves the right to change product design and specifications at any

time without prior notice.

SS500/SS2000/SS3000Gas Analyzer

Hardware Installation andMaintenance Manual

Use this manual with theFirmware Operator’s Manual



Revision History

Revision Engineering Order Date

A EO15547 4/8/14

B ECR16086 3/10 /15



Hardware Installation and Maintenance Manual i

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Lifting/carrying the analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Installing the Analyzer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

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

Mounting the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2To mount the analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Connecting Electrical Power to the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3Protective chassis and ground connections . . . . . . . . . . . . . . . . . . . . . . . . . 2-4To connect electrical power to the analyzer. . . . . . . . . . . . . . . . . . . . . . . . . 2-4

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

To change the 4-20 mA board from source to sink. . . . . . . . . . . . . . . . . . . . 2-8Calibrating the analog output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9Testing and adjusting the 4-20 mA zero and span . . . . . . . . . . . . . . . . 2-10

Connecting the Gas Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10To connect the sample supply line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10To connect the sample return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Conditioning the SCS Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

3: Sample Conditioning System (SCS)

About the SCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Checking the SCS Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

To perform SCS installation checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Starting up the SCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

To prepare for SCS startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3To start up the field pressure reducing station. . . . . . . . . . . . . . . . . . . . . . . 3-4To start up the sample bypass stream on process sample. . . . . . . . . . . . . . . 3-4To start up the analyzer on process sample . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Shutting Down the SCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5To isolate the analyzer for short-term shutdown . . . . . . . . . . . . . . . . . . . . . 3-6To isolate the analyzer for long-term shutdown. . . . . . . . . . . . . . . . . . . . . . 3-7





Hardware Installation and Maintenance Manual iii

LIST OF FIGURES

Figure 1–1. SS500/SS2000 analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Figure 1–2. SS3000 Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Figure 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. . . 1-6

Figure 1–5. Typical normalized absorptionsignal from a laser diode absorption spectrometer . . . . . . . . . . . . 1-7

Figure 1–6. Typical normalized 2 f signal; species concentration isproportional to the peak height . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Figure 1–7. Analyzer Overview (SS3000 pictured) . . . . . . . . . . . . . . . . . . . . . 1-9

Figure 1–8. Electronics control board (AC) for single-channel systems(SS500/SS2000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Figure 1–9. Electronics control board (DC) for single-channel systems(SS500/SS2000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Figure 1–10. Electronics control board (AC) for dual-channel systems(SS3000). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Figure 1–11. Electronics control board (DC) for dual-channel systems(SS3000). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Figure 2–1. Internal view of electronics enclosure (SS500) . . . . . . . . . . . . . . . 2-5

Figure 2–2. AC and DC connection terminal blocks in electronics enclosure. . . . 2-6

Figure 2–3. Mating terminal block (TB2) in electronics enclosure forconnecting signal cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Figure 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-11

Figure A–7. Interconnect diagram for single-channel system(SS500/SS2000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-12

Figure A–8. SS3000 0.8-m/0.1-m cells (H2O/ CO2) outline andmounting dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-13

Figure A–9. SS3000 0.8-m/0.8-m cells (H2O/H2O) outline andmounting dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-14



SS500/SS2000/SS3000 Analyzer

iv 4900002215 rev. B 3-10-15

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

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

Figure A–12. Electrical schematic for SS3000 . . . . . . . . . . . . . . . . . . . . . . . . A-17

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

Figure B–1. Measurement cell types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4

Figure B–2. Stainless steel mirror marking . . . . . . . . . . . . . . . . . . . . . . . . . . B-5

Figure B–3. Stainless steel mirror - mirror side up . . . . . . . . . . . . . . . . . . . . . B-8

Figure B–4. Analyzer component locations . . . . . . . . . . . . . . . . . . . . . . . . . B-10

Figure B–5. Removed measurement cell with pressure transducer face up . . . B-10

Figure B–6. Removing the old pressure transducer . . . . . . . . . . . . . . . . . . . B-11

Figure B–7. Removing excess seal tape from flange . . . . . . . . . . . . . . . . . . . B-11

Figure B–8. Replacing seal tape. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-12

Figure B–9. Replacing pressure transducer . . . . . . . . . . . . . . . . . . . . . . . . . B-12

Figure B–10. Newly installed pressure transducer positioning . . . . . . . . . . . . . B-13



Hardware Installation and Maintenance Manual v

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-1

Table A–2. SS2000 single-channel H2O analyzer specifications. . . . . . . . . . . . A-2

