Ametek 5100 HD User manual

Model 5100 HD
Tunable Diode Laser Spectrometer
User Manual
90709VE REV R
Process Instruments
150 Freeport Road
Pittsburgh, PA 15238

ii | Model 5100 HD Analyzer
O󰀩ces
USA - Pittsburgh
150 Freeport Road
Pittsburgh, PA 15238
Ph. 412-828-9040
Fax [phone]
CHINA
AMETEK Shanghai (SPL)
Room 408, Metro Tower
#30 Tian Yao Qiao Road
Shanghai 200030
Ph. 86 21 6426 8111
Fax [phone]
USA - Delaware
455 Corporate Blvd.
Newark, DE 19702
Ph. 302-456-4400
Fax [phone]
AMETEK Beijing
CITIC Building, Room 2305
19, Jianguomenwai Dajie
Beijing 100004
Ph. 86 10 8526 2111
Fax [phone]
USA - Texas
4903 West Sam Houston Parkway North
Suite A-400
Houston, TX 77041
Ph. 713-466-4900
Fax [phone]
FRANCE
AMETEK Precision Instruments France
Rond Point de l’épine des champs
Buroplus Bat D
78990 Elanbourt
Ph. 33 1 30 68 89 20
Fax [phone]
CANADA
2876 Sunridge Way N.E.
Calgary, AB T1Y 7H9
Ph. 403-235-8400
Fax [phone]
GERMANY
AMETEK GmbH
Rudolf-Diesel-Strasse 16
D-40670 Meerbusch
Ph. 49 21 59 91 36 0
Fax [phone]
MIDDLE EAST – Dubai
AMETEK
PO Box 17067
Jebel Ali Free Zone
Dubai, UAE
Ph. 971-4-881 2052
Fax [phone]
© 2014 AMETEK
This manual is a guide for the use of the Model 5100 HD Version Analyzer. Data herein has been veried and validated and is believed adequate for
the intended use of this instrument. If the instrument or procedures are used for purposes over and above the capabilities specied herein, conrmation
of their validity and suitability should be obtained; otherwise, AMETEK does not guarantee results and assumes no obligation or liability. This publica-
tion is not a license to operate under, or a recommendation to infringe upon, any process patents.

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Contents
Oces.................................................................................................................... ii
Safety Notes...........................................................................................................vi
Electrical Safety.....................................................................................................vi
Grounding..............................................................................................................vi
Sample Gas ............................................................................................................vi
Warning Labels.................................................................................................... vii
Environmental Information (WEEE)................................................................... vii
Secondary Process Seals Requirement ............................................................... viii
Special Warnings and Information...................................................................... viii
Electromagnetic Compatibility (EMC)..................................................................ix
Warranty and Claims ..............................................................................................x
EC Declaration of Conformity...............................................................................xi
CHAPTER 1 Model 5100 HD Analyzer
Overview............................................................................................................. 1-1
Tunable Diode Laser Spectroscopy Theory........................................................ 1-2
Components.................................................................................................. 1-3
Electronics Enclosure................................................................................... 1-3
User Interface...................................................................................................... 1-4
Customer Connection Box .................................................................... 1-4
Sampling System ................................................................................................ 1-5
Sample Cell......................................................................................................... 1-5
Detector........................................................................................................ 1-6
GRIN Lens ................................................................................................... 1-6
Sample Gas Flow ......................................................................................... 1-6
Laser Conguration...................................................................................... 1-6
Measurement................................................................................................ 1-6
Laser Line Locking & Built-in Verication........................................................ 1-7
Laser Line Locking ...................................................................................... 1-7
Built-in Verication...................................................................................... 1-7
Measurement................................................................................................ 1-7
Controller Communications................................................................................ 1-8
Options................................................................................................................ 1-9
Herriott Sample Cell Option ........................................................................ 1-9
High Temperature Sample Cell Option...................................................... 1-10
Space-Coupled Option ............................................................................... 1-10

