AMI The Barracuda 4010LX User manual

Operator Manual
TUNABLE DIODE
LASER ABSORPTION SPECTROMETER
MODEL 4010L
THE BARRACUDA

MODEL 4010LX Overview ___________________________________________________ 2
Method of Measurement _______________________________________________________ 3
Key Innovations_______________________________________________________________5
Safety, Warnings & Cautions ___________________________________________________ 6
Analyzer Installation___________________________________________________________9
Part I: Mounting the Analyzer____________________________________________ 9
Part II: Electrical Connections for the Analyzer________________________________10
Part III: Gas Connections_________________________________________________16
Initiation of Sample Flow __________________________________________19
Calibration ________________________________________________________________ 20
Analyzer Operation _________________________________________________________ 20
COMMAND CENTER Interface Software Set-up____________________________________ 22
Remove the Explosion-proof Cover_________________________________________22
Establish a Communication Link________________________________________ 22
Analyzer Output Setup _______________________________________________ 24
Alarm Setup ________________________________________________________ 27
Controls Both Alarms Setup ______________________________________________29
Datalog Column Setup _______________________________________________ 30
Download Data _______________________________________________________31
Troubleshooting, Maintenance & Repairs___________________________________________ 34
Cleaning the Mirrors _________________________________________________________ 38
Smart Realignment ___________________________________________________________51
Modbus RS485 Communication Protocol __________________________________________56
Specifications _______________________________________________________________59
AMI®Warranty & Support___________________________________________________61
Limited Warranty/Disclaimer _____________________________________________ 61
Limitation of Liability___________________________________________________ 61
Limitation of Remedies ______________________________________________61
TABLE OF CONTENTS
Special Message from Advanced Micro Instruments®(AMI):
Thank you for purchasing this BARRACUDA MODEL 4010LX for your trace moisture
measurement needs. It has a state-of-the-art design and is the industry's most advanced TDL
Moisture Analyzer. You will find that this Analyzer will set a new bar for high performance,
reliability and intuitive design.
Note: Read this manual carefully prior to installation. Please take extra precautions against
any potential leaks when installing and operating your BARRACUDA MODEL 4010LX.
If you have any questions, contact AMI at 714.848.5533 or www.amio2.com.
OPERATOR MANUAL
MODEL 4010L
1

ANALYZER OVERVIEW
Mounting Hole
(x 4)
LCD
Up and Down
Arrow Buttons
Exhaust Port
Sample Gas Inlet Port
Bypass Gas/Liquid Drain
Flow Meter
½" NPT Machined
Holes for Electrical
Connnections (x 2)
(not shown in image)
Explosion-proof
Enclosure
(right side view)
(front view)
Exhaust Port
Sample Gas Inlet Port
Bypass Gas/Liquid Drain
Bypass Flow
Metering Valve
Protective Earth
Ground Lug
Mounting Plate
Sample Gas
Metering Valve
(left side view)
Case Earth
Ground Lug
(Note: No Customer Connections)
2

METHOD OF MEASUREMENT:
WAVELENGTH-MODULATED TUNABLE DIODE LASER
SPECTROSCOPY (WMTDL)
THE BARRACUA MODEL 4010LX utilizes a state-of-the-art, next generation technology
called Wavelength-modulated Tunable Diode Laser Spectroscopy (WMTDL) for fast, accurate
and highly reliable moisture measurements. This proven technology is based on the
Beer-Lambert Law.
HOW WMTDL WORKS
The Beer-Lambert Law states that the amount of light absorbed by the natural gas sample is
proportional to the amount of water vapor in the path of the laser. Hence, by measuring the
amount of absorbed light and the total pressure, the concentration of moisture in a particular
sample can be accurately determined.
The measurement in a MODEL 4010LX is made by tuning the laser wavelength rapidly 2
times per second, back and forth, across the narrow absorption line for a single vibrational/
rotational mode of a water molecule. The number of water vapor molecules in the path of the
laser is determined by the ratio of the detected signal when the laser wavelength is on the
absorption line to the signal when it is off the absorption line. Any variances in the laser
intensity, laser detector gain, obstructions in the optical path or other changes are the same
on and off the absorption line and will cancel out when the ratio is taken – thus, keeping the
measurement stable (in calibration) if variances occur.
Over longer periods of time, the laser wavelength can drift. A standard feature of the MODEL
4010LX Moisture Analyzer is that it tracks the original location of the background methane
absorption. Using AMI’s COMMAND CENTER Software, the customers can easily check for
any drift in the laser wavelength and, if necessary, correct it with a simple click of a button.
(Learn more about this in the Command Center Software overview
3