Table A–3. SS2000 single-channel CO2 analyzer specifications. . . . . . . . . . . . A-3

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

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

Table A–6. Replacement parts for SS500/SS2000/SS3000 analyzers . . . . . . A-19

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




vi 4900002215 rev. B 3-10-15

THIS PAGE INTENTIONALLY LEFT BLANK



Hardware Installation and Maintenance Manual 1–

1

1 - INTRODUCTION

SpectraSensors’ SS500/SS2000/SS3000 products are high-speed, diode-laserbased extractive analyzers designed for extremely reliable monitoring of verylow or trace concentrations of specific components in various backgroundgases. In order to ensure that the analyzer performs as specified, it is

important to closely review the installation and operation sections of thismanual. This manual contains a comprehensive overview of theSS500/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 orhaving direct contact with the analyzer.

How to Use This Manual

Take a moment to familiarize yourself with this manual by reading the Tableof Contents.

There are a number of options and accessories available for theSS500/SS2000/SS3000 analyzers. This manual has been written to address

the most common options and accessories. Images, tables and charts havebeen included to provide a visual understanding of the analyzer and itsfunctions. Special symbols are also used to provide the user with keyinformation regarding the system configuration and/or operation. Pay closeattention to this information.

General Warnings and Cautions

Instructional icons are provided in this manual to alert the user of potentialhazards, important information and valuable tips. Following are the symbolsand associated warning and caution types to observe when servicing theanalyzer. 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 causeelectric shock or burn. Turn off and lock out system beforeservicing.




1–

2 4900002215 rev. B 3-10-15

Instructional Symbols

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

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

Removing label from measurement cell opticalhead will void analyzer warranty.

General notes and important information concerning theinstallation 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.

CAUTION

CLASS 3B INVISIBLE LASERRADIATION WHEN OPEN

AVOID EXPOSURE TO THE BEAM

!

V A



Introduction

Hardware Installation and Maintenance Manual 1–3

Conventions Used in this Manual

In 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 associatedreference.

SpectraSensors Overview

SpectraSensors, Inc. is a leading manufacturer of technologically advancedelectro-optic gas analyzers for the industrial process, gas distribution andenvironmental monitoring markets. Headquartered in Houston, Texas,SpectraSensors was incorporated in 1999 as a spin-off of the NASA/Caltech JetPropulsion Laboratory (JPL) for the purpose of commercializing space-provenmeasurement technologies initially developed at JPL.

About the Gas Analyzers

The SS500/SS2000/SS3000 are tunable diode laser (TDL) absorptionspectrometers operating in the near infrared region of the spectrum. Eachcompact sensor consists of a TDL light source, sample cell and detectorspecifically configured to enable high sensitivity measurement of a particularcomponent within the presence of other gas phase constituents in the stream.The sensor is controlled by microprocessor-based electronics with embeddedsoftware that incorporates advanced operational and data processingalgorithms.

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

A sample conditioning system may also be included with the system that hasbeen specifically designed to deliver an optimum sample stream that isrepresentative of the process systems stream at the time of sampling. MostSS500/SS2000/SS3000 analyzer systems are configured for use at extractivenatural gas sampling stations.

Differences between the SS500, SS2000, and SS3000The SS500 and SS2000 are single-channel analyzers designed to continuouslymeasure the moisture content in natural gas pipelines. The SS2000 offershigher measurement performance in those applications, and its singlemeasurement channel can also be configured to monitor CO2 levels in naturalgas pipelines, or to measure the moisture content in CO2 pipelines. Forperformance specifications, refer to Table A–1 through Table A–3 and Figure1–1 for an image of a standard SS500/SS2000 with a 0.8-m cell.




1–

4 4900002215 rev. B 3-10-15

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

Figure 1–1 SS500/SS2000 analyzer

Figure 1–2 SS3000 Analyzer






1–

6 4900002215 rev. B 3-10-15

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

, (1)

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

. (2)

Figure 1–4 shows the typical raw data from a laser absorption spectrometerscan including the incident laser intensity, I 0() , and the transmitted intensity, I (), for a clean system and one with contaminated mirrors (shown to illustratethe system’s relative insensitivity to mirror contamination). The positive slope

of raw data results from ramping the current to tune the laser, which not onlyincreases the wavelength with current, but also causes the correspondingoutput 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 I 0

exp lN – =

N 1–

l --------------

I

I 0

-------------ln=

3.0

2.5

2.0

1.5

1.0

0.5

Incident Energy I 0()

Raw Signal, I ()Raw Signal, I ()(Contaminated Mirrors)

Wavelength [a.u.]