iv | Model 5100 HD Analyzer
CHAPTER 2 Specications
CHAPTER 3 Installation and Start-Up
Analyzer Requirements ...................................................................................... 3-2
Location........................................................................................................ 3-2
Mounting Requirements .............................................................................. 3-2
Dimensions 5100 HD .................................................................................. 3-3
Wiring ................................................................................................................. 3-4
General Wiring and Conduit Requirements ................................................. 3-4
EMC Grounding, Shielding and Noise Protection....................................... 3-4
EMC grounding method......................................................................... 3-4
Transient and RFI interference.............................................................. 3-5
Secondary Process Seals Requirement......................................................... 3-5
Connecting the 5100 HD to the AC Mains Power ....................................... 3-5
Analyzer Installation .......................................................................................... 3-7
User-Supplied Items .................................................................................... 3-7
Sample Pressure Requirements.................................................................... 3-7
Gas Connections........................................................................................... 3-8
I/O, Communication, and Alarm Relay Connections ....................................... 3-10
I/O Signals.................................................................................................. 3-11
Contact Connection ............................................................................ 3-12
Current Loop Output Connection ........................................................ 3-13
Analog Input - Voltage/Current ........................................................... 3-15
RS-485 Communication Connection ......................................................... 3-15
2-Wire Connection ............................................................................... 3-16
2-Wire Termination Resistor................................................................ 3-16
Relay Alarms.............................................................................................. 3-17
Ethernet Cable Connections....................................................................... 3-18
User Interface.................................................................................................... 3-19
Overview of Keypad .................................................................................. 3-19
Navigation Keys................................................................................... 3-19
Overview of Display .................................................................................. 3-20
Initial Start-Up.................................................................................................. 3-21
CHAPTER 4 User Interface
Menu Map........................................................................................................... 4-2
Alarm .................................................................................................................. 4-5
Disable.......................................................................................................... 4-6
Concentration ............................................................................................... 4-7
Data Valid..................................................................................................... 4-7
System Alarm............................................................................................... 4-7
Test ............................................................................................................... 4-7
NO/NC ......................................................................................................... 4-7
Analog Range ..................................................................................................... 4-8
Max Concentration....................................................................................... 4-8
Min Concentration ....................................................................................... 4-8

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Test Cong.......................................................................................................... 4-9
Modbus......................................................................................................... 4-9
Clock .......................................................................................................... 4-10
Press Disply Units...................................................................................... 4-11
Temp Disply Units ..................................................................................... 4-11
System Test ....................................................................................................... 4-12
Network ............................................................................................................ 4-13
Network...................................................................................................... 4-13
DHCP ......................................................................................................... 4-13
IP Address................................................................................................... 4-13
Subnet......................................................................................................... 4-13
Gateway...................................................................................................... 4-13
Background Gas......................................................................................... 4-14
Units ........................................................................................................... 4-14
Zero and SPAN Check Functions ..................................................................... 4-15
Modbus Registers ............................................................................................. 4-21
Alarm Messages................................................................................................ 4-34
CHAPTER 5 Web Interface
Ethernet Connection ........................................................................................... 5-1
Web Interface Connection .................................................................................. 5-2
Web Interface Screen.......................................................................................... 5-3
Conditions and Messages ................................................................................... 5-4
Alarm Menu........................................................................................................ 5-5
Alarms.......................................................................................................... 5-5
Alarms: History............................................................................................ 5-6
Trends Menu ....................................................................................................... 5-7
Spectra Menu...................................................................................................... 5-9
Settings Menu ................................................................................................... 5-10
Settings: Relays.......................................................................................... 5-10
Settings: Current Outputs........................................................................... 5-11
Settings: Conguration............................................................................... 5-13
Ethernet ............................................................................................... 5-13
System .................................................................................................. 5-14
Modbus ................................................................................................ 5-14
Customization ...................................................................................... 5-15
CHAPTER 6 Maintenance
Cleaning.............................................................................................................. 6-2
Replacing the MCU Battery ............................................................................... 6-2
Containment System Leaks ................................................................................ 6-4
Parameter ID & Modbus Registers..................................................................... 6-5
System Alarm/Warning bit map........................................................................ 6-15
Common Modbus Registers ............................................................................. 6-16
APPENDIX A Auto Cal Feature
APPENDIX B Conguration for Renery Flare Gas