AMI FACTORY CONFIGURATION AND CALIBRATION
Every MODEL 4010LX Moisture Analyzer is rigorously tested and calibrated at the factory
over the entire measurement, temperature, and pressure ranges, using NIST traceable gases
and sophisticated mass flow controllers within a temperature chamber. The performance of the
Analyzer during the 30+ hours of testing and calibration is validated, using NIST traceable
master analyzers, which are further validated using chilled mirrors. The master calibration
variables, which are specific to each analyzer, are permanently loaded into the Analyzer’s
firmware. During the validation, performance testing of all results across all temperatures must
meet a 1% or better accuracy specification prior to passing.
FIELD PERFORMANCE VALIDATION
This factory calibration performed by AMI and the inherent stability of the ratio metric WMTDL
measurement result in an Analyzer that will hold its calibration for many years. A customer
may want to periodically verify the accuracy of the MODEL 4010LX using their own NIST
traceable calibration gas, but it is important to follow AMI's specific steps so that errors are not
introduced. You can read AMI’s recommendations for field validation of a MODEL 4010LX
in appendix A.
4

Advanced Micro Instruments has developed and patented key technologies that enable our devices to
deliver the highest levels of PERFORMANCE, RELIABILITY and EASE-OF-USE. These technologies
are included in THE BARRACUDA MODEL 4010LX and cannot be replicated by any other company.
This powerful software platform comes standard with every MODEL 4010LX
purchase and provides users with access to a full suite of advanced features, including:
– Settings & logic adjustments for 2-fully independent Alarm Relay Contacts
– Security settings to prevent unauthorized adjustments to the Analyzer via the
front panel
– Changing the analog outputs from 4 –20 mA to 1–5 VDC or vice versa
– Datalogger that records measurement readings, temperature of the Cell Block,
gas pressure, brown-outs and power voltage over a period of 15 days @1-min
intervals (data can be displayed on a graph or in tabular format)
– Error Status Display that alerts users to any error(s) detected by the Analyzer
– Communication with the Analyzer via USB Virtual COMport and Modbus
bi-directional RS485 Communication
KEY INNOVATIONS
ELIMINATOR CELL BLOCK
COMMAND CENTER INTERFACE SOFTWARE
ELECTRONICS PLATFORM
command
center
Our patented Cell Block Technology provides the next generation of innovation
for a complete, very compact sample system that virtually eliminates all
potential leak paths while optimizing flow efficiencies. The volume and distance
the sample gas travels prior to entering the laser chamber has been
dramatically reduced.
THE BARRACUDA MODEL 4010LX is programmed with a proprietary
measurement algorithm to carry out trace moisture measurements. Not only will
THE BARRACUDA complete multiple scans every second for the signature
H2O peak and CH₄ (methane) peak, its algorithm contains a compensation
function to account for pressure and temperature. This ensures maximum
stability and accuracy regardless of the methane levels.
MEASUREMENT ALGORITHM AND SMART CALIBRATION
A Smart Calibration feature is also enabled on THE BARRACUDA. Over
time, laser-based Moisture Analyzers eventually see a gradual movement of
their signature peaks on the x-axis of the measurement waveform. THE
BARRACUDA MODEL 4010LX can easily realign the laser to the critical H2O
peak and CH4peak through the touch of a button.
All sample handling components, including the Herriott Cell, have been
machined from a series of solid compact blocks with precision-drilled
intersecting passages in place of long lengths of tubing and compression fittings.
Additionally, metering valves, pressure sensor and flowmeter are all directly
integrated into the machined blocks.
Finally, the ELIMINATOR CELL BLOCK features a unique liquid rejection/
particulate membrane that is sealed between cell blocks. As a result, all
liquids and particulate are effectively exhausted through the bypass without
ever reaching the optical components.
5