S i g n a l [ a . u . ]

0.0

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






1–

8 4900002215 rev. B 3-10-15

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 arepossible (depending on target and background species) at real-time responserates (on the order of 1 second).

All SpectraSensors TDL gas analyzers employ the same design and hardwareplatform. Measuring different trace gases in various mixed hydrocarbonbackground streams is accomplished by selecting a different optimum diodelaser wavelength between 750-3000nm, which provides the least amount ofsensitivity to background stream variations.

Getting Familiar with the Analyzer

SpectraSensors’ SS500/SS2000/SS3000 analyzers are typically comprised of asingle electronics enclosure and associated measurement cell(s). Refer toAppendix A for system drawings. On the front panel of the analyzer, the keypadand LCD display serve as the user interface to each analyzer. The analyzercontrol electronics drive the laser, collect the signal, analyze the spectra andprovide measurement output signals. Refer to Figure 1–7.

Normalized2 f Signal

Wavelength [a.u.]

S i g n a l [ a . u .

]

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



Introduction


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

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

Inside the SS3000 analyzer electronics enclosure is the electronics assemblyas 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 ratingof 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

F1120 VAC Miniature Fuse, 5 x 20 mm, Time Delay 250VAC/0.8A

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

Figure 1–9Figure 1–11 F2

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

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

Figure 1–7 Analyzer Overview (SS3000 pictured)

LCD/KEYPAD

ANALYZERELECTRONICS

ENCLOSURE

MEASUREMENTCELL AND LASER

POWERCONNECTION

MEASUREMENTCELL AND LASER

!

V A




1–

10 4900002215 rev. B 3-10-15

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

TEMPERATURECONTROL BOARD

4-20 mA CURRENT LOOP

BOARD (STACKED)

FUSE(F1)

4-20 mA & SERIAL SIGNALCONNECTIONS

ASSIGNABLEALARM RELAY

GENERAL FAULTALARM RELAYNO

COMMONNC

LASERDRIVERBOARD

BACKPLANE

POWERSUPPLY

CUSTOMER

GROUND

PROTECTIVEGROUND

COMPONENT

GROUND



Introduction


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


4-20 mA CURRENT LOOPBOARD (STACKED)

POWERSUPPLY

FUSE (F2)

TB2

ASSIGNABLEALARM FAULT

GENERAL FAULT

ALARM FAULT

LASERDRIVERBOARD

4-20 mA & SERIAL

SIGNAL CONNECTIONS

NO

NC

COMMON

CUSTOMERGROUND

PROTECTIVEGROUND

COMPONENTGROUND

BACKPLANE




1–

12 4900002215 rev. B 3-10-15

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)

LASERDRIVERBOARD

BACKPLANE

ASSIGNABLEALARM RELAY (Ch. A)4-20 mA & SERIAL SIGNAL

CONNECTIONS

NO

NCCOMMON

CUSTOMERGROUND

PROTECTIVE

GROUND

COMPONENT

GROUND



Introduction


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)

CUSTOMERGROUND

PROTECTIVEGROUND

COMPONENTGROUND

GENERAL FAULTALARM RELAY (Ch. B)

ASSIGNABLE ALARM

RELAY (Ch. B)NO

NC

COMMON

LASERDRIVERBOARD

BACKPLANE




1–

14 4900002215 rev. B 3-10-15





1

2 - INSTALLATION

This section describes the processes used to initially install and configure yourSS500, SS2000, or SS3000 and optional sample conditioning system (SCS).Once the analyzer arrives, you should take a few minutes to examine thecontents before installing the unit.

What Should be Included in the Shipping Box

The contents of the crate should include:

• The SpectraSensors SS500, SS2000, or SS3000

• A document CD, which includes this manual and other systemmanuals

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

• Additional accessories or options as ordered.

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

Inspecting the Analyzer

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

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

Lifting/carrying the analyzer

At approximately 25 lbs (11.5 Kg), the SS500/SS2000/SS3000 can easily belifted from the packaging and moved to the installation location. Take care notto lift or carry the analyzer by the measurement cells or the cables connectedat the top of the analyzer, or damage may occur.

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

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




2–

2 4900002215 rev. B 3-10-15

Installing the Analyzer

Installing the analyzer is relatively easy requiring only a few steps that, whencarefully followed, will ensure proper mounting and connection. This sectionincludes:

• 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 Installation

Depending on the particular model, the configuration of accessories andoptions 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 Analyzer

The SS500/SS2000/SS3000 analyzer is manufactured for wall or Unistrut® (orequivalent) metal framing installations. Depending on your application andconfiguration, the analyzer may come premounted on a SCS panel to bemounted on a wall or Unistrut framing, or without a panel requiring mounting



Installation


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

To mount the analyzer:

1. Select a suitable location to mount the analyzer. Choose a shaded areaor 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 readyfor the electrical connections.