vi | Model 5100 HD Analyzer
Safety Notes
WARNINGS, CAUTIONS, and NOTES contained in this manual emphasize critical
instructions as follows:
An operating procedure which, if not strictly observed, may result in personal
injury or environmental contamination.
An operating procedure which, if not strictly observed, may result in damage
to the equipment.
Important information that should not be overlooked.
Electrical Safety
Hazardous voltages are present in the analyzer housings when power is applied to the
system. Always shut down power source(s) before performing maintenance or trouble-
shooting. Only a qualied electrician should make electrical connections and ground
checks.
Any use of the equipment in a manner not specied by the manufacturer may impair the
safety protection originally provided by the equipment.
Grounding
Instrument grounding is mandatory. Performance specications and safety protection are
void if instrument is operated from an improperly grounded power source.
Verify ground continuity of all equipment before applying power.
Sample Gas
Potential hazards of the sample gas should be taken into consideration
before connecting the sample to the analyzer. Personal protective equipment
and proper ventilation should be used if sample gas is toxic, ammable, or
corrosive. Check the sample line and all connections for leaks before pow-
ering up. Consult plant safety personnel for appropriate exhaust venting
guidelines for specic sample gas type.
NOTE

NOTE


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Warning Labels
These symbols may appear on the instrument in order to alert you of existing conditions.
PROTECTIVE CONDUCTOR TERMINAL
(BORNIER DE L’ECRAN DE PROTECTION)
Schutzerde
CAUTION - Risk of electric shock
(ATTENTION-RISQUE DE DÉCHARGE ÉLECTRIQUE)
Achtung - Hochspannung Lebensgefahr
CAUTION - (Refer to accompanying documents)
(ATTENTION-SE RÉFERER AUX DOCUMENTS JOINTS)
Achtung (Beachten Sie beiliegende Dokumente)
CAUTION - Hot Surface
(ATTENTION-SURFACE CHAUDE)
Achtung - Heiße Oberäche
Environmental Information (WEEE)
This AMETEK product contains materials that can be reclaimed and recycled. In some cases the product
may contain materials known to be hazardous to the environment or human health. In order to prevent
the release of harmful substances into the environment and to conserve our natural resources, AMETEK
recommends that you arrange to recycle this product when it reached its “end of life”.
Waste Electrical and Electronic Equipment (WEEE) should never be disposed of in a municipal waste
system (residential trash). The Wheelie Bin marking on this product is a reminder to dispose of the prod-
uct properly after it has completed its useful life and been removed from service. Metals, plastics, and
other components are recyclable and you can do your part by doing one of the following steps:
•When the equipment is ready to be disposed of, take it to your local or
regional waste collection administration for recycling.
•In some cases, your “end of life” product may be traded in for credit toward
the purchase of new AMETEK instruments. Contact your dealer to see if
this program is available in your area.
•If you need further assistance in recycling your AMETEK product, contact
our o󰀩ce listed in the front of the instruction manual.

viii | Model 5100 HD Analyzer
Secondary Process Seals Requirement
A”This instrument is supplied with a primary process seal only (single seal
device) in accordance with ANSI/ISA 12.27.01-2003. Proper installation of
this instrument requires a secondary process seal if failure of the primary
process seal could allow process uids to enter the conduit or eld wiring
system. The maximum process gas pressure and temperature that will be ap-
plied are 10 psig (170KPa) and 140F (60C).
For more information refer to ANSI/ISA 12.27.01-2003, the 2006 NEC (clauses 501.15
(F) (3) (CI Div 1/2), and 505.16 (E) (3) (CI Zone 1/2)) or the 2006 CEC Part 1 Rules
18-092 (CI Zone 0), 18-108 (CI Zone 1), 18-158 (CI Zone 2), J18-108 (CI Div1), and
J18-158 (CI Div2).
SPECIAL WARNINGS AND INFORMATION
EQUIPMENT USED IN CLASS I, DIV 2 AND ZONE 2 HAZARDOUS LOCATIONS
Refer to Chapter 2 – Specications for details about the suitability of this equipment in hazard-
ous areas.
Explosion Hazard – Substitution of components may impair suitability for
hazardous locations.
Risque d’explosion – La substitution de composants peut rendre ce materiel
inacceptable pour les emplacements sont designés dangereux.
Explosion Hazard – Do not disconnect equipment unless power has been
switched o or the area is known to be non-hazardous.
Risque d’explosion – Avant de déconnecter l’équipement, coupez le courant où
vousassurez que l’emplacement est designé non dangereux.
All input and output wiring must be in accordance with Class I, Division 2 and Zone 2 wiring methods (NEC
Sec 501.4(b) or CEC 18-152) and in accordance with the authority having jurisdiction.