SAFETY, WARNINGS & CAUTIONS
Violation of the National Electrical Code requirements (especially Article 500 that deals with
hazardous areas) may cause a fire or explosion with the potential for serious injury or loss of life.
Make sure no hazardous gas is present in the area before and during installation.
WARNING
Drilling any holes in the enclosure will violate the safety approval and may create risk of harm.
WARNING
A WARNING identifies conditions or procedures that can be dangerous to the user.
A CAUTION identifies conditions or procedures that can cause damage to the Product.
SYMBOL TABLE
WARNING - RISK OF DANGER OR HARM
TO THE USER or RISK OF DAMAGE TO THE
PRODUCT. Consult the operator manual.
Relay
Earth Ground
DC (Direct Current)
RISK OF SHOCK (DC)
Frame Chasis Terminal
Protective Ground
AC (Alternating Current)
Due to non-conductive surfaces, there exists a POTENTIAL ELECTROSTATIC CHARGING HAZARD.
EN RAISON DE SURFACES NON CONDUCTRICES, IL EXISTE UN RISQUE POTENTIEL DE
CHARGE ELECTROSTATIQUE
WARNING
RISK OF SHOCK (AC)
6

WARNING
The following power requirements must be met by the installer of the DC/AC power connections to the
Analyzer:
•You must include an electrical disconnect means and a current limiting device, such as a
switch and fuse. The disconnect device must be marked as a 'disconnect device' and
readily accessible to shut off power to the Analyzer. This will allow the Analyzer to be
quickly shut-off in case of an emergency. The disconnect and current limiting device must
be housed in an enclosure rated for the area classification. Conduit seals may be required
on the enclosure, depending on the area classification.
DC-powered version
Use a 0.25-Amp fuse disconnect.
AC-powered version
Use a 0.20-Amp fuse disconnect.
The voltage rating for the AC Analyzer is 100 to 240VAC at 50/60Hz ± 10%.
AC voltages outside this may cause the Analyzer to malfunction.
You must follow the National Electrical Code (NEC) in your installation. Consult the NEC Handbook
for the correct guidelines and standards.
Class I, Div 1 areas must use rigid conduit with seal-offs.
Class I, Div. 2 areas can use flexible conduit with seal-offs.
The Analyzer has approval for Class I, Division 1, Groups B,C,D. To comply with these
requirements, you need to assure the following:
•The Protective Earth Ground Lug on the front lower left of the Analyzer mounting bracket
must be connected to the High Quality Protective Earth Ground using a16-gauge wire.
Please refer to the image on page 2 of the front view of the Analyzer for the location of the
Protective Earth Ground Lug
WARNING
7

CAUTION
The voltage rating of the DC Analyzer is 10–28V.
•DC input has to be an approved Class 2 or limited energy circuit for DC power
•Voltages outside this range may cause the Analyzer to malfunction.
The voltage rating of the AC Analyzer is 100 to 240VAC at 50/60Hz ± 10%.
•Any AC voltages outside this range may cause the Analyzer to malfunction
Any use of this equipment in a manner not specified in this manual or approved AMI documentation
may impair the protection provided by the equipment.
Toute utilisation de cet équipement d'une manière non spécifiée dans ce manuel ou dans la documen-
tation AMI approuvée peut altérer la protection fournie par l'équipement.
A SEAL SHALL BE INSTALLED WITHIN 50 mm OF THE ENCLOSURE.
UN SCELLEMENT DOIT ETRE INSTALLE A MOINS DE 50 mm DU BOITIER.
WARNING
SUBSTITUTION OF COMPONENTS MAY IMPAIR INTRINSIC SAFETY.
LE REMPLACEMENT DE COMPOSANTS PEUT COMPROMETTRE LA SECURITE INTRINSEQUE.
WARNING
Enclosure materials contain a light metal content of over 10% Aluminum and pose a potential impact
spark ignition hazard. The end user shall carry out a risk assessment prior to installation in an EPL Ga
environment and shall only install the equipment where the risk of impact has been considered to be
negligible.
Les matériaux de boîtier contiennent une teneur en métaux légers de plus de 10% d'aluminium et con-
stituent un risque potentiel d'inflammation. L'utilisateur final doit procéder à une évaluation des risques
avant de l'installer dans un environnement EPL Ga et ne doit installer le matériel que dans les cas où le
risque d'impact a été considéré comme négligeable.
WARNING
8