Connecting Electrical Power to the Analyzer

The analyzer will be configured for 100-240 VAC @ 50/60 Hz single-phase input oroptionally 9–16 VDC or 18–32 VDC input. Check the manufacturing data label orthe terminal block labels to determine the power input requirements. All work mustbe performed by personnel qualified in electrical conduit installation. Conduit sealsshould be used where appropriate in compliance with local regulations.

When mounting the analyzer, be sure not to position theinstrument so that it is difficult to operate adjacent devices. Allow3 feet of room in front of the analyzer and any switches.

It is critical to mount the analyzer so that the inlet and outlet linesreach the inlet and outlet connections on the chassis while stillmaintaining flexibility so that the sample lines are not underexcessive stress.

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

Hazardous voltage and risk of electric shock . Beforeattaching the wiring to the analyzer, make sure all power to thewires is off.




2–

4 4900002215 rev. B 3-10-15

Depending on the analyzer configuration, the electrical wiring can typically beconnected to the analyzer through a conduit hub located at the bottom right orleft 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 chassisgrounds must be connected. Requirements for the protective and chassisgrounds are as follows:

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

• The protective and chassis grounds must remain connected until allother 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 protectiveand chassis ground locations.

To connect electrical power to the analyzer:

1. Open the electronics enclosure door. Take care not to disturb theelectrical assembly inside. Refer to Figure 2–1.

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

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

Interconnection of the analyzer enclosure and cell enclosure shallbe 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) Article501. The installer is responsible for complying with all localinstallation codes.

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

hazard.

Conduit seals should be used where appropriate in compliancewith local regulations.



Installation


3. For AC systems, pull ground, neutral and hot wires (#14 AWGminimum) 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 toconnect to the power terminal block.

5. For AC systems, attach the neutral and hot wires to the powerterminal 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.

For DC systems, connect the minus wire to the terminal marked “”and the positive wire to the terminal marked “+” as shown in Figure2–2.

Because the breaker in the power distribution panel or switch willbe the primary means of disconnecting the power from theanalyzer, 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 beused and clearly marked as the disconnecting device for theanalyzer.

Figure 2–1 Internal view of electronics enclosure

(SS500)





Installation


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

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

4. Strip back the jacket and insulation of the current loop, digital outputrelays and serial cables (shown in Figure 1–8, Figure 1–9, Figure1–10 or Figure 1–11) just enough to connect to the mating terminalblock (TB2), shown in Figure 2–3. The mating terminal block can bepulled up and removed from its base to make the cable connectionprocess easier.

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

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

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

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

9. Close and tighten the electronics enclosure cover.

Conduit seals should be used where appropriate in compliancewith local regulations.

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

121110987654321

TB2




2–

8 4900002215 rev. B 3-10-15

10. To complete the connections, connect the other end of the currentloop wires to a current loop receiver and each external serial cableto 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. Insome instances it may be necessary to change the 4-20 mA current loop outputin the field from source to sink. The work must be performed by personnelqualified in electronics assembly.

To change the 4-20 mA board from source to sink:

1. Disconnect power to the analyzer and open the electronics enclosurecover. 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 Figure1–11.

3. Remove the jumper (JMP1), shown in Figure 2–4, connecting thecenter 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.







Installation


2. Also, confirm that the field pressure reducing station is installedproperly at the sample probe and that the pressure regulator at thefield pressure reducing station is closed (adjustment knob turnedfully 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 byapplying heat until the tube shrinks down around the heat tracebundle.

5. If configured with this analyzer, install the heat trace terminal boxexternal to the SCS enclosure using the supplied GFI Heat TracePower conduit hub.

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

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

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

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

All valves, regulators, switches, etc. should be operated inaccordance 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 beforeattempting to heat the rubber tube.





Installation


Conditioning the SCS Tubing

Newly installed systems invariably have some trace contaminants and/or areintended for measuring trace amounts of gas constituents that tend to cling tosystem walls, which can result in erroneous readings if the constituents are notin equilibrium with the system walls. Therefore, once the analyzer and SCS arecompletely connected, the entire system (i.e., from the sample source valve tothe vent or return) should be conditioned by flowing sample gas through thesystem for up to 12 hours (or until reading stabilizes) after the system ispowered up and before actual readings are taken. Progress of the systemconditioning can be monitored via the gas concentration readings. Once thegas constituents have reached equilibrium with the system walls, the readingsshould stabilize.