| ix
This equipment must be used in a manner not specied by AMETEK, or the protection provided
by the equipment may be impaired.
a) WARNING – EXPLOSION HAZARD – DO NOT DISCONNECT WHILE CIR-
CUIT IS LIVE UNLESS AREA IS KNOWN TO BE NON-HAZARDOUS; and
b) AVERTISSEMENT – RISQUE D’EXPLOSION – NE PAS DÉBRANCHER TANT
QUE LE CIR-CUIT EST SOUS TENSION, À MOINS QU’IL NE S’AGISSE
D’UN EMPLACEMENT NON DANGEREUX.
c) The 5100 HD analyzer is suitable for both indoor and outdoor use. Shield from
direct sunlight.
d) This equipment is suitable for use in Class I, Division 2, Groups A, B, C, D or
non-hazardous loca-tions only.
e) WARNING – EXPLOSION HAZARD – SUBSTITUTION OF COMPONENTS
MAY IMPAIR SUITABILITY FOR CLASS I, DIVISION 2; and
f) AVERTISSEMENT – RISQUE D’EXPLOSION – LA SUBSTITUTION DE
COMPOSANTS PEUT RENDRE CE MATÉRIEL INACCEPTABLE POUR LES
EMPLACEMENTS DE CLASSE I, DIVISION 2;
g) WARNING: EXPOSURE TO SOME CHEMICALS MAY DEGRADE THE
SEALING PROP-ERTIES OF MATERIALS USED IN THE FOLLOWING
DEVICES; identication of the sealed devices
CAUTION

x | Model 5100 HD Analyzer
Electromagnetic Compatibility (EMC)
Read and follow the recommendations in this section to avoid performance
variations or damage to the internal circuits of this equipment when installed
in harsh electrical environments.
The various congurations of the Model 5100/5100 HD Analyzer should not produce, or fall victim to,
electromagnetic disturbances as specied in the European Union’s EMC Directive. Strict compliance to
the EMC Directive requires that certain installation techniques and wiring practices are used to prevent or
minimize erratic behavior of the Analyzer or its electronic neighbors. Below are examples of the tech-
niques and wiring practices to be followed.
In meeting the EMC requirements, the various Analyzer congurations described in this manual rely
heavily on the use of metallic shielded cables used to connect to the customer’s equipment and power.
Foil and braid shielded I/O and DC power cables are recommended for use in otherwise unprotected situ-
ations. In addition, hard conduit, exible conduit, and armor around non-shielded wiring also provides
excellent control of radio frequency disturbances. However, use of these shielding techniques is eective
only when the shielding element is connected to the equipment chassis/earth ground at both ends of the
cable run. This may cause ground loop problems in some cases. These should be treated on a case-by-case
basis. Disconnecting one shield ground may not provide sucient protection depending on the electronic
environment. Connecting one shield ground via a 0.1 microfarad ceramic capacitor is a technique allow-
ing high frequency shield bonding while avoiding the AC-ground metal connection. In the case of shield-
ed cables the drain wire or braid connection must be kept short. A two-inch connection distance between
the shield’s end and the nearest grounded chassis point, ground bar or terminal is highly recommended.
An even greater degree of shield performance can be achieved by using metallic glands for shielded cable
entry into metal enclosures. Expose enough of the braid/foil/drain where it passes through the gland so
that the shield materials can be wrapped backwards onto the cable jacket and captured inside the gland,
and tightened up against the metal interior.
Inductive loads connected to the low voltage “Alarm Contacts” are not recommended. However, if this
becomes a necessity, adhere to proper techniques and wiring practices. Install an appropriate transient
voltage suppression device (low voltage MOV, “Transzorb,” or R/C) as close as possible to the inductive
device to reduce the generation of transients. Do not run this type of signal wiring along with other I/O or
DC in the same shielded cable. Inductive load wiring must be separated from other circuits in conduit by
using an additional cable shield on the oending cable.
In general, for optimum protection against high frequency transients and other disturbances, do not allow
installation of this Analyzer where its unshielded I/O and DC circuits are physically mixed with AC mains
or any other circuit that could induce transients into the Analyzer or the overall system. Examples of elec-
trical events and devices known for the generation of harmful electromagnetic disturbances include mo-
tors, capacitor bank switching, storm related transients, RF welding equipment, static, and walkie-talkies.