STEPS
1. Determine a convenient location to place the Analyzer. The location should ideally
be eye-level.
2. Mount the Analyzer to a wall or bulkhead using the 4 mounting holes or to a 2-inch (5 cm)
pipe using¼" x 2" U-brackets with ¼ nuts.
Note: Equipment shall only be installed and operated in the upright orientation with the mounting
plate vertical.
ANALYZER INSTALLATION
Part I: Mounting the Analyzer
Key Points note: Analyzer weighs 17.0 lbs (7.7 kg)
• The Analyzer can be mounted either indoors or outdoors, where the ambient temperature
remains between 20°F (-6.7°C) and 149°F (65°C)
WARNING:
For both DC and AC models, do not use above 3,200 m (10,500 ft).
WARNING:
The Analyzer weighs 17.0 lbs (7.7 kg) and can pose a risk to the user if dropped.
• When using a solar panel to power the Analyzer, we recommend mounting the solar panel just
above the Analyzer, using the same mast, to serve as a sunshield
9

STEPS
Part II: Electrical Connections for the Analyzer
• Verify your rated power supply matches the operating voltage of your Analyzer before
you begin
• THE MODEL 4010LX is available with either AC or DC Power (you must request your
desired power at the time of your purchase)
Note: Refer to page 60 for the power requirements of your Analyzer.
Note: Both alarm relays are rated for 5A @115VAC or 24VDC.
• Your Analyzer has both 1–5 VDC and 4–20mA isolated analog signals. The ouput can
be changed from 1–5 VDC to 4–20mA or vice versa in the field using the COMMAND
CENTER shown on page 26. It has been setup at the factory per your analog output
requirements at the time of purchase.
Key Points:
1. Remove the two red plastic protective caps from the ½" NPT conduit holes on the explosion-proof
side of the Analyzer. These plastic caps protect the threads of the unit during shipping.
• We provide 2 (two) separate ½" NPT conduit holes to accommodate all electrical connections.
The first conduit opening should be used for power and alarm relay connections. The second is for
analog output and RS485 connections
Note: AC Power and the opening and closing of alarm relays produce both electrical noise and
large inductive spikes that can have an undesirable effect on the measurement readings. This is why
we provide two conduit openings and strongly recommend separating the sensitive analog signal
wiring from the power and relay wiring.
10

2. Install the conduit unions between the explosion-proof housing of the Analyzer and the electrical seal-off.
DO NOT fill the electrical seal-offs yet.
• In order to meet electrical codes for Class 1, Div 1 and Class 1, Div 2, Groups B,C,D, you must use
electrical seal-offs in your installation
• We recommend that you install conduit unions between the explosion-proof housing of the Analyzer and
the seal-offs. This will prove very useful in the event that you have to remove the Analyzer for servicing,
without cutting wires
Left Conduit Union
Electrical Seal-offs
Right Conduit Union
WARNING:
If you are using DC Power and intend on using
the analog output only feature (which is the
same as using 'NO RELAYS'), you can safely
run both DC Power and Analog Output Signal
in a single conduit. However, you must install
an approved ½" NPT plug for hazardous
locations in the unused ½" NPT port.
FAILURE TO DO SO WILL VIOLATE ALL
SAFETY REQUIREMENTS AND POTENTIALLY
RESULT IN AN EXPLOSION!
11

5. Verify the operating voltage of your Analyzer and the correct power requirements before
you continue.
6. Make sure the power source has been turned-off before you begin installing wiring.
3. Remove the explosion-proof cover by rotating it counterclockwise.
Note: A white sheet metal panel inside the explosion-proof housing indicates the
Analyzer has been built for use with DC power, while a black sheet metal panel indicates
AC power.
4. Then remove the Terminal Cover to access the electrical connections.
Terminal Cover
DC Version with Terminal Cover
and white information panel
Terminal Cover
AC Version with Terminal Cover
and black information panel
IMPORTANT: When attaching wiring to the green terminal connectors, use either solid wire or
stranded wire with wire ferrule(s) attached. Verify no loose strands are visible after
installation of wire ferrule(s).
• The green terminal block connectors are combination connectors, which allows you to unplug
the connector during the wiring process. Combination connectors can accommodate
12–24 AWG wire sizes for your electrical connections
12