2–

14 4900002215 rev. B 3-10-15





1

3 - SAMPLE CONDITIONING SYSTEM (SCS)

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

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

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

Personnel should have a thorough understanding of the operationof 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 toreduce the sample pressure and enable operation of the sampleconditioning system at a low pressure. Use extreme caution whenoperating the sample probe isolation valve and field pressurereducing regulator.

The process sample at the sample tap may be at a high pressure.

Make sure that the field pressure reducing regulator is equippedwith an appropriate pressure relief valve.

Process samples may contain hazardous material in potentially

flammable and/or toxic concentrations. Personnel should have athorough knowledge and understanding of the physical propertiesand safety precautions for the sample contents before operatingthe SCS.




3–

2 4900002215 rev. B 3-10-15

About the SCS

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

sample lines, which reduces sample variation.

The system drawings and schematics used in this manual are forillustration purposes only. Always refer to your particular as-builtdrawings for your specific system configuration and

specifications.

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






3–

4 4900002215 rev. B 3-10-15

2. If applicable, confirm that the sample supply line electric tracertemperature controller at the tracer control system is set to thetemperature 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 controlvalves 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 reducingstation is closed (adjustment knob turned fully counterclockwise).

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

4. Slowly open the pressure regulator at the field pressure reducing

station (adjustment knob turned clockwise) and set the pressureregulator to the specified pressure.

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

6. Reconnect the sample transport tubing and set the pressure or theregulator 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 combinedsample bypass and measurement cell effluent from the SCS, if

applicable.

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

3. Set the inlet pressure regulator on the panel to a setting that willmaintain the specified flowmeter settings and provide good controlusing 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 isolationvalve and field pressure reducing regulator.






3–

6 4900002215 rev. B 3-10-15

To isolate the analyzer for short-term shutdown:

The analyzer can be isolated from the process sample tap for short-termshutdown or maintenance of the analyzer without requiring the shutdown ofthe 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 thelines as indicated by no flow on the sample and sample bypassflowmeters.

3. Close the atmospheric vent header shut-off valve for the combinedsample 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 reducethe sample pressure and enable operation of the SCS at a low pressure. Use extreme caution when operating the sample probeisolation valve and field pressure reducing regulator.

Process samples may contain hazardous material in potentiallyflammable and/or toxic concentrations. Personnel should have athorough knowledge and understanding of the physical propertiesand safety precautions for the sample contents before operatingthe SCS.

Due to the high pressure of the process sample, it is advisable toallow the sample bypass flow to continue during short-termisolation of the analyzer. Continuing sample bypass flow allowsthe field pressure regulator to continue normal operation without possible overpressure and activation of the relief valve in theevent the pressure regulator leaks when the downstream flow isdiscontinued.

The sample transport line must be vented to the atmospheric ventheader through the bypass flowmeter to avoid pressure surges.

The procedure given in the following steps can be followedregardless of whether or not the SCS has been isolated from the process tap as described in the previous section.




Sample Conditioning System (SCS)


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 mustbe isolated at the process sample tap.

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

2. Confirm flow in the sample bypass flowmeter (the actual flow is notcritical).

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

4. Allow pressure in the field pressure reducing regulator to dissipateuntil only a low residual pressure is indicated on the pressure gaugeat the field station.

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

Process samples may contain hazardous material in potentiallyflammable and/or toxic concentrations. Personnel should have athorough knowledge and understanding of the physical propertiesand safety precautions for the sample contents before operatingthe SCS.

Due to the high pressure of the process sample, it is advisable toallow the sample bypass flow to continue during long-termisolation of the analyzer. Continuing sample bypass flow allowsthe field pressure regulator to continue normal operation without possible overpressure and activation of the relief valve in theevent the pressure regulator leaks when the downstream flow isdiscontinued.

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





3–

8 4900002215 rev. B 3-10-15

5. Close the field pressure reducing regulator (adjustment knob turnedfully 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 samplebypass 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 thepower distribution panel.

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



Hardware Installation and Maintenance Manual A–

1

Appendix A: Specifications

Table A–1 SS500 H 2O analyzer specifications

Performance

Typical Measurement Ranges

1

1. Consult factory for alternative ranges.

2–20 lbs/MMscf (40–422 ppmv)2–50 lbs/MMscf (40–1055 ppmv)2–100 lbs/MMscf (40–2110 ppmv)

Repeatability ±0.5 lb/MMscf (±10 ppmv) or ± 2% of reading

Response Time 2

2. Software adjustable.

0.25 – 2 seconds (dependent on flow rate and sample

system volume)

Application Data

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

Environmental Relative Humidity 8% for temperatures up to 31°C MAX

Altitude Up to 4000 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 binarygas with methane background

Electrical & Communications

Input 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 .C. contact

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

Digital Output (2) General Fault and Assignable alarms

Physical Specifications

Class 1, Div 2

System Dimensions 439 mm H x 371 mm W x 146 mm D(17.27" H x 14.59" W x5.75" D)

Weight Approx. 25 lbs (11.5 Kg)

Enclosure Type NEMA 3R-304 Stainless Steel

Area Classification

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




A–

2 4900002215 rev. B 3-10-15

Table A–2 SS2000 single-channel H 2O analyzer specifications

Performance

Typical Measurement Ranges 1 0.5–20 lbs/MMscf (0–422 ppmv)0.5–50 lbs/MMscf (0–1055 ppmv)0.5-100 lbs/MMscf (0-2110 ppmv)

Repeatability ±0.2 lb/MMscf (±4 ppmv) or ± 2% of reading

Response Time 2 0.25 - 2 seconds (dependent on flow rate and samplesystem volume)

Application Data

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



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


Input Voltages 3 100–240 VAC, 50/60 Hz9–16 VDC or 18–32 VDC - Optional


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 @ 24 VDCmax loadSerial: RS-232C

Protocol: Modbus Gould RTU, Daniel RTU or ASCIIDigital Output (2) General Fault and Assignable alarms


Class 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)


Enclosure Type NEMA 3R-304 Stainless Steel

Area Classification

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



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

Category II.






A–

4 4900002215 rev. B 3-10-15

Table A–4 SS3000 dual channel H 2O/H 2O analyzer specifications

Performance

Typical Measurement Ranges 1 0.5–20 lbs/MMscf (0–422 ppmv)0.5–50 lbs/MMscf (0–1055 ppmv)0.5-100 lbs/MMscf (0-2110 ppmv)

Repeatability ±0.2 lb/MMSCF (±4 ppmv) or ±2% of reading

Response Time 2 0.25 - 2 seconds (dependent on flow rate and sam-ple system volume)

Application Data

Environmental Temperature Range -4 to 122 °F (-20 to 50 °C)15 to 140 °F (-10 to 60 °C) - Optional



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 depen-dent)

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



Contact Rating

(Inductive Load)

250V, 3A N.O. contact, 1.5A N.C. contact

24V, 1A N.O. and N.C. contact

Communication Analog: (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 & diag-nostics


Size 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

Area Classification




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

age Category II.



Specifications

Hardware Installation and Maintenance Manual A–5

Table A–5 SS3000 dual channel H 2O/CO2 analyzer specifications

Performance

Typical Measurement Ranges (H2O) 1 0.5–20 lbs/MMscf (0–422 ppmv)0.5–50 lbs/MMscf (0–1055 ppmv)0.5-100 lbs/MMscf (0-2110 ppmv)

Repeatability (H2O) ±0.2 lb/MMscf (±4 ppmv) or ±2% of reading

Concentration (CO2)1 0–5%, 0–10%, 0–20%

Repeatability (CO2) ±400 ppmv or 2% of reading, whichever is greater

Response Time 2 0.25 - 2 seconds (dependent on flow rate and samplesystem volume)

Application Data

Environmental Temperature Range -4 to 122 °F (-20 to 50 °C)15 to 140 °F (-10 to 60 °C) - Optional


Altitude Up to 4000 mSample 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 background

CO2: Binary cal gas bottle with methane background




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

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


LCD Display Concentration, cell pressure, temperature & diagnos-

tics


Size 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

Area Classification


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 –1 0

4 9 0 0 0 0 2 2 1 5 r ev

.B 3 -1 0 -1 5

Figure A–5 Drawing of typical full-featured single-channel SCS (SS500/SS200030x30 enclosure



H ar d w ar

eI n s t al l a t i on an d M ai n t en an c eM a

n u al

A –1 1

Figure A–6 Electrical schematic for SS500/SS2000

TO

PROCESSOR

TO

PROCESSOR

120/240

VAC

120/240 VAC

ANALYZER POWER

INPUT

CH. A4-20 mA/RS232 SIGNAL

OUTPUT

C H A N N E L A

C E L L



A –1 2

4 9 0 0 0 0 2 2 1 5 r ev

.B 3 -1 0 -1 5

Figure A–7 Interconnect diagram for single-channel system (SS500/SS2000)