For DC Power:
7. Connect the DC power wires to the appropriate
terminals on the left.
• The + positive and - negative are clearly
marked on the sheet metal cover
• If you decide to use a 2-wire cable with shield for
the power supply connection, AMI provides
quality Shield Earth Ground Terminal Connection
next to the + positive and - negative terminals
For AC Power:
7. Connect the AC power wires to the appropriate
terminals on the left. The wire designations are
clearly marked on the black metal cover.
• H is for the Hot Wire
• N is for the Neutral Wire
• Position (A), as shown above, is for the AC Power
Ground
AC Power Ground
Terminal Connection (A)
Shield Earth Ground
Terminal Connection
1st CONDUIT (POWER & ALARMS):
WARNING:
Analyzer must be connected to a Quality Protective Earth Ground for safety and the highest level of RFI
protection. This is accomplished by connecting an 16-gauge wire from the Analyzer's Protective Earth
Grounding Lug to an 8 foot ground rod or equivalent quality ground. (The Protective Grounding Lug is
located just below the explosion-proof housing as seen in the image above)
Protective Earth
Ground Lug
WARNING:
When using a AC power, never rely on the AC Power Ground as a source for Analyzer safety or ground
protection. Always connect the Protective Earth Ground Lug, shown above, to a high quality ground,
such as an 8 foot ground rod or equivalent.
(must connect to a quality ground)
13

IMPORTANT: IF YOU DESIRE TO USE THE ALARM CONTACT RELAYS, THE ALARM WIRES MUST BE PULLED
THROUGH THE SAME CONDUIT AS THE SUPPLY POWER.
RECOMMENDED: WHEN USING DC POWER, USE A SHIELDED-TWISTED PAIR CABLE AND CONNECT THE
CABLE SHIELD TO THE SHIELD EARTH GROUND TERMINAL SHOWN IN POSITION 'A' OF
THE ILLUSTRATION ABOVE. DO NOT CONNECT THE OTHER END OF THE SHIELD WIRE AS IT
WILL CAUSE UNDESIRABLE GROUND LOOPS!
8. Connect the wires for the two fully adjustable alarm contact relays to their proper terminals.
Note: Both alarm relays are rated for 5A @115VAC or 24VDC.
(DC Power Version is shown for alarm wiring. The AC version will
be identical for alarms, analog output and RS-485 connections.)
A
IMPORTANT: The relay contacts act like a simple switch breaking only a single leg of the circuit. In
keeping with good electrical practices while wiring the alarm contacts, We suggest
SWITCH/BREAK THE HOT LEG only, NOT THE GROUND LEG OF YOUR CIRCUIT.
14

9. Last, connect the wires for RS485 communication to their proper terminals.
NOTE: Always use a twisted 2-conductor cable with shield. Never connect both ends of the shield
to both devices (Analyzer and other device) as it will cause ground loops. Connect the analog
output shield to the shield earth ground shown above.
2nd CONDUIT (ANALOG OUTPUTS & RS485 COMMUNICATION):
(DC Power Version is shown. Instructions are the same for the
AC Power Version)
(DC Power Version is shown. Instructions are the same for the
AC Power Version)
10. Verify all electrical connections and then turn on the source of power. The Analyzer will power-up and
the LCD will blink for a few seconds during power-up. You may see some LEDs blinking within the
explosion-proof housing and NEMA 4X box as this is normal during operation.
Analog Output should be connected using a twisted
2-conductor wire with shield
11. Once you have tested all electrical functions, pour approved potting compound into the electrical
seal-offs.
15

• All gas connections will require using the supplied ferrule set, ¼" stainless steel
compression fittings and customer-supplied ¼" stainless steel tubing
• Sample Gas Inlet Pressure to the Analyzer should be regulated down to the range of 1.0
to 20.0 psig (0.07–1.4 bar), depending on line pressure
• THE BARRACUDA MODEL 4010LX comes internally equipped with a complete Sample
System, including a Liquid Separator that effectively removes liquids and particulates
• However, it is highly recommended that you install a regulated Insertion Gas Probe with
Filter Feature into the pipeline at the Sample Point. An Insertion Probe dramatically
reduces pipeline liquids, condensation and particulates from reaching both the Sample
Gas Line and Moisture Analyzer
• We recommend the Genie® 755 Direct Drive Probe™(offered by A+
Corporation) or equivalent product
Key Points:
Part III: Gas Connections
16