Specifications


Figure A–8 SS3000 0.8-m/0.1-m cells (H 2O/ CO2 )outline and mounting dimensions




A–

14 4900002215 rev. B 3-10-15

Figure A–9 SS3000 0.8-m/0.8-m cells (H 2O/H 2O)outline and mounting dimensions



H ar d w ar


n u al

A –1 5

Figure A–10 Drawing of typical full-featured dual-channel, dual-stream SCS (SS



A –1 6

4 9 0 0 0 0 2 2 1 5 r ev

.B 3 -1 0 -1 5

Figure A–11 Drawing of typical full-featured dual-channel, dual-stream SCS (SSin a 36 X 36 enclosure



H ar d w ar


n u al

A –1 7

C H A N N E L

B

C E L L

C H A N N E L

A

C E L L

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



A –1 8

4 9 0 0 0 0 2 2 1 5 r ev

.B 3 -1 0 -1 5

Figure A–13 Interconnect diagram for dual-channel system (SS3000)



Specifications


Spare Parts

Below is a list of spare parts for the SS500/SS2000/SS3000 analyzers withrecommended quantities for 2 years of operation. Due to a policy of continuousimprovement, parts and part numbers may change without notice. Not all partslisted are included on every analyzer. When ordering, please specify the systemserial number to ensure that the correct parts are identified.

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

Part Number Description2 YRQTY

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 -

0190217102 Pressure Transducer Assembly 1 1

0190217111 Pressure Transducer Assembly for Dual Channel SS3000 1 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 Transducer 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









Maintaining & Troubleshooting

Hardware Installation and Maintenance Manual B–3

Mitigating risks

Refer to the instructions for each situation listed below to mitigate associatedrisks.

Exposure to process gases

1. Shut off the process gas to the analyzer before any service thatwould require opening a part of the sample plumbing.

2. Purge the system with nitrogen.

3. Shut off the nitrogen purge before opening any part of the samplesystem.

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 withthem.

2. Only use tools with a safety rating for protection against accidentalcontact with voltage up to 1000V (IEC 900, ASTF-F1505-04, VDE0682/201).

Explosion hazard

Any work in a hazardous area must be carefully controlled to avoid creating anypossible ignition sources (e.g., heat, arching, sparking, etc.). All tools must beappropriate for the area and hazards present. Electrical connections must notbe made or broken with power on (to avoid arching).

Technicians are expected to follow all safety protocols establishedby 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 concernsrelated to performing service on process equipment located inhazardous areas.

Complete this action before performing any service that requires

working near the main input power or disconnecting any wiring orother electrical components.




B–

4 4900002215 rev. B 3-10-15

Cleaning the Mirrors

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

Determining the type of cell mirror

Measurement cells will come equipped with either a glass or stainless steelmirror. Before determining whether to clean or replace the mirror, identify thetype of measurement cell being used in the analyzer. Analyzers will comeequipped with one or more, depending on configuration, of the cell types shown

in Figure B–1.

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

The sample cell assembly contains a low-power, 10 mW MAX, CWClass 3b invisible laser with a wavelength between 700-3000 nm.Never open the sample cell flanges or the optical assembly unlessthe 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–

8 4900002215 rev. B 3-10-15

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

5. Confirm need to replace mirror due to contamination. If yes, setmirror 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 thento the new O-ring.

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

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

10. Tighten the socket-head cap screws evenly with a torque wrench to13 in-lbs.

Pressure Transducer Replacement

A pressure transducer may need to be replaced in the field as a result of oneor more of the following conditions:

• Loss of pressure reading

• Incorrect pressure reading

The sample cell assembly contains a low-power, 10 mW MAX, CWClass 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–

10 4900002215 rev. B 3-10-15

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 transducer cable from the circular connector.

For new model pressure transducers with quick-disconnects, detachthe pressure transducer cable from the pressure transducer at theconnector using a Phillips-head screwdriver. Do not remove the blackconnector from the cable.

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

11. Dismount the cell from the bracket by removing the four securingscrews (four on top and four on the bottom) using a 9-64” Allenwrench. Place the measurement cell on a clean, flat surface with the

pressure transducer facing up. Refer to Figure 1-2.

Figure B–4 Analyzer component locations

MOUNTINGBRACKETS

CELL INLET

PRESSURE

TRANSDUCER

MEASUREMENTCELL

CIRCULARCONNECTORS

CELL OUTLETSS3000SS500/SS2000

CELLINLET

CELL OUTLET

CIRCULARCONNECTORS

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





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

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

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

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

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

Figure B–6 Removing the old pressuretransducer

Figure B–7 Removing excess seal tape fromflange




B–

12 4900002215 rev. B 3-10-15

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

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

16. Insert the new pressure transducer into the threaded flange keeping

the transducer parallel to the surface for proper fitting.17. Hand tighten pressure transducer 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 transducer










B–

16 4900002215 rev. B 3-10-15

Table B–1 Potential instrument problems and solutions

Symptom Response

Non-Operation (at start up) Is the power connected to both theanalyzer and power source? Is theswitch 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 withequivalent amperage, slow-blow fuse.

Contact a factory sales representativefor service information.

Power Fail Error Turn off the power to the unit andcheck the optical head cables for aloose connection. Do not disconnect

or reconnect any optical headcables with the power connected.

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

Check the inlet and outlet tubes to seeif they are under any stress. Removethe connections to the inlet and outlettubes and see if the power goes up.The existing tubing may need to bereplaced with stainless steel flexibletubing.

Possible mirror contamination issue.Contact a factory sales representativefor service information. If advised to doso, clean the mirrors by following theinstructions under “To clean the mir-rors” on page B-6.

Possible alignment problem. Contact afactory sales representative for serviceinformation.

Capture diagnostic data and send thefile to SpectraSensors (see “To read

diagnostic data with HyperTermi-nal” in the Firmware Manual for thisanalyzer).










B–

20 4900002215 rev. B 3-10-15

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

Symptom Response

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

On the current loop board, check thevoltage between the end of resistor R1closest to the jumper and ground. Ifthe concentration reading is high, thevoltage should be near 1 VDC. If theconcentration reading is low, the volt-age should be near 4.7 VDC. If not, theproblem is probably on the HC12 mainboard. Return to factory for service.

Reading seems to always be high by afixed amount

See “Adjusting Analyzer Reading toMatch Specific Standard(s)” in the

Firmware Manual for this analyzer.

Capture diagnostic data and send thefile to SpectraSensors (see “To readdiagnostic data with HyperTermi-nal” in the Firmware Manual for thisanalyzer).

Reading seems to always be high by afixed percentage

See “Adjusting Analyzer Reading toMatch Specific Standard(s)” in theFirmware Manual of this analyzer.

Capture diagnostic data and send thefile to SpectraSensors (see “To read

diagnostic data with HyperTermi-nal” in the Firmware Manual for thisanalyzer).

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 2or Mode 3” in the Firmware Manual forthis 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 2or Mode 3” in the Firmware Manual forthis analyzer).

Gas concentration is greater than orequal to full scale value.





Service Contact

If the troubleshooting solutions do not resolve the problem, contact customerservice. To return the unit for service or replacement, refer to "ReturnMaterial Authorization".

Customer Service

4333 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 ServiceFax : 1-713-856-6623E-mail : [email protected]

For SpectraSensors International Service, please contact the

SpectraSensors distributor in your area, or contact:

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

Return Material Authorization

If returning the unit is required, obtain a Return Materials Authorization(RMA) Number from Customer Service before returning the analyzer to thefactory. Your service representative can determine whether the analyzer can beserviced 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 America(909) 948-4100

Packing

SpectraSensors analyzer systems and auxiliary equipment are shipped fromthe factory in appropriate packaging. Depending on the size and weight, thepackaging 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 bepacked in the original packaging when shipped when shipped from the factory.If analyzer has been installed and or operated (even for purposes of ademonstration), the system should first be decontaminated (purged with aninert gas) before powering down the analyzer.












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 2-6

Serial output 2-6

PParameters

DiagnosticPkD1 B-18PkDf B-18

Measurement and control4-20 mA Alarm Action B-20

Peak tracking reset B-2Pin numbers 2-7

PortBypass return 2-12Pressure relief vent 2-10, 2-12Sample inlet 2-11Sample 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-1

ResonancesNatural frequencies

Return materials authorization (RMA)number B-21

SSample bypass 3-4, 3-6

Start-up 3-4S l diti i t (SCS) 3 1

System 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-4Tools and supplies B-5

Contamination B-1Electrical noise B-2Excessive sampling gas pressure B-2Gas leaks B-1

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, 3-7

Shut-off 3-2, 3-4, 3-6, 3-7, 3-8

WWarnings

General 1-1Wavelength Modulation Spectroscopy

(WMS) signal detection 1-7

SpectraSensors S2000 Manual

Documents