STEPS
1. Take a deburred length of ¼" stainless steel tubing and slip it through the supplied compression
nut and ferrule set. Confirm that the ferrule properly orientated at one end, and connect it to the
SAMPLE GAS INLET PORT.
Make sure the ¼" stainless steel tubing slips all the way into the compression fitting until it
bottoms out. Tighten the compression nut with 1 & ¼ turns.
2. Connect the other end to the pipeline gas tap or pressure reducing regulator.
Exhaust Port
Sample Gas Inlet Port
Bypass Gas/Liquid Drain
THE BARRACUDA MODEL 4010LX has 3 gas connections on its right side.
Sample Gas Connection
17

3. Take another deburred length of ¼" stainless steel tubing and slip it through the supplied
compression nut and ferrule set. Confirm that the ferrule set is properly oriented and then
connect to the EXHAUST PORT.
Make sure the ¼ stainless steel tubing slips all the way into the compression fitting until it
bottoms out. Tighten the compression nut with 1 & ¼ turns.
4. Run the other open end of the ¼" stainless steel tubing to a safe vented area outside of the
meter building.
CAUTION
The EXHAUST LINE must run slightly downhill the entire way to a safe area to allow any
condensate to drain outside and not back into the Analyzer. If you must run the EXHAUST
LINE vertically through the ceiling, install a 'knock-out' pot to capture the liquid condensate
just prior to going vertical. This will prevent condensate from running back into the Analyzer.
5. Take the final deburred length of ¼" stainless steel tubing and slip it through the supplied
compression nut and ferrule set. Confirm that the ferrule set is properly oriented and then
connect to the BYPASS/DRAIN PORT.
Make sure the ¼ stainless steel tubing slips all the way into the compression fitting until it
bottoms out. Tighten the compression nut with 1 & ¼ turns.
6. Run the other open end of the ¼" stainless steel tubing to a safe vented area outside of the
meter building.
CAUTION
Run the Bypass Line to the outside of the Meter Building in a downhill direction all the way to
a safe location. This will prevent water traps from forming and later freezing in cold weather,
creating a back pressure. A 24" H2O column will create 1 lb of back pressure and cause
readings to fluctuate. A 48" H2O column will create 2 lbs of back pressure and cause
readings to fluctuate even more.
Exhaust Gas Connection
Bypass Gas Connection
18

END OF INSTALLATION
INITIATION OF SAMPLE FLOW TO
THE ANALYZER
Note: SCFH = standard cubic feet per hour
1. Turn the SAMPLE FLOW METERING VALVE to the full clockwise position to the Off Position.
Do not overtighten it! Turn until finger tight only.
Bypass Gas Flow Rate
This can be adjusted using the BYPASS FLOW METERING VALVE Knob. To increase the Flow Rate,
turn the Knob counterclockwise. To decrease, turn clockwise.
Sample Gas Flow Rate
This can be adjusted using the SAMPLE FLOW METERING VALVE Knob. To increase the Flow Rate,
turn the Knob counterclockwise. To decrease, clockwise.
2. Turn the BYPASS FLOW METERING VALVE to the full clockwise position to the Off Position.
Do not overtighten it! Turn until finger tight only.
3. Apply a gas pressure of approximately 20 psig (1.4 bar) and leak test check all fittings back to
the Sample Tap while looking for tiny bubbles (We recommend using SNOOP®). DO NOT
USE the spray bottle as this technique produces bubbles and does not achieve the best results.
4. Once the installation has passed the Leak Test, slowly turn the SAMPLE FLOW METERING
VALVE Knob counterclockwise until the Flow Meter reads approximately 1.0 SCFH (0.5 Lpm).
STEPS
5. Now open the BYPASS METERING VALVE by turning the Knob counterclockwise ½ a turn or
temporarily using an external flowmeter, adjust the bypass flow for 1.0 SCFH. Then, remove
the flowmeter and reattach the bypass tubing.
Note: AMI has chosen this technique since all bypass flow meters have a tendency to plug quickly
due to the volume of liquids and particulates going through the bypass path.
Sample Flow Metering Valve
Bypass Flow Metering Valve
Flow Meter
(indicates flow rate in SCFH)
WARNING:
DO NOT OVERTIGHTEN
THE METERING VALVES or
you will damage them. They
are not ON/OFF VALVES!
19